Demag DR rope hoist

without electrical control

42576444.eps 42349444.eps

42352044.eps

081105 EN 203 640 44 714 IS 813

 Manufacturer Demag Cranes & Components GmbH
P.O. Box 67, D-58286 Wetter
Telephone (+49 2335) 92-0 · Telefax (+49 2335) 927676
www.demagcranes.com

Please fill in the following table before first putting the hoist into service.
This provides you with a definitive documentation of your Demag rope hoist
and important information if you ever have to contact the manufacturer or his
representative.

Owner

Where in use

Range

Serial number

Main hoist motor number

Operating voltage

Control voltage

Frequency

Wiring diagram number

Further documents
Operating instructions
Demag rope hoist FDR 3 - FDR 5- FDR 10 (PRO) 214 932 44 720 IS 813
Demag rope hoist EKDR 3 - EKDR 5- EKDR 10 (PRO) 214 725 44 720 IS 813
Demag rope hoist EZDR 5- EZDR 10 (PRO) 214 961 44 720 IS 813
Demag rope hoist FDR 3 - FDR 5- FDR 10 (COM) 214 990 44 720 IS 813
Demag rope hoist EKDR 3 - EKDR 5- EKDR 10 (COM 214 916 44 720 IS 813
Demag rope hoist EZDR 5- EZDR 10 (COM) 214 965 44 720 IS 813

Dedrive Compact DIC 214 708 44 720 IS 922

20364044.p65/081105

CD Dedrive Compact DIC 213 137 44 716 IS 922

External pulse generator 214 372 44 720 IS 919
Z motor range 214 228 44 720 IS 919
2
 Introduction

This document contains information on rope hoists without electrical control. It ap-
plies for DR-Pro, EKDR-Pro, EZDR-Pro, FDR-Pro, EKDR-Com, EZDR-Com, FDR-
Com rope hoists.

Depending on the type, the standard scope of delivery includes:

- 12/2-pole hoist motor with Microtherm and EG integrated pulse generator

- GS and VE brake modules
- 4-pole hoist motor with Microtherm and mechanical mounting device for AG 1 - 3
external pulse generators
- GS and VE brake modules
- 4-pole cross travel motor with Microtherm
- GE and VE brake modules
- Base plate in the rope hoist electrical enclosure for connecting the hoist motor and
sensors
- SGG geared limit switch
- SGS overload cut-out
20364044.p65/081105

3
 Design overview

Example of EKDR Travel motor

EKDR low-headroom monorail hoist
Thrust rocker

Electrical equipment cover

with terminal strip and
geared limit switch

Gearbox with hoist motor

4/1 bottom block

Fig. 1 42577844.eps

Explanation of size designation / type assignment

EK DR - Pro 3 - 3,2 4/1 - 6 Z - 6/1 - 400 - 00 - 50 - 30 300 45
Rail head width in mm

or track gauge in mm } Only for EZDR

Flange width of the girder in mm

or girder section and size (IPE240)

Maximum cross-travel speed in m/min

Frequency [Hz]

Electrical equipment code 1)

Operating voltage [ V ]

Hoist speed in m/min

Motor type: Z = Cylindrical rotor

Hook path in m

Reeving

SWL in t

Range 3; 5; 10

Demag rope hoist

K = Low-headroom monorail hoist

Z = Crab
F = Stationary

E = Electric travel trolley

1) Code 00 DR without electrical control
Code 01 EKDR with internal electrics for application on a crane. Crane bridge enclosure, DSE-8R control pendant with control cable and cables for the
20364044.p65/081105

mobile floor control must be ordered separately.

Code 02 FDR/EKDR/EZDR with internal electrics and solo electrics with crane switch and transformer fitted in an enclosure on the trolley, for application as a
solo trolley. DSE-8R control pendant with control cable must be ordered separately.
Code 03 Like code 01 but control via radio control system
Code 04 Like code 02 but control via radio control system
4 Code 05 EKDR with fitted parallel interface “in”
 Selection criteria
DR-Pro F-/EKDR 3 - F-/EK-/EZDR 5, 10
The size of the hoist is determined by the load 1. What are the operating conditions? 5. Do the loads need to be lifted and lowered with
spectrum, average operating time per working day, 2. What is the specified safe working load? high precision?
SWL and reeving. 3. To what height must the load be lifted? 6. Is horizontal load travel necessary?
4. What is the required lifting speed? 7. How is the hoist to be controlled?
The load spectrum
(in most cases estimated) can be evaluated in
The group is determined from the operating time and load spectrum
accordance with the following definitions:
Load spectrum Average operating time per day in hours
1 Light
Hoist units which are usually subject to very small 1 Light 4-8 8-16 over 16
loads and in exceptional cases only to maximum 2 Medium 2-4 4-8 8-16
loads.
3 Heavy 1-2 2-4 4-8

4 Very heavy 0,5-1 1-2 2-4

Small partial load
FEM 2m 3m 4m
Small dead load
SWL

Group of mechanisms to
ISO M5 M6 M7
Operating time
2 Medium
Group of
Hoist units which are usually subject to small loads
mechanisms 2 m/M 5 3 m/M 6 4 m/M 7 2 m/M 5 3 m/M 6 4 m/M 7 2 m/M 5 3 m/M7 4 m/M 7
but rather often to maximum loads.
FEM/ISO 1)
2) 2)
Rope reeving 2/1, 4/2 4/1 6/1
Heavy partial load Range SWL in t
Medium partial load
DR 5 2,5 2 1,6 5 4 3,2 - - -
Medium dead load
SWL

DR 10 5 4 3,2 10 8 6,3 16 12,5 -

Operating time

3 Heavy Example
Hoist units which are usually subject to medium SWL 5t
loads but frequently to maximum loads.
Load spectrum “medium” from table
Hoist speed 6 m/min
Heavy dead load Creep hoist speed 1 m/min
Reeving 4/1
SWL

Average hook path 3m

Operating time
No. of cycles/hour 20
4 Very heavy Working time/day 8 hours
Hoist units which are usually subject to maximum or
almost maximum loads.
The average operating time per working day is estimated or calculated as follows:
2 x average hook path x no. of cycles/h x working time/day
Very heavy dead load Operating time/day =
60 x lifting speed
2 x 3 x 20 x 8
Operating time/day = = 2,66 hours
60 x 6
SWL

