MGS-DR load detector Description and notes 061106 EN 21 038 44 r20 18 819Manufacturer Contents Demag Cranes & Components GmbH P.O. Box 67 - D-58286 Walter, Germany Telephone +49 (0) 2335 92-0 Telefax +49 (0) 2325 827676 vwaw-demageranes.com 24 22 23 24 25 26 0 MGS-DR load detector Use Operating principle MGS limit swteh MGS mounting Overload cut-off and overload protection function with Dematik® MGS-OR General Overload signal/protection by MGS Partial load switching point Inspection Function chock (Overload signat DR Safety features Notes for the acceptance test of hoist units with overload protection Fitting and application instructions General Measurements EMC construction guidelines Connection ofthe electrical equipment Technical data and order numbers Tables MGS overoad protective device (Crossbars for MGS MGS limit switch installation instructions Replacing SGS units with MGS Instructions for finding faults MGS dimensions/connection dimensions 8 ” 81 MGS-DR load detector 14 Use 1.3. MGS limit switch 1.4 MGS mounting DDR hoists and supporting structures can be protected by means of the MGS-DR load detector. ‘The units can be used on all DR hoists when certain features are taken into can- sideration. They ae intrinsically safe, i. if hero isa broken wire, no operating voltage orf a input signals missing, the load can no longer be ited ‘The load detector consists of the MGS-OR gested lit switch ane the DR control system. ‘The spring element of the MGS unit consists of an oval steel ring whichis de- fermed by approx. 0,8 mm at rated load, A micreswiteh arranges between the long sides of the spring element is actuated by the spring motion ‘The DR control systam evaluates the microswvitch signal in order to acton the hoist, contals accerdingly ‘The MGS unitis generally installed atthe rope anchorage point (crosshead, retain: ing plate) or atthe upper retum or compensating sheave, ‘The MGS unit must be suspended in such a way that only tensile forces are trans mitted ‘Since hoist units can be subjected to diferent loads in accordance with hele FEM group, the MGS load cut-off point is adjusted tothe relevant rated load before the Unit eaves the factory. Refer tothe table on page @ for hoist unit io MGS order umber assignments Heist units which have load capacities that do not match the FEM classification have to be filed with an MGS unit adjusted tothe special load capacity before leaving the factory. ‘Avoid hard blows against the MGS-OR unit as they might modify the switeh- ing point setting. Protective measures must be taken against radiant heat for operation in hot atmospheres. MGS-DR units are not suitable for operation in acid-ladon atmos- pheres. A stain gauge cater lnk with additional surface protection must be used in such cases, MGS-DR units are supplied with a permanently connected measuring cable as standard, This must be connected direct. MGS-DR limit switches may only be used in connection with a MKA-2 contact ‘valator or a DR control system, Important ‘The partial load switching point cannot be evaluated when a MKA-2 contact evaly- ators used in connection with a MGS-DR unit IMGS-DR units are attached between the ropetretum sheave and the connect. ing structure by means of wo pins. The rope-side pin has a minimum play of 1,3 mm in the retaining hoe ofthe connecting structure to enable the MGS. ing element to expand in length,2 Overload cut-off and overload protection function with Dematik® MGS-DR 24 General 2.2. Overload signal protection by MGS-DR When a load is ied, vibrations accurin the rope which are measured as shor- term load peaks. These vibrations depend on the load, the iting speed and the rope length, they should, however, not result in a cut-out at rated load. |When an unknown loads Iifed at great speed, the measuring system wil switch ‘fin the event ofan averioad, however, an overload ofthe hast unit cannot be prevented with certainty due to run-on ofthe hoist motor, This type of load limita: tion is referred to as overload cut-oft 1, onthe other hand, a toads ited ata relatively small speed, hardly any vibra- tions occur i the rope. If uring the ling process an overload occurs, the measur- ing system wil detect any iad exceeding the rated load very accurately and the hoist unit wil be immediately enitened