300_Demag_Processor_Control_Part_I_MH_1403_EN

Training
DEMAG Processor control Part I

Disclaimer
This work is intended for internal use only. It is your responsibility to verify the contents of
this work. You alone bear responsibility for application of the contents of this work and for
operation of the products of Demag Cranes & Components GmbH (“Demag”).
The contents of this work are not binding. The work is not associated with any obligation of
Demag in any form or with the granting of rights. All information contained in this work has
been compiled and checked by Demag to the best of its knowledge and with due care. This
notwithstanding, Demag provides no guarantee and accepts no liability for completeness
and correctness of the content or freedom from potential property rights of third parties and
any possible resulting damages. In particular Demag shall not be held liable for production
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Copyright © Demag Cranes & Components GmbH 2014 All rights reserved
Demag Cranes & Components GmbH

Training MHS 4
Ruhrstraße 28
58300 Wetter, Germany
2 © Demag A Terex Brand 2014

Inhalt
1 Available documents 9
1 DEMAG Processor control 10

Training
2 Electrical assembly 42
Version 03.14
© Demag A Terex Brand 2014 3

Preface
The purpose of this training is to familiarise you with our products.

The accompanying book for the training is made up of different parts and includes your
training documents.
The aim of the training is to make it easier to handle our products. It is the task of this
course to communicate the principles of mechanics and electrical engineering, to the ex-
tent that they are used in our products.
During the training course, you will learn how to read the electrical drawings and circuit
diagrams.
It will show which function processes can be detected and how a fault can be detected and
potentially eliminated. In addition, the different ways to localise and eliminate a fault will
also be shown.
However, a prerequisite for the above-mentioned objective is that you provide the trainer
with brief.
Information on your current level of knowledge with regard to crane technology, or previ-
ously obtained knowledge in the field of mechanics and electrics. It is also important that
you let him know if any difficulties of understanding arise during the training course.
In the event of faults during operation, the accompanying book for the training can also be
used as a point of reference.
We wish you every success

Symbols /signal words
Important safety information and instructions in these operating instructions are marked by
corresponding symbols and signal words.
Safety instructions and information must be followed. Follow these instructions with care to
avoid any accidents, injuries or damage.
Any locally applicable accident prevention regulations and general safety regulations must
also be followed.
The following symbols and instructions warn against possible injuries or damage and are
intended to assist you in your work.
DANGER
This symbol indicates an immediate hazard which can result in serious injury or death.
WARNING
This symbol indicates a possibly hazardous situation which might result in serious injury
or death.
CAUTION
This symbol indicates a possibly hazardous situation which might result in medium to light
injury.
NOTE
This symbol indicates information on the appropriate use of the machine. Failure to follow
these instructions may result in malfunctions, damage or pollution of the environment.

Inhaltsverzeichnis
Inhaltsverzeichnis
1 Available documents �� 9
2 DEMAG Processor control �� 10

2.1 Introduction �� 10
2.1.1 DR processor control system �� 10
2.1.2 DR contactor control �� 10
2.2 Explanation of terms �� 11
2.2.1 CAN bus �� 11
2.2.2 CANopen �� 12
2.2.3 CANopen safety �� 12
2.2.4 Usichi �� 12
2.2.5 Watch Dog �� 13
2.2.6 Smart Dog �� 13
2.2.7 EEPROM �� 14
2.2.8 Node ID �� 14
2.3 Structure �� 15
2.4 Structure �� 16
2.4.1 General �� 16
2.5 Description of components �� 17
2.5.1 EEPROM �� 18
2.5.2 Processor card �� 19
2.5.3 Basic board �� 20
2.5.4 FI hoist module �� 26
2.5.5 ISS module: �� 27
2.5.6 HSS module �� 29
2.5.7 LS module �� 30
2.5.8 ZMS module �� 31
2.6 Communication �� 32
2.6.1 Possible signal sources �� 32
2.6.2 Interface for control commands �� 34
2.6.3 Display of operating data �� 34
2.6.4 Connection of external peripherals �� 34
2.7 Options and accessories �� 35
2.7.1 External bus terminal �� 35
2.7.2 Large load display �� 36
2.8 DR control system interfaces �� 37
2.8.1 Overview �� 37
2.8.2 CAN bus �� 37
2.8.3 Control command interface �� 38
2.8.4 Control commands via CAN bus �� 39
2.8.5 Digital input signals of the DR control system �� 40
2.8.6 Connection of external CAN modules �� 41
3 Electrical assembly �� 42

3.1 Operating instructions �� 42
3.2 Circuit diagram �� 43
3.2.1 Legend for the content of a standard circuit diagram: �� 44
3.3 Can-Bus - identification �� 45
3.4 CAN-bus final resistors �� 46
3.5 Line voltage - Adjustment �� 47

Inhaltsverzeichnis
3.6 Status indication by LEDs and horn �� 48

3.7 Symbols for warnings and errors �� 49
3.8 Geared limit switch �� 51
3.8.1 Parameters for geared limit switches �� 52
3.9 Crane limit switches �� 53
3.10 Crab limit switches �� 54

