ZMS load detectors on DR hoists

Description and notes

050109 enEN 214 806 44 720 IS 819

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

Contents 0 Foreword 3
1 Principle 3
2 ZMS strain gauge carrier link 4
3 ZMS mounting 4
4 Functioning of the overload protective device 5
4.1 General 5
4.2 Overload protection function 5
4.3 Setting the overload switching point 6
4.3.1 Programming parameters of the overload switching point 6
4.3.2 Correcting the overload switching point 6
4.4 Overload signal 6

5 Load reduction function in specific areas 7

5.1 General 7
5.2 Area-dependent load reduction function 7
5.3 Setting the load reduction 7
5.3.1 Programming parameters of the load reduction 7

6 Functioning of slack rope cut-out 8

6.1 General 8
6.2 Slack rope cut-out function 8
6.3 Setting the slack rope cut-out point 8
6.3.1 Programming parameters of the slack rope switching point 8
6.3.2 Correcting the slack rope cut-out point 8
6.3.3 De-activating the slack rope function 8

7 Safety features 9
7.1 Error messages 9

8 Notes for the acceptance test of hoist units with load detectors 10
8.1 125 % overload for the crane acceptance test 10

9 Display of load in control pendant or radio control system 11

9.1 Load bar display in control pendant or radio control system 11
9.2 Display of load in large load display 11
9.3 Tare function 11

10 ANG-CAN large load display 12

11 Note 12
12 Maintenance 12
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 0 Foreword

The load detector consists of a strain gauge carrier link for 2/1, 4/1 and 4/2
reeving or two strain gauge carrier links for 4/2-2 reeving, the load detection and
load evaluation system integrated in the DR control system featuring an internal
summation possibility and load display control.

1 Principle

DR hoists and supporting structures can be protected against overload by means

of the load detector. In principle, a distinction is made between four functions
which all comprise the load spectrum recorder:
1. Overload protection
2. Overload protection with slack rope cut-out
3. Summation overload protection
4. Summation overload protection with slack rope cut-out
5. Load summation
For overload protection and summation overload protection, an area-dependent
reduction of the load is also possible.
The load detector is intrinsically safe, i.e. in the event of simple faults as well as
a broken wire, missing operating voltage or missing ZMS signal, the load can no
longer be lifted. (see section 7 “Safety features”)
The control system with integrated load detector is designed for operation in
industrial environments.
The system is based on the principle of strain measurement by means of strain
gauges.
A ZMS strain gauge carrier link fitted on the crossbar, retaining plate or return
sheave is subject to strain when a load is lifted. As a result, the resistance values
of the strain gauges arranged on the carrier link change.
This change in resistance is converted into a load-proportional analogue voltage
and evaluated in the integrated load detector.
The strain gauge carrier link must be suspended so that only tensile forces are
transmitted.
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 2 ZMS strain gauge carrier link

For the required strain gauge carrier link, see section 11.
Since hoist units can be loaded with different loads in accordance with their FEM
group, the “rated load” with the parameters of the hoist unit is loaded to the control
system.
For any loads deviating from the FEM group, the “SWL” parameter must be set to
the new value. This is only possible in the production plant or by Demag Service
using the appropriate Demag software tool.
The control system is pre-set with the parameter for the partial load switching point
of 25 % and the parameter for the creep lifting time of 5 sec. If necessary, these
parameters may be adapted to the requirements of the owner by Demag Service.
All strain gauge carrier links are adapted to the SWL in the factory. Avoid hard
blows against the strain gauge carrier link which may result in losing the adapted
value.
For operation in hot and acid-laden atmospheres, protection measures against
heat radiation and corrosion are required.
DR strain gauge carrier links are supplied with a screened cable as standard. The
length of the cable is adapted to the size of the DR hoist, it is provided with the
necessary cable union and a connector. This connector must be plugged directly
onto the basic card, the cable must not be extended.