of. Owing tothe tow speed, here is hardly ‘any rur-on ofthe moor so that overloading of the Rist unit is prevented. This type (of load limitation is called overload protection. Overload protection is therefore only possible in connection with a creep iting speed. The rape force caused by the load is transformed into the actuating path ofa cam ‘by means ofthe spring element (oval ring), which actuates a normally closed switch (MGS). This interrupis a frequency signal. which is fed to two controllers via «3 digital input arrangement, Soth controliers evaluate the signal In the event of an ‘overload, both controllers terminate the lifing motion independently of each other. ‘The lowering motion is always possible regardless of the load. ‘The conivolers permanently exchange the results of thei evaluations via the serial interfaca. I ene ofthe controllers determines that cut-off ofthe MGS unit was net detected by the other controler, the frst contoller creates an error message and prevents the ting motion, Fig. somazeet| 23 24 25 254 oad switching Inspection Function check With DR control ‘The partial load switching point (creep iting time) is not contrlled by the MGS-DR. Unit, Buby the sip measurement of the holst unit motor. Functioning ofthe load detection devices must be checked during the prescribed annual inspection ofthe instalation. \We recommend that the annual inspection be carried out by an experienced De- ‘mag technician, a) with test oad ‘The creep and main lfing motions must be switched of by liting a load >the limit load, The overload symbol must appear onthe display b) without testload ‘The creep and main iting motions must be interupted by removing the MGS plug- In connector (X83). The overload symbol must appear on te display.252 Without DR control, with MKA.2 contact evaluator 2.6. Overload signal 2) with test oad "Glico" A" and“ “onthe front panetnccate thatthe units ready for peraton nd the ready status ‘The the paral oad and < the lt oa, noting wl arp thon fe MKA.2 units used ss an oveoad outa ine cee iting tne has {oe inated when tis Used es overload protection (mln ost cones 25:24 are open," *Font-erting diodes of. The mai iting moton is Teleased again ater the fxed crop iting tine, which eto 5 Seconds, has shapsea 42) By iting alone >the ito84 the creeping an main iting contact mst pon ator a maximum o $28 miliseconds when the bt oad exceeded ») noload ‘Without atest oad, onthe funtion ofthe MKA2 conse evalster can be testes “odo hs, the wire must be disconnected tom terminal 2of the M2 uni ‘Tre unt must then respond as described in 22). 8) Depending on the OSE control pendant type, an overload signals indicated by means ofan overload symbol on the convol pendant aispay for DR hoist unis fitted with @ DR control system, Inthe case of DR hoist unis that are no ited with a OR contol system, but ‘which have a MKA2 contact evaluator, an overload signals ony indicated ‘whan the creep and main ting light-emiting diodes and the OK diode ofthe IMKi2 contact evaluator are extinguished 53 Safety features 3.1 Notes for the accept- ance test of hoist units with overload protec tion A ‘The cable to the contact of the external foad detector, the digital input andthe sig- ‘nal paths of both controler are monitored by the use of a dynamic contol signal ‘The lifting mation is immediately cabled if shor circuit with the contre voltage or a detective imput is detected. Lowering is sll possible (emergency operation}. 22) To enable the test weight of 125% of the rated load to be lited during the ac- ceptance test of hoist units/erane installations with a DR control system, switch 6 of DIP switch no, 301 must ba moved Irom the “OF tothe “On” poston loads greater than the mit load may then be ited fora period of 15 minutes. \When this period has elapsed, the hoist motion wil be switched off when a oad ‘greater than the limit oad is lifted, regardless of the position of switch 6. “To enable the test weight of 125% ofthe rated load tobe ited during the ac- ‘ceptance test of hoist uitscrane installations that are not fted witha DR con- ‘vol sysiom, but which have a MKA-2 contact evaluator, contact input 2-3 of the M&A-2 uni must bo bridged. b Important ‘This jumper must be removed fllowing the acceptance test. ‘Switch off the installation