1 Available documents
1 Available documents
Operating instructions ID no.

DR- Pro EKDR 3 - EKDR 5 - EKDR 10 20352044
DR- Pro EKDR 3 - EKDR 5 - EKDR 10 21472544
Foot-mounted hoist with bracket FDR 3 - FDR 5 - FDR 10 20364444
EZDR 5 - EZDR 10 double-rail crab 20364844
FDR 3 - FDR 5 - FDR 10 foot-mounted hoist 20367544
GDR 3 - GDR 5 - GDR 10 basic hoist 20367944
DR- Pro FDR 3 - FDR 5 - FDR 10 21105544
DR- Pro FDR 3 - FDR 5 - FDR 10 with bracket 21493244
DR- Pro EZDR 5 - EZDR 10 21496144
DR- Com EKDR 3 - EKDR 5 - EKDR 10 21491544
DR- Com EZDR 5 - EZDR 10 21496544
DR- Com FDR 3 - FDR 5 - FDR 10 with bracket 21499044
FDR 3 – FDR 5 – FDR 10 21105144
DR 3 – 10 without electrical control 20364044
DR 10 rope drum brake, type HB 21493644
EZDR 20 21484344
FDR 20 foot-mounted hoist 20357944
EZDR 20 double-rail crab 20358344
FDR 20 with electrical equipment 21111244
FDR 20 without electrical equipment 21484044
DR 20 without electrical control 20366944
DR 20 rope drum brake, type HB 21484844
MGS/ZMS for DR 3 – 10 hoists 21402544
MGS on DR 21103844
ZMS on DR 21480644
DRC-MP radio receiver (D1FH - with frequency hopping) 21499444
DRC-J joystick control system (D1FH - with frequency hopping) 21497544
DRC-DR radio receiver (D2 - with frequency hopping) 21495344
DRC-10 hand-held transmitter (D2 - with frequency hopping) 21492044
DSE-10R control pendant 21479544
ZKKE with EZDR 20 21102544
DR Crane Set with EKDR 21491244
DR Crane Set with EZDR 5 and 10 21481844
Demag cranes with DR 20694644
Demag test and inspection booklet for cranes and hoist units 20612444

2 DEMAG Processor control
2.1 Introduction
The DR control system has been specially developed as a standard parameterisable solu-
tion for the DR rope hoist. It is an inexpensive, bus compatible control system with a high
standard of safety. The DR control system offers configurable functionality, safety, flexibility,
operating data monitoring and analysis functions with a scope rarely found in standard
hoist units.
As an alternative, a conventional contactor control system is available for customers with
difficult environmental conditions or with a connection to an unstable mains supply.
Another alternative is to order the DR rope hoist without an electronic control system. This
must be installed locally by the customer.
2.1.1 DR processor control system
2.1.2 DR contactor control

DEMAG Processor control Part l
2.2 Explanation of terms
2.2.1 CAN bus
The CAN bus (Controller Area Network) is a serial bus system developed by Bosch/Daim-
ler in the eighties. The CAN bus connects different control units and sensors in a monitored
network. The different components (nodes) are uniquely identified by a“Node ID”, a fixed
address.
• It is a standardised, serial process for data transmission. In the CAN bus, data can
be exchanged between different control units and sensors, in a vehicle for instance.
• The system can be so configured that the nodes are able to exchange information
directly.
Some of its advantages are:

• almost universal availability, worldwide
• standard-based protocols
• More... control, transparency, operational reliability, plant efficiency, energy utilisa-
tion, plant service life.
• Less ... cables, assembly work, switchgear cabinet space, control systems, wear,
maintenance and product downtime.
Data transmission takes place via two conductors (CAN High and CAN Low), resulting in
greater reliability in the transmission of data and signals.
CAN technology is used in the following sectors, among others:

Road vehicles, machine controllers, medical technology, computers, automation, plant
construction and household appliances

2.2.2 CANopen
CANopen is a communications protocol based on CAN:

• Standardised solution for the networking of machines in automation.
2.2.3 CANopen safety
An extended variant of the CANopen protocol. The order of transmission is governed here
by the priority of the message.
• Standard for particularly reliable signal transfer.
• In conjunction with a second processor, safety category 3 in compliance with DIN
EN14492 and 954, i.e. single fault safety, is achieved.
2.2.4 Usichi
Apart from the familiar CAN bus signals, there are other digital signals which are used,
among other things, for the limit switches. Two voltage types are available for this:
Control voltage 48VAC:
• Control voltage power supply
• Signal voltage (e.g. external stop signal)
Pulsed control voltage Usichi

• The normal control voltage is switched on and off by the main controller in equal cy-
cles. For 50ms in every 250ms.
The “Usichi” voltage is used for the generation of dynamic input signals. Almost all critical
signals are thus constantly checked:

2.2.5 Watch Dog
The term Watchdog (also known as WDC for Watchdog Counter) is used for a system mod-
ule that monitors the function of other components. If it detects a possible malfunction, this
is signalled according to system convention or an appropriate jump command is initiated to
correct the problem detected. The signal or the jump commands serve directly or indirectly
as a trigger for other cooperating system components to solve the problem.
In particular, Watchdogs are used in electrical devices controlled by microcontrollers in
order to forestall a complete breakdown of the device due to software failure. The failure
of an automatic microcomputer system is prevented by the software communicating to the
Watchdog at regular intervals that it is still operating correctly.
2.2.6 Smart Dog
In the case of the intelligent Watchdog, the microcontroller must answer a question put by
the external Watchdog module correctly, so this is also known as a challenge-response
concept.
In the case of a fault, not only is a reset of the microcontroller carried out, but the Watchdog
usually brings the complete system (regardless of the microcontroller apparently running
out of control) to a safe status. Example: The three-level concept with intelligent Watchdog
in the electronic accelerator pedal (E-Gas) in a car. Through a skilful choice of the com-
puting operations triggered by the questions, the internal CPU modules (ALU, program
memory, RAM memory and register) can be monitored.

