Operating instructions

Single-load balance control system (pneumatic)

210302 EN 214 654 44 720 IS 853

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

1 Safety instructions 3
Contents
1.1 Symbols 3
1.2 Appropriate use 3
1.3 Inappropriate use 3
1.4 General safety information 4
1.5 Safety instructions for using pneumatic equipment 5
1.6 Safety instructions for assembly and disassembly 5
1.7 Safety instructions when first putting the unit into service
after completing installation 5
1.8 Safety instructions for operation 5

2 Technical data 6
2.1 Single-load balance control system scope of delivery 6
2.2 Operating principle 6
2.3 Weight 6

3 General 7
3.1 Inspection regulations 7
3.2 Noise emission measurement according to DIN 45653 7
3.3 Operating site 7
3.4 Storage and shipping 7
3.5 Operating conditions 7

4 Description 8
4.1 Putting into service 8
4.2 Operation 8
4.2.1 End of shift 8
4.2.2 Sudden compressed air pressure drop 8
4.3 Taking the unit out of service and transportation 9
4.4 Changing the load 9

5 Inspections/maintenance 10
5.1 Inspection before starting work and during operation 10
5.2 Inspections and maintenance 10
5.3 Hoses and valves 10

6 Fault list 11
6.1 Single-load balance control system 11

7 Single-load balance control system component parts 12

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2
 1 Safety instructions

1.1 Symbols The following symbols and recommendations indicate potential safety hazards or
causes of damage or provide useful information.

Hazard warning
This symbol appears in the operating instructions next to all instructions relating to
safety at work wherever a potential danger to life and limb exists.
Follow these instructions at all times and be particularly careful and cautious.
Pass on safety instructions to all persons entrusted with working on the product in-
cluding the power supply.
In addition, observe all general safety regulations at all times.

Operating hazard for the installation

This symbol in the operating instructions indicates all warnings which, if not complied
with, may result in damage to the product.

1.2 Appropriate use The product may only be operated when in perfect working order by trained person-
nel in accordance with the relevant safety and accident prevention regulations. This
also includes compliance with operating and maintenance conditions specified in the
operating instructions.
Single-load balance control systems are used with a system pressure of 6 bar (max.
permissible pressure 10 bar, with limited service life of the mechanical components).
For maintenance work on the single-load balance control system, the supply of ener-
gy must be interrupted and it must be ensured that all pressurised components are
free of pressure.
During operation or when the energy supply is not switched off, pneumatic compo-
nents are pressurised. In the event of inappropriate operation and non-compliance
with the existing regulations, this may result in fatal situations.
Serious personal injury or damage to property may occur in the event of:
• unauthorized removal of covers,
• inappropriate use of the product,
• incorrect operation,
• insufficient maintenance,
• working on pressurised parts.

1.3 Inappropriate use Certain work and practices are prohibited when using the product as they may in-
volve danger to life and limb and result in lasting damage to the product, e.g.:
• Manipulating pneumatic equipment
• Supplying energy other than the compressed air specified on the type plate
• Non-compliance with specified mounting positions
• Non-compliance with the min./max. permissible operating temperature
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3
 1.4 General safety informa- Persons under the influence of drugs, alcohol or medicines which affect reactions
must not install, put into service, operate, maintain, repair or disassemble the prod-
tion uct. Any conversions and modifications to the installation must comply with the tech-
nical safety requirements. Work on pneumatic equipment may only be carried out by
specialists in accordance with technical regulations. The product must be taken out
of service immediately and the relevant energy supplies must be disconnected in the
event of any malfunctions.
Malfunctions must be eliminated immediately.
National accident prevention regulations and codes of practice and general safety
regulations must be observed when operating our products. Important information
and instructions are marked by corresponding symbols. Follow these operating and
safety instructions to avoid personal injury and damage to machinery.
The operating instructions must be kept available at the place where the product is in
use at all times.
They include significant aspects and appropriate excerpts from the relevant guide-
lines, standards and regulations. The owner must instruct his personnel appropriately.
If the safety instructions given are not observed in any way, personal injury or even
death can result. Observe general statutory and other obligatory regulations relating
to accident prevention and environmental protection and basic health and safety
requirements in addition to those included in these operating instructions.
Such requirements may also relate, for example, to the handling of hazardous materi-
als or the provision/wearing of personal protection equipment.
Comply with these regulations and general accident regulations relevant for the place
at which the product is used and follow the instructions therein when working with
the product.
The product may still constitute a danger to life and limb if it is not installed, operated,
maintained or used appropriately by personnel which have not been trained or spe-
cially instructed.
The safety instructions must, if required, be supplemented by the owner with instruc-
tions and information (e.g. factory regulations) relating to organization of work, work-
ing procedures, operating personnel, etc. Supervising and reporting obligations as
well as special operating conditions must also be taken into consideration.
Personnel assigned to working with the product must have read the operating in-
structions and the safety instructions.
All activities relating to the product which are not described in the operating instruc-
tions may only be carried out by specifically trained specialist personnel. The owner
must ensure that personnel work in a safety and hazard-conscious manner in compli-
ance with the operating instructions. The owner must ensure that the product is only
operated when in proper working order and that all relevant safety requirements and
regulations are complied with.
The product must be taken out of service immediately if functional defects or irregu-
larities are detected.
In the event of a stoppage (e.g. if defects regarding safe and reliable operation are
detected, in emergency situations, in the event of operating malfunctions, for mainte-
nance purposes, if damage is detected or after finishing work), the operator/experi-
enced technician must carry out all prescribed safety measures or observe that they
are automatically carried out. Personal protective clothing must be worn as necessary
or as required by regulations. Personnel must not wear loose clothing, jewellery in-
cluding rings or long hair loose. Injury may occur, for example, by being caught or
drawn into the mechanism.
All safety and hazard warnings on the product, its access routes and energy supply
must be preserved completely and in legible condition.
Modifications, additions to and conversions of the product which may impair safety in
any way must not be carried out without the approval of Demag. Safety devices must
not be rendered inoperative. Only genuine Demag spare parts may be used. Observe
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prescribed deadlines or those specified in the operating instructions for routine