Operating time For the “medium” load spectrum and an average daily operating time of 2,66 hours,
the table shows group 2 m. For a load capacity of 5 t and 4/1 rope reeving, the table
indicates hoist size DR 5 - 5.
Selection table
Range Group of SWL Hook path Lifting speed m/min SWL Hook path Lifting speed m/min
mechanisms to t m V1 V2 V3 t m V1 V2 V3
FEM/ISO
2/1 4/1
2 m/M 5 1,6 3,2
F-/EK-
3 m/M 6 1,25 12; 20 12/2 18/3 2-25 3) 2,5 6; 10 6/1 9/1,5 1-12,5 3)
DR 3
4 m/M 7 1 2

2 m/M 5 2,5 5
F-/EK-/EZ-
3 m/M 6 2 12; 20 12/2 18/3 2-25 3) 4 6; 10 6/1 9/1,5 1-12,5 3)
DR 5
4 m/M 7 1,6 3,2

2 m/M 5 5 10

3 m/M 6 4 12; 20 10/1,7 2-18 3) 2-25 3) 8 6; 10 5/0,8 1-9 3) 1-12,5 3)

4 m/M 7 3,2 6,3

F-/EK-/EZ-
4/2 6/1 4)
DR 10
2 m/M 5 5 16
20364044.p65/081105

5,8; 11,35;
3 m/M 6 4 10/1,7 2-18 3) 2-25 3) 12,5 6,7; 13,3 2,7/0,4 0,7-6 -
15,2
4 m/M 7 3,2 10

1) Gearbox service life 20 % above the FEM value 3) for 87 Hz delta operation
2) 4/2 and 6/1 rope reeving only for DR 10 4) 6/1 rope reeving only for EZDR 10 5
 DR-Com F-/EKDR 3 - F-/EK-/EZDR 5, 10
The size of the hoist is determined by the load
spectrum, average operating time per working day,
SWL and reeving.
1. What are the operating conditions? 5. Do the loads need to be lifted and lowered with
2. What is the specified safe working load? high precision?
3. To what height must the load be lifted? 6. Is horizontal load travel necessary?
4. What is the required lifting speed? 7. How is the hoist to be controlled?

The load spectrum The group is determined from the operating time and load spectrum
(in most cases estimated) can be evaluated in
accordance with the following definitions: Average operating time
Load spectrum
per day in hours

1 Light 1 Light 2-4

Hoist units which are usually subject to very small
loads and in exceptional cases only to maximum 2 Medium 1-2
loads.
3 Heavy 0,5-1

4 Very heavy up to 0,5

Small partial load
Small dead load
SWL

FEM 1 Am
Group of mechanisms to
Operating time
2 Medium
ISO M4

Hoist units which are usually subject to small loads

but rather often to maximum loads. Group of mechanisms to FEM/ISO 1) 1 Am/M 4

Rope reeving arrangement 4/1

Heavy partial load
Medium partial load Range SWL in t
Medium dead load
SWL

DR 3 3,2

Operating time DR 5 5

3 Heavy DR 10 10
Hoist units which are usually subject to medium
loads but frequently to maximum loads.
Example
SWL 5t
Heavy dead load Load spectrum “medium” from table
Hoist speed 4.5 m/min
SWL

Creep hoist speed 0,8 m/min

Operating time
Reeving 4/1
4 Very heavy Average hook path 3m
Hoist units which are usually subject to maximum or
almost maximum loads.
No. of cycles/hour 10
Working time/day 8 hours
Very heavy dead load
The average operating time per working day is estimated or calculated as follows:
2 x average hook path x no. of cycles/h x working time/day
Operating time/day =
60 x lifting speed
SWL

2 x 3 x 10 x 8
Operating time Operating time/day = = 1,7 hours
60 x 4,5
For the “medium” load spectrum and an average daily operating time of 1,7 hours,
the table shows group 1 Am . For a load capacity of 5 t and 4/1 rope reeving, the
table indicates hoist size DR 5 - 5.

Selection table Range Group of mechanisms SWL Hook path Lifting speed
to m/min
FEM/ISO t m V1

4/1

F-/EKDR 3 2,5 6; 10 4,5/0,8

3,2

4
F-/EK-/EZDR 5 1 Am/M 4 6; 10 4,5/0,8
5
20364044.p65/081105

6,3

F-/EK-/EZDR 10 8 6; 10 4/0,7

10

6 1) Gearbox service life 20 % above the FEM value

20364044.p65/081105

7
 Key data pole-changing hoist drives DR 3 – DR 5 – DR 10
Design is in accordance with the VDE regulations and the design rules of the FEM, to meet the high demands made on
electric hoists.

Main/creep lifting F6 Required supply cable conductor cross sections and fuse links
Range DR 3 No. of Code P % CDF n Starts/h Rated current IN and starting current IA cos cos
poles for 50 Hz
400 V ϕN ϕA
Motor size kW rpm IN (A) IA (A)

ZBR 100 12 0,55 20 430 240 4,6 7 0,53 0,72

V1
C 12/2 - B050 2 3,4 40 2800 120 8,5 40 0,78 0,88

ZBR 100 12 0,8 20 4 10 240 5,7 9 0,55 0,75

V2
D 12/2 - B050 2 5,3 40 2780 120 11 55 0,88 0,85

Mains connection delay fuse for 50 Hz 1) Supply lines for 5% voltage drop ∆U and starting current IA for 50 Hz 2)
Range DR 3
400 V 400 V (∆U 20 V)

Motor size A mm² m

ZBR 100 C 12/2 20 1,5 25

ZBR 100 D 12/2 25 1,5 19

Range DR 5 No. of Code P % CDF n Starts/h Rated current IN and starting current IA cos cos
poles for 50 Hz
400 V ϕN ϕA
Motor size kW rpm IN (A) IA (A)