2.2.7 EEPROM
An EEPROM (acronym for electrically erasable programmable read-only memory, also

E2PROM) is a non-volatile electronic memory module whose stored information can be
electrically erased. It is related to other deletable memories such as UV light erasable
EPROMs and Flash memory, which can also be electrically erased. It is used for the stor-
age of small data volumes in electrical devices in which the information must also be pre-
served when there is no power supply or in which it must be easy to modify individual
memory elements or data words.
2.2.8 Node ID
ON 345 345 345

012
012
012
67
67
67
89A
89A
89A
EF
EF
EF
B CD B CD B CD
1 2 3 4 5 6 7 8
An individual component in a network or bus system is known as a node. The node ID is the
address of the node, with which it can be uniquely identified in the network.

2.3 Structure
The electrical components of the DR 3, 5 and 10 rope hoists are compactly accommodated
in a plastic enclosure. In the crane and the DR 20, the electronics are installed in a metal
switchgear cabinet with protection class IP54.
• The drive control of the electrical peripherals is realised by various modules connected
to the basic board.
• All external connections to the control unit are plug-in type.
• Change-over of pole-changing motors is of floating design.
Important features are:

• Flexibility; adaptable to individual applications by means of modules
• Easy retrofit of options (e.g. electronic load recording in the DR Pro, cross-type limit
switches and many others).
• An advanced function can be easily implemented by means of the digital outputs inte-
grated in the basic board.
Concept
The DR control system was designed for controlling a hoist and a travel axis and is there-
fore ideally suited for operation of a crab. For control of the crane travel or a second crab,
separate DR control units are used.

2.4 Structure
2.4.1 General
The DR control system is of modular design. It consists of a basic board with a processor
card and plug-in function modules.
EEPROM
ZMS module
Modular board
LS module ISS module HSS module FI module

2.5 Description of components

Every DR control system can be fitted with the following additional modules:
• EEPROM:
◦◦ electrically erasable, programmable read-only memory
◦◦ All the operating data are stored on the EEPROM.
• Basic board with dual processor control board:
◦◦ The crab and the crane have identical basic boards and processor cards. The
processor card is permanently connected to the basic board by soldered joints.
◦◦ None of the plugs required for the lifting axis are soldered into the crane control
system base board.
◦◦ The two processors monitor each other to ensure high fail-safe reliability.
◦◦ The processor card works with the parameters and data sets stored in the EE-
PROM. It controls the inputs and outputs as specified by the program.
• Modules
◦◦ For drive control of the main axis (hoist or crane travel) and for the realisation of
additional functions, an axis or function module can be attached.
The following modules are available:
• ZMS module / MA module:

◦◦ Module for the evaluation of an electronic strain gauge carrier link or a measuring
pin.
• FI module:
◦◦ For the control of a frequency inverter with CAN interface.
• ISS module
◦◦ Intelligent contactor control system comprising circuit breakers, main contactor
and no-load switching relays for direction and speed (up to motor size ZB 132).
• HSS module:
◦◦ Conventional contactor control system comprising relays for the control of a con-
ventional contactor circuit. The contactors are permanently wired with all lines as
an external block.
• LS module:
◦◦ Module with circuit breakers for the frequency inverter operation of crane travel.
The power supply for the brake and the frequency inverter is realised in this way.

2.5.1 EEPROM
All the operating data and parameters for the DR control system are stored here. The pa-
rameters can be read with the software “IDAPSY” and can be modified according to the
software licence.

2.5.2 Processor card
Various functions of the DR control system are realised on the processor card. This is also
where the node ID of the DR control system in the CAN bus is assigned.
Functions of elements on the processor card:
• Hex encoding switch 302: Overload correction / MGS - external load evaluation
• Hex encoding switch 303: Slack rope correction
• Hex encoding switch 304: Partial load correction
NOTE
Settings carried out by DIP switch or HEX switch are only applied after a restart.
• DIP switch301
◦◦ 1 - 2: Node ID
◦◦ 3: Baud rate
◦◦ 4: Crab / Crane brake application
◦◦ 5: Crab / Crane ID
◦◦ 6: Overload test ON / OFF
◦◦ 7: Control on load test bench
◦◦ 8: CAN / Parallel control
• EEPROM slot
• X41 Slot for the DRC-DR radio receiver card
• Blue LED: CAN bus status
• Green LED: HCS12 status
• Red LED: Fault
• Flash DIP: SW301
• DIP switch 305
◦◦ 1: 1: Bus termination CAN (final resistor)
◦◦ 2 - 5: Free (future applications)
◦◦ 6: Deactivation of the rotary encoder evaluation (emergency opera-
tion mode)

2.5.3 Basic board
• Plug-in connections which only exist on the crab card.

• Plug-in connections which only exist on the crane card.

Description:
X1 / X73 main supply line:

• For DR20 and crane application, there is no socket connection (connection by fast-
on - X73).
• The 400V AC power supply is always connected via an external contactor (also see
X66 - Crane contactor).
X2: CAN bus and control voltage power supply:

• The CAN bus plugs are wired in parallel. They are used to connect other nodes into
the CAN bus network (also see X44 and X74).
◦◦ PIN 1: CAN High
◦◦ PIN 6: 1L5 48VAC
◦◦ PIN 7: CAN Low
◦◦ PIN 8: GND_ Ext
◦◦ PIN 12: 1L4 48VAC
X5: Geared limit switch:

• Limit switch responsible for cut-off of lifting motion (hoist limit switch; [E_020_01]).
• The lifting and lowering movements are cut off via the integrated geared limit switch
(SGG) with four switches which can be separately adjusted.
◦◦ PIN 1: Upper emergency limit switch OE1
◦◦ PIN 2: Upper emergency limit switch OE2 (L4)
◦◦ PIN 3: Upper emergency limit switch OB1 (USichi)
◦◦ PIN 4: Upper emergency limit switch OB2 (USichi)
◦◦ PIN 5: Lower emergency limit switch UB1 (USichi)
◦◦ PIN 6: Lower emergency limit switch UB2 (USichi)
◦◦ PIN 7: Lower emergency limit switch UE1
◦◦ PIN 8: Lower emergency limit switch UE2 (L4)
X10 Lifting axis:

• Brake release, function and temperature monitoring.
◦◦ PIN 1: Thermo-switch on the hoist motor normally closed
◦◦ PIN 2: Thermo-switch on the hoist motor 1L4
◦◦ PIN 3: Brake release contact normally closed
◦◦ PIN 4: Brake release contact 1L4
◦◦ PIN 5: Hoist brake 180DC
◦◦ PIN 6: Hoist brake 180DC

X13 / X201 Line trolley inverter:

• Power supply of the brake module (for trolley, internal on basic board).
◦◦ PIN 1: L1
◦◦ PIN 2: L2
◦◦ PIN 3: L3
X14 Brake cross travel:

• Brake power supply (180V DC).
X15 crab FI control system:

• Frequency inverter control system (crane / crab / hoist FI; [E_080]).
◦◦ PIN 1: Analogue signal (0- 10VDC)
◦◦ PIN 2: FI GND / Analogue GND
◦◦ PIN 3: Enable signal
◦◦ PIN 4: Travel signal (left)
◦◦ PIN 5: Travel signal (right)
◦◦ PIN 6: Ready to travel
◦◦ PIN 7: 24VDC power supply
◦◦ (from frequency inverter to basic board)
◦◦ PIN 8: Brake release signal
X16 Limit switch travel axis (crane - crab):

• Limit switch (Long travel / cross travel limit switch [E_020_02])
◦◦ PIN 1: Usichi
◦◦ PIN 2: Right - Forward
◦◦ PIN 3: Left - Reverse
◦◦ PIN 4: 1L5
For cranes with pole-changing motors:: X16 PC

For cranes with frequency inverter operation: X16
CAUTION
In the case of the DR crab, X16FI must be left free!
X27 / X71 / X72 Control voltage 48VAC:

• Connection for in / out control voltage power supply.

X34 Overspeed brake:

• Contact for the rope drum brake.
◦◦ PIN 1: NC (emergency stop)
◦◦ PIN 2: NC
X35 Rope limit switch:

◦◦ PIN 1: NC (emergency stop)
◦◦ PIN 2: NC
X37 Holding brake:

• (Brake [E_090_06 / E_090_07])
◦◦ PIN 1: L4 to coil 48VAC
◦◦ PIN 2: L5 to coil 48VAC
X44 / X74 CAN-bus

◦◦ PIN 2: CAN L
◦◦ PIN 3: GND Ext.
◦◦ PIN 7: CAN H
X47 Bypass control:

• (Bypass control Yes / No / Type; [E_100_01])
◦◦ PIN 2: UniIn 1
◦◦ PIN 5: 1L5
X48 Fast-to-slow switch travel axis (crane - crab):

• Limit switch (Long travel / cross travel limit switch [E_020_02])
• (Crab position / Limit switch evaluation [E_030_04])
◦◦ PIN 2: Fast-to-slow - Right / Forward
◦◦ PIN 3: Fast-to-slow left - Reverse
◦◦ PIN 4: 1L5

X52 EG pulse generator:

• The pulse generator generates 30 pulses per revolution and is used for pole-changing
motors.
◦◦ PIN 1: + 12 Ext
◦◦ PIN 2: A
◦◦ PIN 3: A
◦◦ PIN 4: B
◦◦ PIN 5: B
◦◦ PIN 6: GND EXT.
X53 MGS / External load detection:

• Load detection (with / without overload; [E_060_01])
• (without / with / number of ZMS; [E_060_02])
◦◦ PIN 1: 12V (DC, 6.1 KHz)
◦◦ PIN 2: Evaluation
X54 Horn Piezo sound transmitter 100dB/im:

◦◦ PIN 1: + 12VDC
◦◦ PIN 2: - 12VDC
X66 Crane contactor:

• Defines where the crane contactor is located (default is in the crane)
• Basic parameter (solo hoist [E_10_06])
◦◦ PIN 1: Contactor A1
◦◦ PIN 2: Contactor A2
◦◦ PIN 3: NC (feedback)
X99 Uni- Out1, Uni- Out2:

• Floating relay, max 230V 2A.
• Additional functions (UniOut1/ UniOut2 [E_010_35 / E_010_39])
◦◦ PIN 1 - 2: UniOut1
◦◦ PIN 3 - 4: UniOut2

X134 Emergency stop:

◦◦ Jumper JP 11:
▫▫ 1-2: Limit switches
▫▫ 2-3: Emergency stop
◦◦ Jumper JP 13:
▫▫ GND with GND Ext. (EMC measure)
WARNING
In the case of Parallel-IN, the jumper must be removed from terminal X134 and the signal
“No Emergency Stop” directed to X134.1!