checks/inspections.

4
 1.5 Safety instructions for For handling pneumatically operated components, note that:
using pneumatic • potential hazards may be caused by stored compressed air.
equipment • dynamic movements may be caused as a consequence of the compressibility of
compressed air.

1.6 Safety instructions for • Installation and disassembly work may only be performed by experienced techni-
cians.
assembly and disas-
• Installation and disassembly work must be co-ordinated by the person carrying out
sembly the work and the owner within the scope of their responsibility.
• The assembly zone must be made safe.
• The installation must be isolated in accordance with the relevant technical regula-
tions (pneumatic equipment).
• Customer-specific regulations must be observed.
• Only appropriate, tested and calibrated tools may be used.

1.7 Safety instructions • The working area must be made safe.

when first putting the • First check that the rated pressure specified on the type plate matches the own-
er’s supply system.
unit into service after • In the course of putting the product into service, it may be necessary to render
completing installation safety devices or features inoperative when carrying out adjustments or function
checks.
• When putting the unit into service, it may be necessary to perform work in the
danger zone, therefore, it must be ensured that only appropriately trained person-
nel are employed for this work.

1.8 Safety instructions for
operation
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All instructions and measures described in the operating instructions with regard to
safe operation and items concerning general safety and accident prevention which
have to be observed before, during and after putting into service must be strictly
complied with. Any failure to comply can lead to accidents resulting in fatalities.
The product must be taken out of service immediately or not put into operation if any
defects relating to operating safety and reliability are detected.
Safety devices must not be rendered inoperative or modified in contradiction to their
intended use.
Only operate the product when all protective devices and safety-relevant equipment,
e.g. movable protective devices and emergency-stop devices, are fitted and fully
functioning.
In the event of damage to pneumatic devices and lines, immediately switch off the
unit.
Ensure that nobody is endangered by operation of the product before switching it on
or putting it into operation.
If the operator notices persons who may be exposed to a risk to health or personal
safety by operation of the equipment, he must suspend operation immediately and
may not resume operation again until the persons are outside the danger zone.
Before putting the product into operation, the operator must be satisfied that the
product is in safe and correct operating condition.
Work on the product may only be carried out when instructions to this effect have
been issued, when operation and function of the equipment have been explained and
when the working and danger zone has been made safe.
Cooling devices, such as ventilation openings, may not be rendered permanently

inoperative (e.g. covered or closed). Special local conditions or special applications

can lead to situations which were not known when this chapter was written. In such
cases, special safety measures must be implemented by the owner.