ZBR 100 12 0,8 20 410 240 5,7 9 0,55 0,75

V1
D 12/2 - B050 2 5,3 40 2780 120 11 55 0,88 0,85

ZBR 132 12 1,4 20 400 240 9,6 15 0,54 0,68

V2
D 12/2 - B140 2 8,9 40 2870 120 18 120 0,89 0,85

Mains connection delay fuse for 50 Hz 1) Supply lines for 5% voltage drop ∆U and starting current IA for 50 Hz 2)
Range DR 5
400 V 400 V (∆U 20 V)

Motor size A mm² m

ZBR 100 D 12/2 25 1,5 19

ZBR 132 D 12/2 50 2,5 15

Range DR 10 No. of Code P % CDF n Starts/h Rated current IN and starting current IA cos cos
poles for 50 Hz
400 V ϕN ϕA
Motor size kW rpm IN (A) IA (A)

ZBR 132 12 1,4 20 400 240 9,6 15 0,54 0,68

V1
D 12/2 - B140 2 8,9 40 2870 120 18 120 0,89 0,85

Mains connection delay fuse for 50 Hz 1) Supply lines for 5% voltage drop ∆U and starting current IA for 50 Hz 2)
Range DR 10
400 V 400 V (∆U 20 V)

Motor size A mm² m

ZBR 132 D 12/2 50 2,5 15

20364044.p65/081105

1) Fuse links also apply in conjunction with a cross travel motor.

8 2) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ.
 Key data cross travel drives DR 3 – DR 5 – DR 10

The cross travel drives of the DR without electrical control are designed for operation with a Demag frequency inverter in the
120 Hz range. We recommend that Demag DIC Dedrive Compact frequency inverters be used. Owing to the large input voltage
range of the Dedrive Compact, the DR without electrical control can be operated with mains voltages of 380...480 V with
50...60 Hz. At 380 V, the max. frequency must be reduced by 5 Hz.

Key data of inverter-controlled cross travel drive DR 3, DR 5, DR 10 - 2/1 - 4/1 - 4/2

Range DR 3-10 No. of poles %CDF Output Current cos ϕ n Recommended
P at 220 V for 50 Hz inverter type

Motor size kW I (A) rpm Dedrive Compact

ZBA 71 B4 - B003 4 60 0,37 2,6 0,54 1375 DIC-4-004-E

Key data of inverter-controlled cross travel drive EZDR 10 -Pro 6/1

Range DR 10 No. of poles %CDF Output Current cos ϕ n Recommended
P at 220 V for 50 Hz inverter type

Motor size kW I (A) rpm Dedrive Compact

ZBA 90 A4 - B007 4 60 1,1 5,1 0,74 1400 DIC-4-007-E

Example for calculating the cross sec- ZBR 100 C 2/12, 400 V required length 25 m
tions of the conductors of cables ex- Known cross section x required length 2,5 x 25
ceeding the length indicated in the table: = = 4 mm2
Known cable length 16
20364044.p65/081105

9
 Key data of inverter-operated hoist drives DR 3, DR 5, DR 10
Design is in accordance with the VDE regulations and the design rules of the FEM, to meet the high demands made on
electric hoists.

The hoist drives of the DR without electrical control are designed for operation with a Demag frequency inverter in the 87 Hz
range. We recommend that Demag DIC Dedrive Compact frequency inverters be used. Owing to the large input voltage range of
the Dedrive Compact, the DR without electrical control can be operated with mains voltages of 380...480 V with 50...60 Hz. At
380 V, the max. frequency must be reduced by 5 Hz.

Range DR 3 No. of poles Code FEM classification % CDF Output Current cos ϕ n Recommended
P at 220 V for 50 Hz inverter type

Motor size kW I (A) rpm Dedrive Compact

ZBR 100 B 4 - B050 2m DIC-4-017

ZBR 100 B 4 - B050 4 V3 3m 60 4,2 16,9 0,85 1350 DIC-4-014

ZBR 100 B 4 - B050 4m DIC-4-014

Range DR 3 Mains connection delay fuse for 50 Hz 1) Supply lines for 5% voltage drop ∆U 2)

400 V 400 V (∆U 20 V)

Inverter type A mm² m

DIC-4-017 16 1,5 58

DIC-4-014 16 1,5 70

Range DR 5 No. of poles Code FEM classification % CDF Output Current cos ϕ n Recommended
P at 220 V for 50 Hz inverter type

Motor size kW I (A) rpm Dedrive Compact

ZBR 132 B 4 - B140 2m 8,3 29,0 0,87 1420 DIC-4-025

ZBR 112 A 4 - B140 4 V3 3m 60 DIC-4-025

5,3 18,7 0,84 1430
ZBR 112 A 4 - B140 4m DIC-4-017

Range DR 5 Mains connection delay fuse for 50 Hz 1) Supply lines for 5% voltage drop ∆U 2)

400 V 400 V (∆U 20 V)

Inverter type A mm² m

DIC-4-025 35 2,5 65

DIC-4-017 16 1,5 58

Range DR 10 No. of poles Code FEM classification % CDF Output Current cos ϕ n Recommended
P at 220 V for 50 Hz inverter type

Motor size kW I (A) rpm Dedrive Compact

ZBR 132 C 4 - B140 2m 10,2 38,0 0,84 1425 DIC-4-040

ZBR 132 B 4 - B140 V2 3m 60 DIC-4-032

8,3 29,0 0,87 1420
ZBR 132 B 4 - B140 4m DIC-4-025
4
ZBR 132 C 4 - B140 2m 50 13,1 46,5 0,83 1410 DIC-4-040

ZBR 132 C 4 - B140 V3 3m DIC-4-040

60 10,2 38,0 0,84 1425
ZBR 132 C 4 - B140 4m DIC-4-032

Range DR 10 Mains connection delay fuse for 50 Hz 1) Supply lines for 5% voltage drop ∆U 2)

400 V 400 V (∆U 20 V)

Inverter type A mm² m

DIC-4-040 50 6,0 97
20364044.p65/081105

DIC-4-032 35 4,0 80

DIC-4-025 35 2,5 65

1) Fuse links also apply in conjunction with a cross travel motor.