before carrying out any cabling and wiring and ‘maintenance work.4 Fitting and application instructions 441 General 4.2. Measurements 4.3 EMC construction guidelines 44 Connection of the electrical equipment MGS-OR protection switches are bull and tested to DIN 57411 Part VDE 0811 Part 1 and DIN ISO 9001 and leave the factory in perfectly safe condition. Yo main- tain this condition and ensure safe operation, the operator must comply wit the instructions and warnings contained in this document, Measurements on the devices or on cables connected to them may only be carried ‘out with high-res'stance voltmeters or similar measuring devices. Measurements With simple valtage and contnuly testers (buzzere) may destoy the equipment. ‘Aunts have beon tested in accordance withthe EMC directives and comply with the relevant standards rogarding interference emission and resistance to interor- ence for application in industal environments, “To comply withthe EMC requirements, the folowing points must be considered for Integration into overall systems: + Integration of electronic components to meet EMC requirements + Use of prescribed and approved cables, particularly screened cables as 2 uired by the operating instructions, if required + Connection othe cable shilds according to the operating instructions + Adherence to minimum distances for the appication of cables and wiring with ‘ferent voltages. MGS-DR overload switches are electrically connected direct tothe crane circuit board. Plug connector X83 is coded to prevent reverse polly and can only be connected In one plug positon. The same plug postion is used when an SGS unit is replaced by an MGS unit5 Technical data and order numbers Technical data MGs. Limit ewiten Part no, ‘06 table below ‘Switening capacty: so maza v= “Ambient temperature: -20°C to +70°C ‘Type of enclosure (Per Mounting position: any DR 3-10 measuring cable: uyy4x025 Part no: 496 933 44 DR 20 measuring cable: LIVCY 4 x0,25 screened Par no. 466 420 44 MGS part nos. ona Pert 0. “wire Ties ors Ovetoad cake Sn Tees Sunes Sd Tear Dread toda Ta a0 “Grormed tok and 71912939 “Omid anor an iY 730 e439 oR 20 mut grove ‘The part numbers contain the following pars: MGS complete with cable and plug connector -2ott head pins +2 off retaining rings + corresponding number of spacer rings and shims0 6 Tables 6.1 MGS overload protective device Table 1: MGS overload protective device for DR 3-10‘Table 2: MGS overload protective device for DR 20 Reins aa | Fe Face oo GST] WES swicki pa] WS pane 720 Te zo 688000 Ose 600 2m ico 350000 72038838 = 00 om 0000 230000 Tose om = sis00 Siro ¢0 TOSS "2000 ar 00 2060 THe 2000 2 S000 ss0n00 T0555 “ "eon or ‘aco ‘0000 055035 0 oe 350) T000| 7058555 “0200 ar ace? 28000 05255 "00 2 m3 350000 790 58539 = 00 om eicar ‘0000 79058439 ‘000 7 m3 ‘e700 TOS 000 Tar e008 aan co asa co00| 2m 000 ‘50000 Ts ” 00 3 200 “e000 0s 5000 = a0) 7000 TOs 72500 co sas ‘e708 7050635 00 an 7009) zrsa00| T0567 “ oo = ‘zoo 20000 | 70% 00 oe 19750 000 7505085 7000 an 3280 37000 705065 ” "e000 om 70000 060 Tse 72500 a 5625 760,00 Tas "2 6.2. Crossbars for MGS Designation ‘Oran | Reevng | FEM oes ‘ORS {eran swe_| petro. | type | patna | pe ine WES oveioadprowet| A | ai | am] Fors weessss_[ Fors | aoscos | ron | ‘oases ‘NOS overoad protect] ate [an | aw] FORD | wrwemsa | rons | e7omcrsa | ronvo | a7oasess NGS overload potest] A | an | em | FORS | woeassa_| rows | eroaersa | roRw | a7oamess IMGS ovaroad prowet| —F20 | an | am | FORS | «7oeaeas | roms | e7ocazs_| roRIO | aroanrss MGS ovarend protct.| —Fa0 | at [an | FoRa | eroea7aa | roms | eocass | eonw | awaea Was ovetond prowet| ao | an | am] FoR] |_ememsa | rons | eoerss | roa | «oem NGS oveieadprect| wa | ai | am | Swans | women | as | seas | aOR | aoe NGS overoadprstect| Hz | a | am | xara | 7eeesa | eos | woerss | eoRt | aoe MGS overoadprotect| ta | a | em | EXORD | sroearss | exors | a7oerase | exon10 | a7oeons0 Wa overondprowet | Heo | an | an | exORD | esas | exes | «morn [coro | womrn ‘MoS overioed prowet | —Hz0 | an | an | exoRa | woes | ewes | aoeem [aOR | «sem MOS overioed rect | rao | an | am | exons | a7oatosa | exons | weerrm | aOR | aon NGS oveicadpretet| mf eons | aeusiss | ezoR Io | araesi NGS overload protect. | ae rons | areasnss | eave | ase inc overion