5
 2 Technical data

2.1 Single-load balance

control system scope
of delivery

Distribution block
with 2 additional com- 7
pressed air connections

High-precision
pressure controller
to counterbalance the 5
load weight
6

4
3 1

42533244.eps

The control system comprises:

1. High-precision pressure controller
2. Return valve
3. Hoses: PU hose, inner dia. 8 mm, outer dia. 10 mm
4. Screw-in connection (1/2” outer thread)
5. Distribution block for connecting the compressed air supply with two additional
outlets for special functions (not assigned in the basic version).
6. Mounting plate (for the Demag D-BP rope balancer in this case)
7. Quick-release coupling 7,2 mm

2.2 Operating principle The single-load balance control system is suitable for operation with pneumatically
operated manipulators, rope balancers, etc.
For operation of a pneumatic single-load balance control system, the manipulators,
rope balancers etc. to be controlled must be provided with a compressed air cylinder
with single function that acts against the suspended load.
The standard variant of the pneumatic single-load balance control system is designed
for D-BP rope balancers, D Lift lifting axes and D Arm parallelogram arms with a
working pressure of max. 10 bar.
Using the single-load balance control system, a pre-selected load can be manipulat-
ed.
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2.3 Weight Weight of the complete control system approx. 3,3 kg

6
 3 General

3.1 Inspection regulations Routine inspections

Single-load balance control systems must be inspected by an experienced technician

at least once a year.
Routine inspections mainly consist of a visual inspection and a function check which
should include a check to determine the condition of components and equipment
regarding damage, wear, corrosion or other alterations and a check to determine the
integrity and efficiency of safety devices. It may be necessary to dismantle the unit in
order to inspect wearing parts.

3.2 Noise emission meas- The noise emission level (LpAF) is:
urement according to less than
+2
70 dB (A)
DIN 45635
at a distance of 1 m from the control system.
These noise emission levels were measured under maximum load.
Structural influences such as
• transmission of noise via steel structures
• reflection of noise from walls, etc.
• outgoing air noise of the control systems
were not allowed for in the above measurements.

3.3 Operating site The single-load balance control system may only be used in buildings and enclosed
areas.

3.4 Storage and shipping The air inlet openings are closed to prevent dirt from entering the system.
These openings may only be opened immediately before the valve is fitted.

Status as delivered/for transportation

The high-precision pressure controller of the single-load balance control system is
adjusted to a set pressure of 0 bar in the factory. Therefore, no hazardous situation
can occur when putting the unit into service.
For transportation of the single-load balance control system and its components to
be operated at a later stage, the high-precision pressure controller must be adjusted
to a set pressure of 0 bar again.

3.5 Operating conditions Single-load balance control systems can be operated at an ambient temperature of
+5° to +50°C.
Other operating conditions are also possible.
Please refer to the manufacturer for information on any modifications that may be
necessary. See page 2 for the address.
Compressed air specifications in accordance with ISO 8573-1:
• Solid particles Class 3 (< 5 µm)
• Water Class 4 (dew point < +3°C)
• Oil Class 4 (< 5 mg/m³)
The quality of the compressed air supply must be ensured by means of an upstream
maintenance unit.
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 4 Description

42533244.eps

Single-load balance control system

The single-load balance control system is used to balance a load (e.g. welding tongs
or similar) that must be pre-set on the high-precision pressure controller.
The single-load balance control system can be used for
- Demag D-BP rope balancers,
- Demag D Arm parallelogram arms,
- Demag D Lift lifting axes.
The single-load balance control system must only be used in combination with a
maintenance unit that guarantees the required compressed air specification (see
section 3.5).
During operation, the load may not be changed since owing to the pre-setting of the
high-precision pressure controller hazardous rope movements might occur.
To change the load, first take the unit out of service, then set the new load weight
and put the unit into service again.

4.1 Putting into service When the load has been attached, the load weight must be counterbalanced. To do
this, increase the set pressure on the high-precision pressure controller using the
setting wheel until the load starts to rise slowly. Then reduce the set pressure again
until the load is maintained in balance.
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 4.2 Operation
4.2.1 End of shift
4.2.2 Sudden compressed air
pressure drop
4.3 Taking the unit out of
service and transporta-
tion
4.4 Changing the
load
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The pre-set pressure in the cylinder of the handling device enables the load to be
balanced. Movement is effected via the load itself or by means of an operating handle
(depending on the design of the handling device).
At the end of the shift, the load must not remain in suspended balanced condition. It
must be lowered and moved to a safe parking position. During lifting or lowering
operation, the load must not be detached or the load weight be changed since this
may result in hazardous movement of the load.
In the event of a sudden pressure drop, the return valve on the single-load balance
control system prevents the load from dropping by closing the pressurised cylinder. In
the event of an extended failure of the compressed air supply, the load gradually
lowers in small steps.
To take the unit out of service, move the load to a safe depositing or parking position
– it is not required to detach it from the supporting means.
To deposit the load, the set pressure is reduced to 0 bar. Turn the hand wheel on the
high-precision pressure controller clockwise to this effect. The load is slowly lowered
down to the ground. As soon as the supporting rope is free of tension, you may re-
move the load.
Adjust the high-precision pressure controller with special care since otherwise rapid
load movements and therefore hazardous situations may occur.
For transportation of the unit, make sure the high-precision pressure controller is set
to 0 bar to avoid hazardous movements of the rope while taking the unit into service.
Increasing or reducing the load in balanced condition results in unwanted movements
of the load. If the load to be handled is increased/reduced, counterbalance the new
load again on the high-precision pressure controller.
Take the unit out of service (see section 4.3).
Take it into service again with the new load weight (see section 4.1).
9
 5 Inspections/maintenance