10 2) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ.
 Parameter settings for recommended Demag DIC Dedrive Compact frequency inverter

Please refer to the table below for the required parameter settings.
For the hoist drives, rotary encoder feedback on the motor is required. We recommend that the Demag AG 2 external pulse gen-
erator be used together with the EM-ENC-02 extension module for the Demag Dedrive Compact frequency inverter.
After entry of the rated motor values, it is absolutely necessary to perform parameter identification.

No. Name Unit ZBA ZBR

71 B4 90 A4 100 B4 112 A4 132 B4 132 C4
60% 50% 60%
030 Configuration - 410 210

370 Rated voltage V 220

371 Rated current A 2,6 5,1 16,9 18,7 29,0 46,5 38,0

372 Rated speed rpm 1375 1400 1350 1430 1420 1410 1425

373 No. of pole pairs - 2

374 Rated cosine phi - 0,54 0,74 0,85 0,84 0,87 0,83 0,84

375 Rated frequency Hz 50

376 Mech. rated output kW 0,4 1,1 4,2 5,3 8,3 13,1 10,2

417 Frequency switch-off limit Hz 250 100

418 Min. frequency Hz 5 8

419 Max. frequency 1) Hz 120 84 85 86

420 Acceleration Hz/s 25 42 42,5 43

421 Deceleration Hz/s 50 42 42,5 43

490 Operating mode encoder 1 - 0 4

Pulse number per revolution of
491 - - Depending on rotary encoder used
encoder 1

721 Amplification speed controller - 3 10

Integral action time speed
722 ms 200 100
controller

For further details regarding commissioning, the many control possibilities, the various hoist functions and the selection of further
additional components of the DIC Dedrive Compact, refer to the operating instructions 214 708 44 and 214 716 44. The permis-
sible ambient conditions must be complied with.
20364044.p65/081105

1) At 380 V, the max. frequency must be reduced by 5 Hz. 11

12
Fig. 2
1

Top-hat rail, 200 mm long

5
PE
J
EG
PE
1 2 3 4 5 6
3 4
2 2-pole HUB
2 pol. hoist
12VE A 1A B 1B GDNE

12 pol. HUB
12-pole hoist
PE PE PE
6 7 8 9
X52
L 10 K 11 12

U V W U V W
SGS SGG Kreuz1
Cross1 Cross2
Kreuz2

1 2 PE 1 2 3 4 5 6 7 8 1 2 3 PE 1 2 3 PE

ThH ThH Brg Brg BrH BrH SGS SGS PE SGG1SGG2 SGG3SGG4 SGG5 SGG6 SGG7 SGG8 X161 X162 X163 PE X418 X482 X483 PE
X11

A X53 X5 X16 X48

X9 PE PE
Connection plate with terminal strip for DR with 2-/12-pole hoist

B C D E F G H I

42354944.eps
20364044.p65/081105
 Customer connections
1 Top-hat rail
2 12-pole hoist motor connection
3 2-pole hoist motor connection
4 EG integrated pulse generator
5 Protective earth conductor PE
6 Thermo-switch hoist motor
7 Brake release contact hoist motor
8 Brake hoist motor
9 SGS overload protective device, electro-mechanical
10 SGG geared limit switch
11 Cross travel cut-out system, general
12 Cross travel cut-out system, preliminary (v2 → v1)

All terminals must be connected with up to 4 mm² Cu cross section, except

2-pole hoist and PE which must be connected with up to 16 mm² Cu cross
section.

Factory connections

A Terminal X11 (12-pole hoist motor)

B Terminal X9 (2-pole hoist motor)
C Terminal X10 (signals hoist motor)
D Terminal X53 (SGS)
E Protective earth conductor PE
F Terminal X5 (SGG)
G Terminal X16 (cut-out)
H Terminal X48 (prel.)
I Protective earth conductor PE
J Protective earth conductor PE
K Protective earth conductor PE
L Connection X52 (integrated pulse generator hoist motor)
20364044.p65/081105

13
14
Fig. 3
1

Top-hat rail, 200 mm long

5
PE
J
EG
PE
1 2 3 4 5 6
3 4
2 2-pole hoist
2 pol. HUB
12VE A 1A B 1B GDNE

12-pole hoist
12 pol. HUB
PE PE PE
6 7 8 9
X52
L 10 K 11 12

U V W U V W Cross1 Cross2
SGS SGG Kreuz1 Kreuz2

1 2 PE 1 2 3 4 5 6 7 8 1 2 3 PE 1 2 3 PE

ThH ThH Brg Brg BrH BrH SGS SGS PE SGG1SGG2 SGG3SGG4 SGG5 SGG6 SGG7 SGG8 X161 X162 X163 PE X418 X482 X483 PE
X11

A X53 X5 X16 X48

X9 PE PE

B C D E F G H I
Connection plate with terminal strip for DR with 4-pole hoist motor

42356144.eps
20364044.p65/081105
 Customer connections
For the DR with 4-pole hoist motor, the connection is made directly in the motor
terminal box

1 Top-hat rail
2 -
3 -
4 -
5 Protective earth conductor PE
6 -
7 -
8 -
9 SGS overload protective device, electro-mechanical
10 SGG geared limit switch
11 Cross travel cut-out system, general
12 Cross travel cut-out system, preliminary (v2 → v1)

All terminals must be connected with up to 4 mm² Cu cross section, except

2-pole hoist and PE which must be connected with up to 16 mm² Cu cross
section.