protect. a | a Eons | araessss | ezon10 | a7oes633 iMag ovaiong pratt] wo | an | _an Ean | sae MGS overiond protect] mao | an | Eon o | arsere MGS oveiosdproteet| veo | an | a ror 0 | «796003 NGS overiond aetee am Tone | wees IMCS everioa protec. en eon | a0800 IMG overioud prow. or [ae ezon0 | 4799007 MGS limit switch installation instructions EZOR 20, 41 roeving Fig.2 Fit retaining plate (3) Insert rope end with rope wedge into rope socket (9) and first sus- end it rom the retaining plate with 1 head pin (1) without MGS unit (@), bletly apply load to te bottom black so thal the rope and rope ‘wedge are pulled into the rope socket. Then remove the ead and remove the head pin from the retaining plate Grease head pin (2) and insert tino the upper bore hale ofthe ce taining plate then push the MGS unt onto the head pin (the recess in the MGS housing must face towards the upper bore hol), then insert the head gin all the way in Push rope socket (2) between the retaining plate sides from below, ‘ensure thatthe lower half ofthe MGS units within the rope socke, ‘an insert 2nd greased head pin (1) all the way through Check that lower head pin (1) can move freely inthe retaining plate ‘bore hole withthe attached rope socket and MGS unit (play be- ‘ween bore hole circumference and head pin must be 21,3 mm) ‘Secure both head pins (1/2) with thrust washers (4/7) and secure them with double spring clips (516), Refer tothe next page for arrangement of the cable. Complete the ‘lectical connections according to the circult diagram,DR3-10 cable arrangement 2H reeving Fig. + Load connecting cable (1) out of the top ofthe crossbar. + Secure the connecting cable to the cross mem- ‘ber ofthe DR rope hoist using cablo Les (2). + Attach the connecting cable tothe travel roller housing using cable cps (3). Note: ‘The cable clips must be glued to the housing; before fitting them, clean the areas where they are attached to the housing using cleaning ‘solvent (rae of grease). + Secure the connecting cable tothe connecting ‘od of the DR rope hoist using cable guides (4. + Lead the connecting able nto housing (5) use ing cable cis. + Connecting cable (1) can be led direc into ‘housing (6) when the switch is installed, cable clips then do not need tobe used from the ‘outside, Secure any excess connecting cable Inside the housing as shown inthe diagram. + Introduce a suitable length ofthe connecting cable into the electrical housing, + Secure any excess connecting cable in the housing using cable clips (7)8 Replacing SGS units with MGS Replacement for 24 reeving 86S removal MGS-DR installation ‘The inner| when fiting the MGS unit. ore hole of the lever must be usedReplacement for 4/1; 6 reeving ‘56S removal MGS-OR instalation Note: ‘The inner bore hole of the laver must be used when fitting the MGS unit, Fig. 59 Instructions for finding faults Dematik® MGS load limit switeh Faitimessremant ‘cae Remeay 3) MGS ncn comaced Wig ener “The pug coma aad blo lestra he 9e toy tebe be connactat he eats Inne pus poten epaca ha pug os 5) Satoh cams Weoacn aac Teck he EH Une lnd =>nosontty Wana oe Teasing a om oF aaa ‘DWGS peace tad Repaca he MS wit (Pay toronto toed capac) 3) Sica and 15 ed Tare GS ut 2MGS ot of ahstrane ‘Fore ncorectyvanenied {8168 unt cetecve hook ope sebension ar ing hese he WS ot apace he MKA2 unto OR cantata 710 MGS dimensions/connection dimensions x Important: Check distance 2 betwoen the lower pin and the connecting structure when instling the MGS unit (2,,,© 1.3mm). ‘The contact surfaces between the MGS Unit and the pin must be lubricated using a i sullable agent (0.9. Molykote Longther 2, +] part ne. 872 389-44), See page 9 for Holst unit- MGS assignment | 3} NT Fig. 6 ssomastsape fantmed] tA] ¢ [© [eos] p [ow we west | amet | tem | eves | amen | ‘red | orem | to bas os fs fe |e | so |m|v | bes a zs | esa | 22 | = bee se [or | wo [oa [ae | peaaaea [ass | m0 | ot 150 | sos | a7 | ora so | 1m | we | a | 260 | rose |2ase| « Connection dimensions Tor | won | pws | K Soa] mee 8 teen | ‘wr | foot | toms | tet | baa os | 76 sao | = a bas ae |» | mo | = = 2 pravaea | vo | = | 8 | 2 6 = a wo | o | ao | 2 a °19 NotesDemag Cranes & Components GmbH PO. Box 67 - D-58286 Wotter, Germany ‘Telephone +49 (0) 2336) 92.0 Telefax +49 (0) 2895) 927676 www. demagcranes.com