2.5.4 FI hoist module
• Relay for controller enable

• Contactor for voltage supply of hoist brake with control
• Inputs for monitoring the brake contactor
• Power supply unit for fan
The module is used for controlling a hoist inverter with CAN interface.
In the FI module, the frequency inverter acts as the power unit. Since communication with
the inverter is via the CAN-bus, only the relay of the interface remains for controller enable:
X4 / X 92 (hoist brake control) to X201:

◦◦ PIN 1: L1
◦◦ PIN 2: L2
◦◦ PIN 3: L3
X80:
◦◦ PIN 1: +24V DC
◦◦ PIN 2: 0V
X60:
◦◦ PIN 1: X210A, 1)
◦◦ PIN 2: X210A, 3)
◦◦ PIN 3: X10A, 3)
◦◦ PIN 4: X10A, 2)
◦◦ PIN 5: F042 / 95
◦◦ PIN 6: F 042 - 96
NOTE
Parameter [E_080_06], Type of hoist or crane control system: 2

2.5.5 ISS module:
ISS module - Intelligent contactor control:

The circuit variant “no load” switching only uses one contactor to switch a pole-changing
motor in two speeds and two directions. The two switch-over relays switch-over two phases
for speed (K2) and direction (K3) at “no load”.
NOTE
Before switching over relay K2 or K3, current must have been interrupted with main con-
tactor K1.
The switching sequence must be:

• Main contactor K1 is switched off.
• Direction and speed are set with K2 and K3.
• Main contactor K1 is switched on.
The ISS module has the following components:

• Contact breakers, according to motor size with the ratings: 10, 14, 25A.
• ISS power unit (contactor control with no-load switching relays) with control
• ISS logic
• Inputs for monitoring power contactor K1
WARNING
The ISS module is used up to motor size ZB 132.

X11: V1
◦◦ Pin1: 1U
◦◦ Pin2: 1V
◦◦ Pin3: 1W
X9 V2
◦◦ Pin1: 2U
◦◦ Pin2: 2V
◦◦ Pin3: 3W
NOTE

2.5.6 HSS module
HSS module - conventional contactor control system for control of a conventional

contactor control circuit:
• The power contactors are permanently wired with all lines as a block. Connection to
the HSS module is via connector X90
• In the HSS variant, the external contactor unit is the power component. On the HSS
moduke itself, there is only the interface to the control system, consisting of:
◦◦ Four auxiliary relays for control of the external contactors
◦◦ Inputs for monitoring the contactors
X90 Conventional contactor control:

◦◦ PIN 1 - 2: NC K041 (K1)
◦◦ PIN 3 - 4: NC K042 (K2)
◦◦ PIN 5 - 6: NC K043 (K3)
◦◦ PIN 7: Coil K3 (Lower)
◦◦ PIN 8: Coil K1 (Lift)
◦◦ PIN 9+10: Coil K2 (Fast, V2)
◦◦ PIN 11: 1L5
◦◦ PIN 12: Brake
◦◦ PIN 13: Brake
◦◦ PIN 14: Free
NOTE

2.5.7 LS module
The contact breaker module is used for long travel in combination with a frequency inverter.
For long travel with a frequency inverter, the magnetic motor brake must be released be-
fore the travel starts. The LS module supplies the brake module integrated into the basic
board with 400V AC for this purpose.
X101 … X107:
◦◦ PIN 1: L1
◦◦ PIN 2: L2
◦◦ PIN 3: L3
NOTE
Parameter [E_080_06], Type of hoist: 2

2.5.8 ZMS module
The ZMS module contains all the electronics required for the power supply and evaluation
of the measuring bridge. It is used for the evaluation of strain gauge carrier links (ZMS) and
measuring pins (MA).
The ZMS / MA module permits the execution of all additional functions dependent on load
measurement. They include:
• TARE of the load measurement
• Monitoring of slack rope
• Load display (directly on the DSE-R and DRC-10, or using a large load display)
• Load summation (if there are two crabs)
X7-X8: ZMS
◦◦ Pin1: Green (+12V)
◦◦ Pin2: Brown (-12V)
◦◦ Pin3: White (In-)
◦◦ Pin4: Yellow (In+)
NOTE
ZMS 1 is always connected to contact X7 (right).

Contact X8 (left) is always used for ZMS 2. This is necessary in the case of 4/2/2 rope
reeving.
CAUTION
The ZMS modules for the ZMS and for the MA are different.
The module version is entered in the EEPROM. The content in the operating data area
(E_150_30 bis E_150_39) can be read using the software “IDAPSY”.
NOTE
Parameter [E_060_02] without/with/no. of ZMS: 1...3

2.6 Communication
Communication in the DR control system takes place via a CAN bus with the protocol
CANopen safety. This specification also makes it possible to implement safety relevant
functions via the CAN bus.
Signal transmission by means of the CAN-bus system makes it possible to:

• the implementation of safety relevant functions.
• the transmission of travel commands.
• The easy realisation of data transmission in both directions permits:
◦◦ easy read-out of information.
◦◦ quick modification of parameters and settings.
◦◦ a preventive maintenance function.
◦◦ rapid response to faults.
2.6.1 Possible signal sources
The following can be used as sources for manual travel and control commands:
• Cable-connected DSE
• DRC-10 radio control system with radio receiver DRC-DR

• DRC-J radio control system with radio receiver DRC-DR
• HBC Spectrum radio control system
• DPC parallel module for the conversion of digital control signals
NOTE
The integration of rope hoists with DR control into automated systems is straightforward
(process or automatic crane). Here the control commands are given by the system control
unit.

2.6.2 Interface for control commands
In the DR control system there is a CAN interface for control commands. Apart from the
control commands for all travel and hoist movements and the “Stop” command, this inter-
face also includes all the special commands needed for operation (such as Horn, Test limit
switch etc.).
2.6.3 Display of operating data
The CAN interface works bidirectionally. A screen is integrated in the DSE and the radio
control units, permitting the display of operating data.
2.6.4 Connection of external peripherals
Via the CAN interface, a Wago terminal can be connected to the DR control system to add
digital inputs and outputs. An advantage of the Wago terminal is the possibility of position-
ing it decentrally.