3 ZMS mounting

For 2/1, 4/1, 4/2 and 4/2-2 reeving arrangements, the relevant crossbars have
been standardised. Selection is made in line with the customer’s requirements.
Other designs are made to order.
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 4 Functioning of the overload protective device

4.1 General When a load is lifted, vibrations occur in the rope which are measured as short-
term load peaks.
These vibrations depend on the load, the lifting speed and the rope length, they
should, however, not result in a cut-out.
This is ensured by forming a mean value based on several measurements.
If a load is lifted at a relatively small speed, hardly any vibrations occur. If during
the lifting process an overload occurs, the measuring system will detect any load
exceeding the rated load very precisely and the hoist unit will be immediately
switched off. Owing to the low speed, there is hardly any run-on of the motor so
that overloading of the hoist unit is prevented.
This type of load limitation is called overload protection. Therefore, overload pro-
tection in only possible in connection with a creep lifting speed and an adjustable
creep lifting time unequal 0 sec.

4.2 Function overload The connector of the strain gauge carrier link is plugged onto the basic card.
When the mains voltage has been switched on, the control system runs through
protective device an initialisation phase and a test of the load detector.
Upon successful completion of the initialisation phase, the control system is ready
for operation, creep and main lifting are enabled.
When a load is lifted at main lifting speed, the control system automatically
switches off main lifting for the duration of the pre-set creep lifting time by means
of the load detector once the partial load switching point has been exceeded.

A) When loads smaller than the “SWL” are lifted, main lifting is enabled again after
the creep lifting time has expired. Any overload caused, for example, by a load
getting caught is detected when the “SWL” is exceeded. Creep and main lifting
are switched off.
B) When the “SWL” is reached due to overload, creep lifting is also switched off.
The load can then only be lowered. When the rope is unloaded by the pre-set
hysteresis and after an on-delay of 2 sec., both speeds are enabled again. The
creep lifting time, however, is only started again, when the partial load switching
point is exceeded again.

Rope tensile force

% Load limit %
Load limit
110 110 Load ≥ 110 %
Rated load Rated load
100 A) 100
B)
Load > approx. 12.5 % < 110 %

Partial load
Partial load 12.5-50 %
12.5-50 % Time Time
Hoist Hoist
speed speed
Main lifting Main lifting

Creep
Creep Time lifting Time
lifting TF TF

Fig. 1 40992344.eps
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 4.3 Setting the overload
switching point
4.3.1 Programming parameters of
the overload switching point
4.3.2 Correcting the overload
switching point
4.4 Overload signal
6
On delivery of the DR hoist, the “SWL” parameter which determines the switching
point is pre-set to the default value of the DR hoist. If necessary, it may be re-pro-
grammed to a lower value.
In addition, the switching point can also be changed in %-increments with reference
to the “SWL” by means of rotary encoding switch Code302:
Setting Modification
0 -20%
1 -18%
2 -16%
3 -14%
4 -12%
5 -10%
6 -8%
7 -6%
8 -4%
9 -2%
A 0% (default value)
B +2%
C +4%
D +5%
E +5%
F +5%
Any overload is signalled in the following way:
• Continuous sequence of short acoustic signals by the Piezo sound transmitter
• Activation of all segments of the load bar display in the display of control
pendant or radio control system
• Display of the “Overload” icon in the radio control system display
• Lifting motion interlocked, only lowering possible
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 5 Load reduction function in specific areas
5.1 General
5.2 Area-dependent load
reduction function
5.3 Setting the load
reduction
5.3.1 Programming parameters of
the load reduction
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In certain cases, it may be necessary to additionally reduce the SWL only in spe-
cific areas of cross and/or long travel. This is done with the area-dependent load
reduction function.
If the “Area-dependent load reduction” parameter is unequal 0, the SWL of the DR
hoist is limited to the SWL specified by the “Max. load with load reduction” parameter
in the areas of cross and/or long travel defined by additional area limit switches. This
applies to individual DR hoists and cranes with load summation. Setting of these
parameters is only possible in the production plant or by Demag Service using the
appropriate Demag software tool.
Functioning of the area-dependent load reduction can be adjusted by means of the
“Area-dependent load reduction” parameter. The “Max. load with load reduction”
parameter indicates the reduced SWL in kg.
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 6 Functioning of slack rope cut-out

6.1 General If a payload and/or a deadload is lowered, it might become necessary to detect set
down of the load and unloading of the rope to switch off the lowering motion. This
is done with the integrated slack rope cut-out function.