The unit must be disconnected from the compressed air supply before carrying out
any maintenance or repair work.
Single-load balance control systems require little maintenance. Despite this, continu-
ous function checks and visual inspections must be regularly carried out by qualified
personnel (safety officers, engineers). The owner should have the unit checked by an
experienced technician at least once a year. He should check the correct functioning
and condition of components regarding damage, wear, corrosion or any other chang-
es. The safety devices must be particularly checked to ensure that they are complete
and effective.
If defects are detected, the unit must not be returned to service before the cause has
been determined and the defect eliminated.
The power supply must be disconnected and secured against restoration before
maintenance and repair work is carried out. In addition, measures must be taken to
prevent unwanted lowering of the load. All inspections, maintenance and repair work
must be documented.
Refer to the relevant operating instructions of the components and their control sys-
tems for fault analysis purposes.
Typical faults might be:
• The unit does not balance the load.
• The unit jolts or does not lift and lower loads smoothly
• The unit sways when at rest.

5.1 Inspection before The operator must check all functions before starting work.
starting work and Check for unwanted lifting motions and/or unusual noise when switching on the com-
pressed air supply. The single-load balance control system must be taken out of
during operation service immediately if its functions are not guaranteed or any defects are detected.

5.2 Inspections and main- If routine maintenance reveals that the intervals are too long, they should be adapted
to the specific operating conditions.
tenance
Only use genuine Demag parts for repairs.
The use of spare parts not approved by Demag renders any liability and guarantee
claims void.

5.3 Hoses and valves Hoses, valves and unions must be visually inspected before starting work.
The unit must be switched off immediately and the parts specified must be replaced if
any of the following situations occur:
• damage or surface wear,
• hard, stiff, charred hoses or cracks resulting from the effects of heat,
• badly corroded valves,
• leaks in hoses or valves,
• blistered, soft or loose outer layer.
It must be ensured that the entire handling device (hoses, valves, etc) are not under
pressure before defective parts are removed.
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 6 Fault list

6.1 Single-load balance

control system
Fault: Cause:
Load can no longer be moved Leak in compressed air supply
Compressed air supply is switched off
Leak in hose line between compressed air
connection of control system and return valve
Manual force for lowering/lifting motion not the Pre-setting of pressure not precise
same
Remedies:
Return valve prevents load from falling in spite of
compressed air failure.
The load can be lowered manually by reducing the
set pressure on the high-precision pressure
controller.
See instructions for taking out of service.
When the compressed air supply has been
restored, proceed as for putting into service.
Correct setting of high-precision pressure controller

Manual force for lowering/lifting motion increases Worn seal on handling device. Replace seal, re-lubricate (see operating instructions
considerably Insufficient lubrication of relevant handling device)

See also fault list, inspection and maintenance work instructions of the relevant handling device
(e.g. Demag D-BP 55 and D-BP 110 rope balancer operating instructions, 214 421 44)
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7 Single-load balance control system component parts

42532444.eps

Item no. Part no. Quantity Designation Material Standard

1 82656144 1 Mounting plate D-BP 55

1 82666144 1 Mounting plate D-BP110
2 82658744 1 Distributor block 3/8"
3 34327644 2 Screw plug G3/8X 9
4 34363844 1 Seal G3/8" DR38EL
5 34363744 1 Plug coupling 3/8"
6 34364644 1 Plug connection 3/8"
7 15235199 2 Thread forming screw CE M 5X 30 ST-Z A2F DIN 7500
8 34364144 1 Plug connection 1/2"
9 34364444 1 Tube 10x1,5schw.
10 34364444 1 Tube 10x1,5schw.
11 34364644 1 Plug connection 3/8"
12 82655644 1 Pressure governor 3/8" 100HR
13 34364544 1 Check valve R 3/8
14 32011099 2 Hex.socket cylind.screw M 6 X 10 8.8 A2F DIN 6912
15 33700699 2 Hexagonal nut M 6 CU 3 ISO- 4032
16 34364744 1 Right-angle plug D10

21465301.tbl
Printed in Germany MBR/040402/5H

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.