2.7 Options and accessories
2.7.1 External bus terminal
The external bus terminal comprises multiple components from the firm WAGO. It includes
a bus transceiver for connection to the CAN bus used by the DR control system and has
various digital input and output terminals.
Fast, intelligent, convincing, robust - Modular control units of the WAGO I/O SYSTEM
750:
• Control units for all normal field buses
• Programming with CoDeSys V2.3
• Different performance classes for a wide variety of
• automation tasks
• Combination of PLC functionality with IT standards
• Many different protocols and libraries are available
• WAGO I/O SYSTEM 750 – modular, compact, versatile

2.7.2 Large load display
The DR control system with an integrated load detector is designed and programmed for a
ZMS strain gauge carrier link. The DR control system can also be used for operation with
a load display
The load display is not a weighing device and cannot, therefore, be used as crane weigh-
ing scales. It provides a three-figure digital display of the load in t within its tolerance limits.
The components are designed for operation in an industrial environment.
From the strain gauge carrier link, the integrated load detector receives an analogue signal
proportional to the load, which is summated and averaged over the measurement interval.
A tare value to be considered is then deducted, if necessary. The result is then output to
the load display via the CAN bus.
ANG-CAN large load displays are suitable for fitting to crane girders or crabs.
CAUTION
Measurements on the control system and the ANG-CAN large load display or on cables
connected to them may only be carried out with high-resistance voltmeters or analys-
ers. Measurements with simple voltage and continuity testers (buzzers) may destroy the
equipment.
NOTE
More information in operating instructions 214 957 44.
NOTE
Parameter: [E_060_03] Load detection; [E_061_17] Load detection; [E_050_03] ID Can

2.8 DR control system interfaces
2.8.1 Overview
Just as varied as the tasks and application possibilities of the DR control system are its
interfaces. In addition to different facilities for the transmission of commands by the opera-
tor or from a higher level control system and the signalling of operating status and events,
there are also interfaces for additional external components and some which are only used
for programming, parameter programming or troubleshooting.
2.8.2 CAN bus
The interface to the DR control system is provided by a CAN bus (Controller Area Network).
As generally used in the automotive sector, the CAN bus connects a network of different
control units and sensors. The protocol CANopen safety used here makes it possible to
transmit even safety relevant data via the CAN bus.
The following signals are transported via the CAN bus:

• Transmission of safety relevant signals from the control unit
• Transmission of commands by the control unit
• Transmission of commands via DPC parallel module
• Connection of the DR control system to a PRC or automatic crane
• Exchange of safety relevant signals between DR control systems
• Exchange of operating status and data with other DR control systems
• Output of operating status and data on the control system display
• Control of a large load display
• Control of digital outputs via I/O modules
• Read-out of parameters and monitoring and operating data by means of IDAPSY
• Reading and resetting of service data by means of IDAPSY
• Parameter programming by means of IDAPSY

2.8.3 Control command interface
The control signal source expected by the DR control system is defined by DIP switch
301.8 and the parameter Source of control signals (see IDAPSY). DIP switch 301.8 switch-
es the signal of the Emergency Off function between Parallel In at 48V and the CAN bus
protocol.
NOTE
Parameter: [E_010_40], [E_010k40] Interface for control commands.

2.8.4 Control commands via CAN bus
Control commands via CAN bus use the CANopen safety protocol
Thanks to the secure communication complying with safety level SIL-4, safety relevant
functions can also be implemented via the CAN bus, in addition to the travel/control com-
mands and display data. This secure communication is used by the following control pen-
dants and remote control units:
• Control pendant family DSE-...
• Radio control systems from Scanreco (DRC-10 or DRC-J)
• Radio control systems from HBC (Spectrum)
• DPC parallel module
Today, the following travel and control commands are transmitted via the CAN bus:
NOTE
PDO (Process Data Object) is a bus object used for the transmission of simple control
signals in the DR control system.
SRDO (Safety Related Data Object) is a secure bus object used for the realisation of
safety functions such as Stop and Emergency Off. This object is always duplicated and
the two versions are constantly compared.

2.8.5 Digital input signals of the DR control system
Every DR control system has digital inputs of different types and for different purposes. The
number of inputs depends on the type of DR control system and the axis module employed.
Many have a specific function, some limit switch inputs have special features related to the
limit switch variant and the three “universal” inputs can each be assigned a function de-
pending on its parameter programming. Here is an overview:
Apart from the inputs listed here, there are also other inputs for detection of the switching
status of contactors depending on the drive arrangement. As a rule, these inputs are di-
rectly adapted to the axis module concerned and are therefore not mentioned here.
CAUTION
It should be borne in mind that the three universal inputs are intended for different func-
tions (bypass control, load or speed reduction, approach support, destination positioning
control, specific motion enabling), but only one function can be assigned to each. It should
also be noted here that some functions require two or even all the universal inputs. The
functions of the universal inputs are determined by the parameter programming of the
functions mentioned above.

2.8.6 Connection of external CAN modules
Thanks to the bus concept of the DR, it is possible to realise even complex
functions such as bypass control or distancing without the usual need for
extensive wiring between the individual control units.
Naturally, the CAN bus can also be used for extensions if there are not
enough DR control digital inputs and outputs (see „1.8.1 Externe Bus-
Klemme“ auf Seite 35). If necessary, additional signals, unrelated to the
function of the DR control systems, can also be transmitted via the CAN
bus. In this case, however, care must be taken to ensure that the so-called
bus load (the degree of utilisation of the bus system over time as a percent-
age) does not reach a critical level.

3 Electrical assembly
3.1 Operating instructions
NOTE
working and safety instructionsworking and safety instructionsFurther information in oper-

ating instructions 21481844.
All electrical components are supplied as Plug and Lift/Drive Sets in order to simplify the
work of the technicians on site and to keep the costs of a repair or extension to the system
as low as possible.
All connection options and possibilities are described in the circuit diagram or in the
operating instructions.
DANGER
Dangerous electric current

There is danger to life and limb.
Work on electric equipment may only be carried out by qualified specialist personnel in
compliance with the safety regulations.
• Before starting work, switch off the electric power supply and secure against restora-
tion.