Factory connections

A Terminal X11 (12-pole hoist motor)

B Terminal X9 (2-pole hoist motor)
C Terminal X10 (signals hoist motor)
D Terminal X53 (SGS)
E Protective earth conductor PE
F Terminal X5 (SGG)
G Terminal X16 (cut-out)
H Terminal X48 (prel.)
I Protective earth conductor PE
J Protective earth conductor PE
K Protective earth conductor PE
L Connection X52 (integrated pulse generator hoist motor)
20364044.p65/081105

15
 Cable unions

DR 3 cable unions DR 5 cable unions

2 2

1 1

3
3

42355044.eps
42355144.eps

DR 10 cable unions Cable unions, DR 3, DR 5, DR 10 cover

2

Fig. 4 42355244.eps 42355344.eps

1 Round cable union M251)

2 Round cable union M201)
3 Twist-type cable entry gland for cable glands up to max. 12,5 mm
4 Round cable union M25
20364044.p65/081105

1) Screw-type unions must have long threads (approx. 15 mm)

e.g. cable union Schlemmer-Tec, manufacturer no. 5307620 (M20 x 1,5)
16 cable union Schlemmer-Tec, manufacturer no. 5307125 (M25 x 1,5)
 Connection diagrams

Hoist motor connection diagrams

Pole-changing hoist drive ZBR 100 motor terminal block

Y/Y
U 4 2 1

CW CCW wh gn bn
1L1 1L2 1L3 2L1 2L2 2L3 SP1 SP2 TB1 TB2
1S3 1S2 1S1

1U 1V 1W 2U 2V 2W BD1 BD2
T1 T2 T3 T11 T12 T13

U U U U U U
Re-start block min.
250 ms! 1SP1 1SP2 1SP3 2SP1 2SP2 2SP3

1U 1V 1W 2U 2V 2W BD1 BD2 TB1 TB2 1S3 1S2 1S1

T1 T2 T3 T11 T12 T13 SP1 SP2
1SP1 1SP2 1SP3 2SP1 2SP2 2SP3

low high
GS 1L1 1L2 1L3 1L1* 1L2* 1L3* L+ 1L-
speed speed VE 7 ~
6 ~
RD BU WH 5 ~ 41003284.eps
4
3
2 - ZBR 132 motor terminal block
X1 1 + PCB in DR
Switchgear
cabinet Y/D 2V
TB1
TB2
1S2
1S1

RD T12
U 4 2 1

Motor SP1 SP2 TB1 TB2

wh gn bn
1S3 1S2 1S1
U 2U 2W
BD1 BD2
1U 1V 1W T11 T13
U U U
T1 T2 T3

1V BD2 BD1 U U U U U U

1U 1W
Thermo-switch

1SP1 1SP2 1SP3 2SP1 2SP2 2SP3

Brake monitoring

PE M
3~
2U 2W 1U 1V 1W 2U 2V 2W BD1 BD2 TB1 TB2 1S3 1S2 1S1
2V T1 T2 T3 T11 T12 T13 SP1 SP2
1SP1 1SP2 1SP3 2SP1 2SP2 2SP3

U U U

1L1 1L2 1L3 1L1* 1L2* 1L3* L+ 1L-

42356044.eps 41004384.eps

Hoist drive with frequency inverter Motor terminal board

1L1 1L2 1L3 2L1 2L2 2L3

U2 V2 W2
X1

4 2 1
Frequency
inverter hoist RD
TB1 TB2
wh gn bn

U1 V1 W1 VE+ GS1 BD1 BD1 BD2 1S3 1S2 1S1

~ Re-start block min.

250 ms!
W2 U2 V2
VE GS

U V W
~ Switch-
U1 V1 W1
WH
-
BU RD
+
7 6 5 4 3
WH BU
-
2
+
1

1L1 1L2 1L3

gear 4 3 X1 2L3 2L2 2L1 BD2 X1
TB1
TB2
1S2
1S1

cabinet GS
U1 V1 W1 VE
GS
VE 7 ~
6 ~ Motor
RD BU WH 5 ~
4 terminal box
3
X1 2 -
1 +

RD

BD2 BD1

PE M
3~ Motor
Thermo-switch

Brake monitoring

U2
V2
W2

Fig. 5
42355944.eps 03800784.eps
20364044.p65/081105

17
 Cross travel motor connection diagram

Cross-travel drive with frequency inverter Motor terminal block

1L1 1L2 1L3 2L1 2L2 2L3

U

Switch-
gear SP1 SP2 TB1 TB2

cabinet U1 V1 W1
BD1 BD2
T1 T2 T3
GE
~ VE 7
6 ~
~ RD BU WH
5 ~
4
3
2 -
X1 1 + U1 V1 W1 BD1 BD2 TB1 TB2
T1 T2 T3 SP1 SP2
TB1
TB2

RD
Motor terminal
block
U L1 L2 L3 L+ L-

V1 BD2 BD1
U1 W1

PE M
3~
Thermo-switch

Motor
Brake

Fig. 6 42355844.eps 41003384.eps

EG integrated pulse See operating instructions for Motors, type Z, ident. no. 214 228 44
generator

Brake release contact See operating instructions for Motors, type Z, ident. no. 214 228 44

Temperature sensor, hoist See operating instructions for Motors, type Z, ident. no. 214 228 44
and cross travel motor
20364044.p65/081105

18
 Brake control

Various control modules are available for controlling Demag B003 to B680 disk
brakes with DC magnets.
All modules can also be fitted inside the switchgear cabinet.
In this case, the brake coil must be protected against switching voltage peaks by
means of a varistor, part no. 260 898 84, in the motor terminal box.
All rectifiers feature varistor protection against overvoltage at the AC input and on the
switching contact terminal as standard.
The braking rectifiers are approved for a max. AC voltage of 500 V AC.
Brake cut-out in the AC or DC circuit is possible with GE rectifiers (cross travel) and
GS rectifiers (hoist) depending on the connection.
Brake application times are highly dependent on the way in which the brake is
switched off.
For the DR without electrical control system, cut-out in the DC circuit by using the
VE module is necessary.

Operation with frequency inverters

If ZB cylindrical rotor brake motors are operated together with inverters, the
brake must be provided with a separate power supply and control.

Brake control modules

• GE brake rectifiers (normal excitation)
GE brake rectifiers are used for the cross travel drive of the DR as standard.
They mainly consist of a half-wave rectifier with integrated free-wheeling circuit.
• GS brake rectifiers (high-speed excitation)
GS brake rectifiers are used for the ZBR motors of the DR hoist drives as
standard.
The GS module includes a reversible rectifier which overexcites the brake for ap-
prox. 0,3 seconds to release it and supplies it with the appropriate holding voltage
from a half-wave rectifier (overexcitation factor of 2,5 with 3-phase connection).

Important: When used with a pole-changing motor, GS modules must always

be provided with a separate power supply.