6.2 Slack rope cut-out If the “Deadload” parameter is set to unequal 0, the lowering motion of the hoist
unit is switched off when the value drops below 0,8 x deadload.
function

6.3 Setting the slack rope

cut-out point
6.3.1 Programming parameters of
the slack rope switching point
The slack rope cut-out function can be switched on via the “Deadload” parameter
and the switching point can be adjusted. Setting of these parameters is only pos-
sible in the production plant or by Demag Service using the appropriate Demag
software tool.

6.3.2 Correcting the slack rope cut-
out point
In addition, the switching point can also be changed in %-increments with
reference to the “Deadload” value by means of rotary encoding switch Code303:
Setting Modification
0 -5%
1 -4%
2 -3%
3 -2%
4 -1%
5 0% (default setting)
6 +1%
7 +2%
8 +3%
9 +4%
A +5%
B +5%
C +5%
D +5%
E +5%
F +5%

6.3.3 De-activating the slack rope
function
In certain operating situations, it may be necessary to de-activate the slack rope
function for a brief time. This is possible with the key-operated switch on the DSE-8R
control pendant and with the “Check limit switch” key on the radio control system.
The deadload can then be deposited.
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 7 Safety features

The load detector and the relevant hoist unit control system are provided with a
series of monitoring devices which, when triggered, prevent a lifting motion and
output fault messages.

7.1 Error messages

Error codes of DR control systems

1 up to 99: Error codes of selected trolley (trolley 1)
No. Designation Source Display Signal horn Description

8 Slack rope detected HCS12 yes only with ZMS

10 ZMS1 offset voltage HCS12 yes Measured analogue value too small

11 ZMS2 offset voltage HCS12 yes Measured analogue value too small

12 V monitoring system has detected an error in one of

12 Ref. voltage HCS12 yes
the two voltages
Error on ZMS evaluation detected during check caused
13 Deviation error HCS12 yes
by deviation

14 Load difference too large HCS12 yes only with two ZMS

no overload detection
15 HCS12 yes HCS12 has detected overload, PIC not
PIC
Error on ZMS1, check in analogue part, spec. Input of
33 Hardware error ZMS1 HCS12 yes
control system

41 Overload HCS12 no n n n n n n => from ZMS or SGS

Hardware error ZMS2 Error on ZMS2, check in analogue part, spec. Input of
42 HCS12
(missing? PW) control system
ZMS error, for lifting axis only emergency operation still
73 ZMS_FAULT PIC yes
permissible

81 LOAD_LIMIT_EXCEED PIC yes Event: Overload

200 up to 299: Error codes of non-selected trolley (or trolley 2)

208 Slack rope detected HCS12 yes only with ZMS

210 ZMS1 offset voltage HCS12 yes Measured analogue value too small

211 ZMS2 offset voltage HCS12 yes Measured analogue value too small

12 V monitoring system has detected an error in one of

212 Ref. voltage HCS12 yes
the two voltages
Error on ZMS evaluation detected during check caused
213 Deviation error HCS12 yes
by deviation

214 Load difference too large HCS12 yes only with two ZMS

Error on ZMS1, check in analogue part, spec. Input of

233 Hardware error ZMS1 HCS12 yes
control system

241 Overload HCS12 no n n n n n n => from ZMS or SGS

Hardware error ZMS2 Error on ZMS2, check in analogue part, spec. Input of
242 HCS12
(missing? PW) control system
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ZMS error, for lifting axis only emergency operation still

273 ZMS_FAULT PIC yes
permissible

281 LOAD_LIMIT_EXCEED PIC yes Event: Overload

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 8 Notes for the acceptance test of hoist units with overload
protection

8.1 125 % overload for the To enable lifting of the test weight of 125 % of the rated load during the acceptance
test of hoist units/crane installations, DIP switch Code 301 switch 6 must be moved
crane acceptance test to the “ON” position with the control system being switched on.
The acceptance-test function remains active for approx. 15 min. with the DIP
switch being switched on, then it is de-activated. It can only be activated again by
switching the DIP switch off and on again.
To enable lifting of the test weight of 125 % of the rated load during the acceptance
test of hoist units/crane installations, terminals 23 and 24 or terminals 13 and 14 as
well as 23 and 24 on the Dematik® FAW-1/FWL must be jumpered.
Attention!
This jumper must be removed following the acceptance test.