3.2 Circuit diagram
NOTE
All DR rope hoists are supplied with a corresponding circuit diagram.

Complete, detailed information on DEMAG circuit diagrams can be found in the Training
Manual for DEMAG circuit diagrams.

3.2.1 Legend for the content of a standard circuit diagram:
Appendix title: Contents of pages:

Cover Deckblatt
Contents Inhaltsverzeichnis
Legend Legende
10D11 Crane powerfeed
10D41 Crane end carriage
11D21 Cross travel unit crab 1
11D31 Hoist unit crab 1
12D21 Cross travel unit crab 2
12D31 Hoist unit crab 2
18N21 Load display
19N11 Floor control
19N14 Control system radio
TERM Retaining plate
Layout Device arrangement
PartList Device list
CableList Cable list
Connection Connection diagram 01 3
NOTE
The order number which appears on the cover of the circuit diagram is the same order
number as that for sale of the system.
Parameter E_10_12, Basic data/order data/order number

3.3 Can-Bus - identification
Settings for identification of a DR control system:

In order to enable identification of the DR control system on the CAN-bus, it is necessary to
make some settings by means of DIP switch 301 before switching the system on.
DIP-Switch 301.5 - Distinction between crane and crab control system.

• Off: Crab control
• On: Crane control system
DIP-Switch 301.1-2 - Setting the used node ID for the DR control system
ON 345 345 345

012
012
012
67
67
67
89A
89A
89A
EF
EF
EF
B CD B CD B CD
1 2 3 4 5 6 7 8
DIP-Switch 301.3 - Setting the communication speed on the CAN bus:

• Off: 125Kbit
• On: 256Kbit

3.4 CAN-bus final resistors
For the CAN bus, a final resistor of 120 Ohm is required at either end of the bus cable.
These resistors are fitted in the individual CAN subscribers. Since each of these final resis-
tors is a load on the bus, the useful signal level on the bus decreases with each additional
resistor. Two final resistors are ideal, more than three should not be fitted.
NOTE
Cust Info No. 05-2008, Setting of CAN bus resistors in a modular electrical system.
• Only the resistors on the logic boards can be adjusted.

• Resistors of the DSE, DPC module (Parallel-IN) and radio control are always active.
• In the hoist frequency inverters, the large load display and the WAGO I/O module
(Parallel-OUT), the final resistors are always deactivated (basic setting).
The following rules must be applied:

• As far as possible, there should be only two final resistors in the CAN bus system and
never more than three.
• The resistors must be fitted at the ends of the CAN bus.
• Branch lines up to a length of 5 m should be designed without a final resistor. For ca-
bles > 5 m the final resistor must be set.
Fault with incorrect distribution of final resistors:

• sporadic, brief failure of the crane contactor.
Possible DR error messages: 1, 2, 40, 48, 50, 80, 88, 90, 92

(When checking with the software IDAPSY)
NOTE
Parameter [E_050_13], Final resistor crab

Parameter [E_050K13], Final resistor KRBG

3.5 Line voltage - Adjustment
The line connection voltage and the control voltage must be measured and checked for any
deviations and fluctuations.
The primary side connections of the control transformer make it possible, within a limited
range, to adjust the control voltage to local conditions.
DANGER
The PE connection (protective earth) must always be connected!

A faulty earth can lead to danger to life and limb and to malfunctions of the electronic
components!

3.6 Status indication by LEDs and horn
LED display:
The three LEDs show the current status of each basic board:
• Green: HCS status
• Blue: PIC status
• Red: Alarm
DANGER
The possible flash codes can be found in the error code list.
Horn:
The horn signals system errors with various different signal codes:
DANGER
The possible signal codes can be found in the error code list.

3.7 Symbols for warnings and errors

Whether a signal indicates a warning or an error message is shown by a corresponding
symbol in the manual control display:
Definition of a Warning:
• Warnings indicate operating modes in which certain functions are not operationally
possible.
• Warnings are not entered in the error memory.
Definition of an Error:
• An error is linked to a condition which causes the loss, or at least a reduction, of the
ability to perform a function demanded.
• Errors are entered in the error memory.
• When the unit is put into operation for the first time or after conversions and upgrades,
special causes of errors may occur, for example:
◦◦ Incorrect adjustment
◦◦ Incorrect wiring
◦◦ Incorrect configuration (e.g. operating limit switch, fast-to-slow switch for V2)
◦◦ Incorrect parameter programming (e.g. crane crab programmed as solo hoist)
◦◦ Use of software versions which are not compatible
Symbol Meaning
Fault icon
The fault icon is displayed in the event of a fault. The code of the fault is
displayed in the row below. If there are several faults at the same time, the
code displayed changes in cycles.
Overload icon
The overload icon is displayed in the event of an overload. The load of the
selected crab(s) is also displayed in the row below if the hoist is fitted with
a ZMS unit.
Brake icon
The brake icon is displayed if the additional brake has been applied.
“Caution. Safety function deactivated” icon

This icon indicates that a function relevant for safety such as a reduced
load or by-pass control has been de-activated by the operator.
Key icon
The key icon indicates Off mode. To switch the unit on, an electronic On
key must be entered.
STOP
STOP
STOP
STOP

Symbol Meaning
STOP symbol
STOP STOP indicates STOP mode. The system can be switched into Run mode
STOP
STOP with the electronic key.
"No radio connection" icon

The “No radio connection” icon is displayed if the hand-held transmitter
DRC-10 is unable to establish a connection with the corresponding DRC
radio receiver.
Warning icon
The warning icon is displayed in the event of a warning. The code of the
warning is displayed in the row below.