To ensure perfect functioning for cut-out of the GS and VE modules, i.e. switching
with overexcitation, min. 250 ms must expire between cut-out and switching on
again.

• VE voltage relays (voltage-dependent high-speed trip relay)

VE voltage relays can be combined with GE, GS and GP brake rectifiers. VE
voltage relays must only be used for brakes with a separate power supply.
These modules are preferably used for inverter-fed motors. They are used for
high-speed demagnetization of the brake to achieve fast brake application times
without the need for additional wiring for brake cut-out in the DC circuit. VE
voltage relays are connected to the brake power supply. The contact in the DC
circuit is opened when the brake is switched off.
20364044.p65/081105

19
 SGG geared limit switch

Adjusting screw, black Adjusting screw, white

SGG/terminal strip connection

SGG Switch contacts

1 1

2 2

3 3

4 4

5 5

6 6

7 7
For adjusting the geared limit switch, a hexagon socket key, 4 mm, is required. 4

8 8

Fig. 7 42589444.eps

Adjusting instructions for SGG Before setting the switching points, make sure that live contacts are provided with a
touch guard in order to protect them against accidental contact.

Allow for run-on!

Operating principle Each contact is allocated to a cam disk which is infinitely adjustable.
The cam disks can be adjusted independently by means of the white adjusting
screws.

Adjust When turning the white adjusting screw clockwise, the cam disk is also turned clock-
wise. The switching point is shifted upwards in accordance with the hook path.
When turning the screw anti-clockwise, the switching point is shifted downwards.
Standard cam disks are designed in such a way that a max. useful path and a run-on
path are available.

Setting the contacts for individual The geared limit switch is already permanently connected with the control system via
adjustment: the system connector cable. For setting the contacts, turn the white adjusting screw
until the contact maker opens the contact.
If the run-on path is exceeded, the contact either opens or closes.

Setting the contacts for adjustment in The contacts are adjusted in blocks by means of the black adjusting screw. All cam
blocks: disks are adjusted together, while the relative adjustment of the individual contacts
remains unchanged. When turning the black adjusting screw clockwise, the cam
disks are also turned clockwise.

Approach cut-out points several times to check the limit switch functions are
operating correctly!
20364044.p65/081105

20
 Technical data

Transmission ratio: i = 205 with block setting of all cam disks designed for min. >1x106 switching
operations

Switch contacts: 4

Contact type: Change-over contact, snap-action contact, NC with automatic disconnection,

contact material: silver/silver

Cam disc: with 15° leading cams

Switching point repeat accuracy: approx. +/-15 mm on hook, least favourable case for 2/1 reeving and hook path
12 m. In this case, the 47 revolutions on the drive shaft result in an adjusting angle
of 79,71° on the cam shaft for i = 205.

Electrical connection: Terminal strip direct connection on PCB.

Technical features:
Compliance with standards EN 60204-1 IEC 947-5-1 EN 60947-T5-1
EN 60529 EN 50013 IEC 536
Ambient temperature Continuous operation -40 °C to +80 °C
Type of enclosure IP 54
Insulation class Class II
Approvals CE and CSA

Technical features of
switching elements:
Positive opening to rated operating volt-
age Ui
Thermal continuous current Ith
Category acc. to VDE 0660:
VDE 0660 part 200 from 7/92
250 V AC and 24/80 V DC
6A
AC-15, 230 V AC/1,5 A

Mechanical service lives in switching DC-13, 60 V DC/0,5 A

cycles 10 x 106 switching operations
Terminal identification Acc. to EN 50013
Approvals CE-UL/CSA
Current load to plug connector 6 A / 85 °C 250 V AC
Outer dimensions:
Length up to pinion cover approx. 165 mm
Enclosure dimensions approx. 91 x 72 mm
Overall height approx. 95 mm
20364044.p65/081105

21
 Load detector

SGS overload cut-out,

electro-mechanical

Position switch

Receptacle with tab, 6,3-2.1

Socket connector, 2-pole

Fig. 8 42355444.eps

Depending on the design, the SGS overload switch is set to the rated load of the DR
and integrated in the DR hoist. The SGS contact must be evaluated in addition to
avoid any vibration in the system caused by switching off and on again.

We recommend the use of MKA-2 contact evaluators for standard applications.

This unit prevents premature enabling of the lifting motion and the resulting vibration
processes by means of signal filtering. The unit is available for three control voltage
ranges, it is included in the supply depending on the order.

In combination with the SGS, only the ‘overload cut-out’ function can be used.

SGS Load link

Input voltage:
Output signal:
V switching capacity:
Ambient temperature:
Type of enclosure:
Mounting position:
24 V, 9600 Hz
Load limit contact NC -X53
4 A/230 V AC; 1 A/24 V DC
-30° C to +80° C
IP 67
Any
20364044.p65/081105

22
 MKA-2 front plate/connec-
tion diagram/dimensions

1)

A1 13 14 23 24 1) Jumpers for crane acceptance test.

Remove jumpers after acceptance test.

O.K CLK Dematik ® MKA-2

46953144

MGS
gn br/ws ge

1 2 3 4 A2
MKA-2 dimensions

MKA-2 front plate

Overload protec-
tion
Position 1 (not

71
SGS)
Position 2
Overload cut-out

45,0 113,0
Jumper positions
40995644.eps
Fig. 9 41873344.eps

Dematik® MKA-2 contact evaluator

Part no.: For control voltage 220...240 V, 50/60 Hz 469 531 44
110...120 V, 50/60 Hz 469 532 44
42...48 V, 50/60 Hz 469 533 44
24 V, 50/60 Hz 469 534 44

Other voltages in special designs:

Possible contacts: 2 NO contacts
Rated cut-out capacity: 230 V; 5 A AC11, 4 A conditional nominal short-circuit current
Operating voltage range: 90 to 100 % of the nominal value
Nom. consumption: max. 4 VA
Ambient temperature range: -20° C to +70° C
Mode: Suitable for continuous operation
Type of enclosure: IP 40 to DIN 40050
Conductor connection: max. 2 x 2,5 mm² with self-releasing washers
20364044.p65/081105