Switch off the installation before carrying out any cabling and wiring and
maintenance work.

789
456

AB

Code304 Partial load correction (ZMS)

CDE
23

F0 1

789
456

AB

Code303 Slack rope correction (ZMS)

CDE
23

F0 1

789
456

AB

Code302 Overload correction (ZMS)

CDE
23

F0 1

CAN / parallel control

8

Control on test bench

7

Overload test ON
6

Trolley / crane due to CAN ID

5

Code301
Trolley fast/slow/programmable brake application
4

CAN Baud rate

3
2

CAN ID
ON

Note:
All DIP switches are set to OFF by default.

42662044.eps
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 9 Display of load in control pendant or radio control system

The display of the control pendant or the radio control system shows the load de-
termined by the load detector minus the tare value.
If there are several hoist units, trolley selection determines which load value is
displayed.
Selection Displayed value
I Load value of trolley 1
II Load value of trolley 2
I+II Summation load value of both trolleys

The selected trolley is shown in the display of the Demag radio control system or
the Demag control pendant.
The load display is not a weighing device and cannot, therefore, be used as
crane weighing scales which can be calibrated.

9.1 Load bar display in The bar display of the control pendant or the radio control system shows the rela-
tive loading of the entire crane with reference to the currently max. permissible
control pendant or SWL.
radio control system If there are several hoist units, the summation load is always used for calculation of
the bar display. It is based on the max. SWL specified by the operating situation of
the crane:
• Trolley 1 or trolley 2
• Trolleys 1 and 2 selected: Max. summation load of the crane
• Crane or trolley in area with reduced load: Max. load with load reduction
The relative load is shown in 5 steps of approx. 20 %, each.

9.2 Display of load in The large load display shows the load determined by the load detector minus the
tare value. If there are several hoist units, trolley selection determines which load
large load display value is displayed.

Selection Displayed value

I Load value of trolley 1
II Load value of trolley 2
I+II Summation load value of both trolleys

It is also possible to assign a separate large load display to each trolley.

9.3 Tare function Taring to the displayed load value is possible by using the Tare key.
Depending on the “Tare function” parameter, this is the F2 key on the DSE-8R and
16R control pendant and on the radio control system.
The tare key must be actuated for 5 sec. The tare range is 100 %.
The load deducted from the tare value depends on trolley selection:

Selection Deducted tare value

I or II Tare value of the individual trolleys
I+II Summation tare value of both trolleys

The tare function and the lower load displayed after taring have no influence on the
other functions of the load detector.
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10 ANG-CAN large load display

See description/notes 214 957 44

11 Note

Table 1 Strain gauge carrier links used

Reeving 2/1 4/1 6/1 8/1 4/2 8/2

Rope hoist SWL / Part no.:

0.625 t 0.625 t
DR 3 - - - -
701 914 33 701 918 33

1.250 t 1.250 t
DR 5 - - - -
703 918 33 703 914 33

1.250 t 1.250 t 1.250 t 1.250 t

DR 10 - -
705,918 33 705,914 33 705 918 33 705,918 33

6.250 t 6.250 t 6.250 t 6.250 t 4,0 t 4,0 t

DR 20
730 578 33 730 578 33 730 578 33 730 578 33 479 908 33 479 908 33

12 Maintenance

Functioning of the load detector must be checked during the annual inspection of
the installation.
We recommend that the annual inspection be carried out by an experienced
Demag technician.

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www.demagcranes.com ► Contact and Demag worldwide
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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.