3.8 Geared limit switch
Function for setting the geared limit switches to the required limit switch variant:
The lifting and lowering movements are cut off via the integrated geared limit switch (SGG)
with four switches which can be separately adjusted.
• Switch S1 always is emergency limit switch for lifting.

• Switch S4 always is emergency limit switch for lowering.
• Switches S2 und S3 (Usichi) can be parameterised with IDAPSY. The functions as-
signed to them are shown in the circuit diagram.
The emergency limit switches of hoist units S1 and S4 operate electrically.
NOTE
Correct programming of the parameters for the required limit switch variant is necessary
in any case:
Parameter E_020_ 01, Hoist limit switch

3.8.1 Parameters for geared limit switches
Parameter [E_020_01], Hoist limit switch
Parameter S3 S4
value
0 none, only emergency limit func-
tion
1 Fast lifting Fast lowering
2 Fast lifting Phase failure
3 Fast lifting Operating limit lowering
4 Operating limit lifting Fast lifting
5 Operating limit lifting Fast lowering
6 Operating limit lifting Phase failure
7 Operating limit lifting Operating limit lowering
9 Double limit + Fast lifting Double limit + Fast lowering
12 Double limit Lifting Fast lifting
13 Double limit Lifting Fast lowering
14 Double limit Lifting Phase failure limit
CAUTION
Values 9 – 15 are only available/usable from software version 4.00.
Parameter S3 S4
value
15 Double limit Lifting Double limit Lowering

3.9 Crane limit switches
B1 A1
A2 B2
A B
3
3
2
2
1
1
6
3
5 2
4
1
For crane travel cut-off at the limit positions, for collision prevention and for distancing be-
tween cranes, a total of four digital inputs are provided in the DR control system. One input
is required for limit switch cut-off in each direction and one input for fast-to-slow cut-off.
Connection of crane limit switches:
• X48: Fast-to-slow cut-off

• X16: Limit switch cut-off - a distinction is made here between:
◦◦ X16: PC for pole-changing motors (electrical)
◦◦ X16: FI for frequency inverter operation (Usichi)
NOTE
When connecting, the correct parameter must always be set according to the design vari-
ant and, in the case of single boards, an additional jumper must be set.
Parameter E_020_K08, Limit switch

3.10 Crab limit switches
B1 A1
A2 B2
A B
3
3
2
2
1
1
6
3
5 2
4
1
The wiring of crab limit switches is similar to that of crane limit switches:
• X48: Fast-to-slow switch (Usichi)
• X16: Limit switch cut-off (Usichi)
If there are two crabs, only one needs to be fitted with the cut-off device for distancing. The
other crab receives the required information via the CAN bus (OSSD signals), when the
corresponding parameters have been programmed.
NOTE
When connecting, the correct parameter must always be set according to the design vari-
ant and, in the case of single boards, an additional jumper must be set.
Parameter E 0_20_02, Limit switch

Notes


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Training

DEMAG Processor control Part I

Demag Cranes & Components GmbH

2 © Demag A Terex Brand 2014

1 DEMAG Processor control 10

© Demag A Terex Brand 2014 3

The purpose of this training is to familiarise you with our products.

We wish you every success

© Demag A Terex Brand 2014 5

6 © Demag A Terex Brand 2014

2 DEMAG Processor control ��������������������������������������������������������������������������� 10

3 Electrical assembly ��������������������������������������������������������������������������������������� 42

© Demag A Terex Brand 2014 7

3.6 Status indication by LEDs and horn ���������������������������������������������������������������� 48

8 © Demag A Terex Brand 2014

Operating instructions ID no.

© Demag A Terex Brand 2014 9

2 DEMAG Processor control

2.1.1 DR processor control system

2.1.2 DR contactor control

10 © Demag A Terex Brand 2014

2.2 Explanation of terms

2.2.1 CAN bus

Some of its advantages are:

CAN technology is used in the following sectors, among others:

© Demag A Terex Brand 2014 11

CANopen is a communications protocol based on CAN:

2.2.3 CANopen safety

Pulsed control voltage Usichi

12 © Demag A Terex Brand 2014

2.2.5 Watch Dog

2.2.6 Smart Dog

© Demag A Terex Brand 2014 13

An EEPROM (acronym for electrically erasable programmable read-only memory, also

ON 345 345 345

14 © Demag A Terex Brand 2014

Important features are:

© Demag A Terex Brand 2014 15

LS module ISS module HSS module FI module

16 © Demag A Terex Brand 2014

2.5 Description of components

The following modules are available:

• ZMS module / MA module:

© Demag A Terex Brand 2014 17

18 © Demag A Terex Brand 2014

2.5.2 Processor card

© Demag A Terex Brand 2014 19

2.5.3 Basic board

• Plug-in connections which only exist on the crab card.

20 © Demag A Terex Brand 2014

X1 / X73 main supply line:

X2: CAN bus and control voltage power supply:

X5: Geared limit switch:

X10 Lifting axis:

© Demag A Terex Brand 2014 21

X13 / X201 Line trolley inverter:

X14 Brake cross travel:

X15 crab FI control system:

X16 Limit switch travel axis (crane - crab):

For cranes with pole-changing motors:: X16 PC

In the case of the DR crab, X16FI must be left free!

X27 / X71 / X72 Control voltage 48VAC:

22 © Demag A Terex Brand 2014

X34 Overspeed brake:

2 DEMAG Processor control �� 10

3 Electrical assembly �� 42

3.6 Status indication by LEDs and horn �� 48