Mounting position: Any

Mounting: Quick mounting for carrier rail 35 mm
Weight: 390 g
23
 Block wiring diagram

Dematik® SGS/MKA-2 as overload cut-out

L1,L2,L3 PE

F2

K3 K4

M
3

M2

L4

S2 S1
A1

S1 S2
U1 Dematik MKA-2
23
U1
24 A2 2 3
S3 S3

Jumper in position 2
= Overload cut-out Equipment designation
K4 K3
(see page 23, fig 9)
SGS1 SGS2 B1 = SGS limit switch
K3 K4
F2 = Fuse ‘main hoist motor’
K3 = Contactor ‘Main lifting’
Brown

Yellow

K4 = Contactor ‘Main lowering’

L5
Lifting Lowering M2 = Main hoist motor
SGS
S1/S2 = Pushbutton lifting/lowering
21 22 S3 = Emergency limit switch lifting/lowering
U1 = MKA-2 contact evaluator
Fig. 10 42356644.eps

Function: SGS / MKA-2 as overload The SGS load link is plugged into position SGS on the PCB (SGS 1, SGS 2, PE).
cut-out The outgoing terminal connections are connected to the MKA-2 contact evaluator.
DR terminal SGS 1 on MKA terminal 2 and DR terminal SGS 2 on MKA terminal 3.
Plug the jumper behind the front plate of the MKA-2 into position 2, i.e. between the
pins in the middle and at the bottom.
(see also description of MGS/MKA-2 load detectors (206 689 44))
When SGS and MKA are used in combination, only the ‘overload cut-out’ function
can be used.
Only use contacts 23 - 24 of the MKA.
20364044.p65/081105

24
 ZMS, FGB-2, FWL overload protection

FGB-2 with PVC module

ZMS

Screening over outer sheath

Fig. 11 42355544.eps

Calculating and setting the

overload switching point
Rope FEM Nominal load [t] Lever ZMS 2/1 4/1 6/1 4/2 LF [x10-3]
hoist
2/1 4/1 6/1 4/2 A/B Nom. load Value S1 to S7 Value S1 to S7 Value S1 to S7 Value S1 to S7 2/1 4/1 6/1 4/2
[t]
2m 1,6 3,2 75 1101001 75 1101001 1,0596
DR 3 3m 1,25 2,5 0,5 0,625 60 0011110 60 0011110 - - - - 2,2222 - -
4m 1 2 49 1000110 49 1000110 4,3403
2m 2,5 5 75 1101001 75 1101001 1,0596
DR 5 3m 2 4 0,64 1,25 61 1011110 61 1011110 - - - - 2,0696 - -
4m 1,6 3,2 50 0100110 50 0100110 4,0422
2m 5 10 16 5 110 1100111 115 1100111 122 0101111 115 1100111 0,2778 0,2289 0,2778
DR 10 3m 4 8 12,5 4 0,5 1,25 93 1011101 93 1011101 115 1100111 93 1011101 0,5425 0,4800 0,5425
4m 3,2 6,3 10 3,2 75 1101001 74 0101001 78 0111001 75 1101001 1,0596 1,1109 0,9375 1,0596

Calculation example for FWL overload Rope hoist A/B

cut-out DR 3 and 10 0,5
DR 5 0,64

Example: Nominal load x A/B x 110 8 t x 0,5 x 110

DR 10-Pro, 8 t in 4/1 FWL switch value = +5 = + 5 = 93
No. of ropes x nominal load ZMS 4 x 1,25 t
ZMS = 1,25 t
20364044.p65/081105

A/B = 0,5
For a detailed description: see document 206 880 44

25
 FWL load spectrum recorder

Application The service life of hoist units mainly depends on the selection of the appropriate
group of mechanisms, i.e. the correct estimation of operating time and load spec-
trum. Over long periods of utilization, however, operating conditions may change at
a later date which may result in a longer or shorter service life. The conversion from
single to double-shift operation for a production crane, for example, results in dou-
bling daily utilization and, therefore, results in correspondingly faster wear of the drive
mechanisms.
Since hoist units are designed for specific periods of operation based on the rules of
fatigue strength, failures must be expected after the end of the theoretical service life
has been reached.
FWL units record all loads on the hoist unit during operation, in a power-failure safe
and long-term memory. The load spectrum recorder indicates experienced utilization.
It therefore continuously provides information on the operating conditions and the
calculated remaining service life of the hoist unit.

Mode of operation The load spectrum recorder measures the lifted load and the hoist motor operating
period.
The measured load is compared with the SWL and a relative load is calculated. Since
wear on the moving parts of the hoist unit increases disproportionately with rising
load, the value for relative loading is evaluated accordingly. Owing to this evaluation,
operation of the hoist unit with half the rated load only creates (1/2)3 = 1/8 of the load
spectrum value (LK value) which is reached by operation with rated load.
For ¼ rated load, therefore, the LK value is (1/4)3 = 1/64, etc.
The operating time of the hoist unit is measured as the duty time of the lifting and
lowering motions. Since wear can be assumed proportionally to the operating time,
the measured value is integrated as a proportion of time in the displayed LK value.
Double the operating time with identical load as a consequence corresponds to a
doubled LK value.
The load spectrum recorder collects the measured loading of the hoist unit, continu-
ously for any load and duty intervals. The LK value therefore corresponds to the sum
total of loads experienced so far. In contrast to the elapsed operating time counter, it
is not the pure duration of operation of the hoist unit that is displayed but the load on
the hoist unit is recorded, which is of far greater importance for wear, and evaluated
according to its influence.
The counter in the load spectrum recorder is calibrated so that when the strain gauge
carrier link is loaded with the SWL in group of mechanisms 1 Bm, the LK value
counts +1 per second.
This makes the load spectrum recorder an effective instrument for monitoring hoist
units.
Based on continuous recording of the displayed LK value, in particular in conjunction
with maintenance work, the owner of the hoist unit can easily obtain important infor-
mation for cost-effective planning of maintenance and preventive maintenance work.
It is possible to analyse utilization of hoist units on the basis of the recorded LK values
to appropriately plan any extension or modernisation measures.
The loading and operating time class to FEM can be verified at any time in conjunc-
tion with the elapsed operating time counter.
20364044.p65/081105

