Demag DR rope hoist - Demag Cranes & Components

Demag DR rope hoist
without electrical control
42576444.eps
42352044.eps
42349444.eps
081105 EN 203 640 44 714 IS 813

Manufacturer Demag Cranes & Components GmbH
P.O. Box 67, D-58286 Wetter
Telephone (+49 2335) 92-0 · Telefax (+49 2335) 927676
www.demagcranes.com
Further
documents
Operating
instructions
Please fill in the following table before first putting the hoist into service.
This provides you with a definitive documentation of your Demag rope hoist
and important information if you ever have to contact the manufacturer or his
representative.
Owner
Where in use
Range
Serial number
Main hoist motor number
Operating voltage
Control voltage
Frequency
Wiring diagram number
Demag rope
hoist
FDR
3 - FDR
5-
FDR
10
( PRO)
214 932
44
720 IS 813
Demag rope
hoist
EKDR
3 - EKDR
5-
EKDR
10
( PRO)
214 725
44
720 IS 813
Demag rope
hoist
EZDR
5-
EZDR
10
( PRO)
214 961
44
720 IS 813
Demag rope
hoist
FDR
3 - FDR
5-
FDR
10
( COM)
214 990
44
720 IS 813
Demag rope
hoist
EKDR
3 - EKDR
5-
EKDR
10
( COM
214 916
44
720 IS 813
Demag rope
hoist
EZDR
5-
EZDR
10
( COM)
214 965
44
720 IS 813
Dedrive Compact
DIC
214 708
44
720 IS 922
CD Dedrive
Compact
DIC
213 137
44
716 IS 922
External pulse
generator
214 372
44
720 IS 919
Z motor
range
214 228
44
720 IS 919
2 20364044.p65/081105

20364044.p65/081105
Introduction
This document contains information on rope hoists without electrical control. It applies
for DR-Pro, EKDR-Pro, EZDR-Pro, FDR-Pro, EKDR-Com, EZDR-Com, FDR-
Com rope hoists.
Depending on the type, the standard scope of delivery includes:
- 12/2-pole hoist motor with Microtherm and EG integrated pulse generator
- GS and VE brake modules
- 4-pole hoist motor with Microtherm and mechanical mounting device for AG 1 - 3
external pulse generators
- GS and VE brake modules
- 4-pole cross travel motor with Microtherm
- GE and VE brake modules
- Base plate in the rope hoist electrical enclosure for connecting the hoist motor and
sensors
- SGG geared limit switch
- SGS overload cut-out
3

Design overview
Example of EKDR
Fig. 1
Thrust rocker
Electrical equipment cover
with terminal strip and
geared limit switch
4/1 bottom block
Explanation of size designation / type assignment
EK DR - Pro 3 - 3,2 4/1 - 6 Z - 6/1 - 400 - 00 - 50 - 30 300 45
Travel motor
EKDR low-headroom monorail hoist
Gearbox with hoist motor
42577844.eps
Rail head width in mm
} Only for EZDR
or track gauge in mm
Flange width of the girder in mm
or girder section and size (IPE240)
Maximum cross-travel speed in m/min
Frequency [Hz]
Electrical equipment code 1)
Operating voltage [ V ]
Hoist speed in m/min
Motor type: Z = Cylindrical rotor
Hook path in m
20364044.p65/081105
E = Electric travel trolley
1) Code 00 DR without electrical control
Code 01 EKDR with internal electrics for application on a crane. Crane bridge enclosure, DSE-8R control pendant with control cable and cables for the
mobile floor control must be ordered separately.
Code 02 FDR/EKDR/EZDR with internal electrics and solo electrics with crane switch and transformer fitted in an enclosure on the trolley, for application as a
solo trolley. DSE-8R control pendant with control cable must be ordered separately.
Code 03 Like code 01 but control via radio control system
Code 04 Like code 02 but control via radio control system
4 Code 05 EKDR with fitted parallel interface “in”
Reeving
SWL in t
Range 3; 5; 10
Demag rope hoist
K = Low-headroom monorail hoist
Z = Crab
F = Stationary