26
 Calculation of the elapsed The FWL load spectrum recorder makes is possible to determine the past duration
of service and, as a consequence, also the remaining duration of service.
safe working period (SWP)
For measuring, the nominal load of the ZMS is used as the reference nominal load.
This means that the FWL counts the full load seconds of the ZMS. If the ZMS is not
to be loaded with its own nominal load (for hoist unit nominal load), the displayed
value needs to be corrected by a specific factor. This correction factor must be en-
tered into the crane test and inspection booklet when the unit is put into operation.
The duration of service S in hours (to FEM 9.755) is calculated by means of the
following formula:
S = LK × LF S = Duration of service in full load hours

LK = FWL counter reading

LF = Load spectrum factor

Example: DR 3 3m
Counter LK = 10014
LF = 0,5425 x 106

Full load hours S = 10014 x 0,0005425 = 5,43 hours

FGB-2/FWL as overload protection and load spectrum recorder for hoist units with pole-changing motors
Switch 8 ON = overload protection

L1, L2, L3, PE

F1

Equipment designation
B1 = Strain gauge
F1 = Fuse ‘Hoist motor’
K1 K2 K3
K1 = Contactor ‘Creep lifting/creep lowering’
K2 = Contactor ‘Main lifting’
K3 = Contactor ‘Main lowering’
M1 = Creep – main hoist motor
M P1 = Elapsed operating time counter
3
S1/S2 = Pushbutton lifting/lowering
M1 S3 = Emergency limit switch lifting/lowering
L4 S4 = Preliminary limit switch ‘Main lifting’
K2 K3
S2 S1 U1 = Frequency evaluator/load spectrum
recorder, overload
U2 = FGB-2 frequency generator
A1 16 U3 = Hoist unit control (e.g. 250 ms re-start
S1
A1 1 2 3
U1 FWL P1 block)
U3 A2 1 2 3 10
A2 4 5 6 7
Screen
Brown
Green

White

13 23
U1 U1
14 24
U2 FGB-2
S3 S3 S3 S3
Screen

Yellow
Brown

S4
Green

White

K2 K3 K3 K2
B1 ZMS
K1 K2 K3

L5
Creep Main
Lifting Lowering Lifting Lowering
Fig. 12 42356544.eps
20364044.p65/081105

27
 Cross travel limit switch

Position switch XCK-MR

Position switch
2 x switching in steps with rotating stop

Positive lock connector 6,3 mm with lock

Contact block Contact block

‘A’ ‘B’
Connector, 3-pole
Core 1 on pin 1
Core 2 on pin 2
Core 3 on pin 3
Connector -X16
Connection of cable on
switch:

Connector, 3-pole
Core 4 on pin 1
Core 5 on pin 2
Core 6 on pin 3
5 mm offset without
Screw-type union M20 with long
thread (approx. 15 mm) connector -X48
Fig. 13
42355444.eps

Switching crossbar positions with Type XCK-MR54D1

contact arrangement
+180° +90° 0° -90° -180°

A11 A12
B21 B22
B11 B12

With rotating stop

Key data:
Housing: Zinc die-cast
Type of enclosure: IP66
Mechanical service life: 2 million switching cycles
Actuating speed: max. 90 m/min

Min. moment for actuation: 0,5 Nm

Positive opening: 0,75 Nm

Cable unions: 3 x M20

Rated operating data: AC-15: 240 V; 3 A

DC-13: 125 V; 0,55 A

Connection/cross section: Flat terminal with washer M3,5/max. 2 x 1,5 mm²

Earth lead connection/cross section: Flat terminal with washer M3/max. 1,5 mm²

Short-circuit protection: Fusible link 10 A, gG (gL)

20364044.p65/081105

Contact type: No snap function, positive opening of NC contact 21-22

28
 Option packages

Cross travel inverter

DR PRO and DR COM Package 1.1 1.2

Package 1 Inverter DIC-4-004 DIC-4-007
537 713 84 537 715 84
Braking resistor
- 537 732 84
120 Ohm 0,4 KW
Braking resistor
537 730 84 -
220 Ohm 0,2 KW

Order cable between trolley motor and FI separately, e.g. 4 x 1,5 + 2 x (2x0,5),
part no.: 719 096 45

Cross travel limit switch Cross travel

limit switch
DR PRO and DR COM
Package 2 EKDR 3 - 10 With mech. fittings 719 074 45
EZDR 5 - 10 With mech. fittings 719 174 45
Selection via logic
Fitted in the factory

Overload cut-out, F series Package 3.1 3.2 3.3 3.4 3.5 3.6
Only for DR PRO Rope hoist DR 3 DR 5, 10 DR 3 DR 5, 10 DR 3 DR 5, 10
Package 3 0,625 t 1,25 t 0,625 t 1,25 t 0,625 t 1,25 t
ZMS
Selection via logic 491 390 44 491 391 44 491 390 44 491 391 44 491 390 44 491 391 44
Fitted in the factory FGB-2 (terminals) 469 674 44
469 669 44 469 668 44 469 667 44
FWL
42-48 V 110-120 V 220-240 V

Order cable LIYCY 3 X 0,5 mm² between FGB-2 and FWL separately,
part no. 464 495 44

Accessories for parameter For programming the parameters, order an operating unit (key-pad, see table 1) or an
programming interface module and the ‘Parcom Compact’ parameter programming software (see
table 2).

Table 1
KP 500 operating unit 537 722 84

Table 2
KP232 interface module 537 769 84
RS 232 module CM - 232 537 723 84
Data line PC 1,8 m 537 237 84
Parcom Compact parameter
537 752 84
programming software
20364044.p65/081105

29
30
Notes

20364044.p65/081105
20364044.p65/081105

Notes

31
 Printed in Germany Basse/081105/5H

Demag Cranes & Components GmbH

P.O. Box 67, D-58286 Wetter
Telephone (+49 2335) 92-0 · Telefax (+49 2335) 927676
www.demagcranes.com

Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Subject to change. Not liable for errors or omissions.