20364044.p65/081105
Selection criteria
DR-Pro F-/EKDR 3 - F-/EK-/EZDR 5, 10
The size of the hoist is determined by the load
spectrum, average operating time per working day,
SWL and reeving.
The load spectrum
(in most cases estimated) can be evaluated in
accordance with the following definitions:
1 Light
Hoist units which are usually subject to very small
loads and in exceptional cases only to maximum
loads.
SWL
Operating time
2 Medium
Hoist units which are usually subject to small loads
but rather often to maximum loads.
SWL
SWL
SWL
Operating time
Operating time
Operating time
Small partial load
Small dead load
Heavy partial load
Medium partial load
Medium dead load
3 Heavy
Hoist units which are usually subject to medium
loads but frequently to maximum loads.
Heavy dead load
4 Very heavy
Hoist units which are usually subject to maximum or
almost maximum loads.
Selection table
Very heavy dead load
Range Group
of
mechanisms
to
FEM/
ISO
F-/
EK-
DR
3
F-/
EK-/
EZ-
DR
5
F-/
EK-/
EZ-
DR
10
1. What are the operating conditions?
2. What is the specified safe working load?
3. To what height must the load be lifted?
4. What is the required lifting speed?
The
g
roup
is
Group
of
mechanisms
F EM/
ISO
1)
determined
from
the
operating
time
and
load
spectrum
Rope reeving
2 / 1,
4/
2
5. Do the loads need to be lifted and lowered with
high precision?
6. Is horizontal load travel necessary?
7. How is the hoist to be controlled?
Load spectrum
Average
operating
time
per
day
in
hours
1 Light 4-8 8-16 over
16
2 Medium 2-4 4-8 8-16
3 Heavy 1-2 2-4 4-8
4 Very heavy
0, 5-1
1-2 2-4
Group
of
mechanisms
to
FEM 2 m
3 m
4 m
ISO M 5
M 6
M 7
2m/ M 5 3m/ M 6 4m/ M 7 2m/ M 5 3m/ M 6 4m/ M 7 2m/ M 5 3m/ M7
4 m/
M 7
2 )
/ 1
4 6 / 1
Range SWL in
t
DR 5
2, 5 2 1, 6 5 4 3, 2 - - -
DR 10
5 4 3, 2 10 8 6, 3 16 12, 5 -
Example
SWL 5 t
Load spectrum “medium” from table
Hoist speed 6 m/min
Creep hoist speed 1 m/min
Reeving 4/1
Average hook path 3 m
No. of cycles/hour 20
Working time/day 8 hours
The average operating time per working day is estimated or calculated as follows:
2 x average hook path x no.
of
cycles/h x working
time/day
Operating time/day =
60 x lifting speed
Operating time/day
2 x 3 x 20 x 8
=
= 2,66
60 x 6
For the “medium” load spectrum and an average daily operating time of 2,66 hours,
the table shows group 2 m. For a load capacity of 5 t and 4/1 rope reeving, the table
indicates hoist size DR 5 - 5.
SWL Hook path
Lifting speed
m/ min
SWL Hook path
Lifting speed
m/
min
t m V1 V2 V3 t m V1 V2 V3
2/ 1
4/
1
2 m/
M 5 1,
6
3,
2
3 m/
M 6 1, 25
12; 20
12/ 2 1 8/
3 2-25
3)
2,
5
4 m/
M 7
1 2
1) Gearbox service life 20 % above the FEM value
2) 4/2 and 6/1 rope reeving only for DR 10
hours
2 )
6; 10
6/ 1 9 / 1,
5 1-12,
5 3)
2 m/
M 5 2,
5
5
3 m/
M 6 2 12; 20
12/ 2 1 8/
3 2-25
3)
4 6; 10
6/ 1 9 / 1,
5 1-12,
5 3)
4 m/
M 7 1, 6
3,
2
2 m/
M 5 5
10
3 m/
M 6 4 12; 20
1 0/
1,
7 2 -18
3)
2-25
3)
8 6; 10
5 / 0,
8 1 -9
3)
1-12,
5 3)
4 m/
M 7 3, 2
6,
3
4 / 2
6/
1 4)
2 m/
M 5 5
16
3 m/
M 6 4
5,
8;
11,
35;
15,
2
1 0/
1,
7 2 -18
3)
2-25
3)
12,
5 6, 7;
13,
3 2, 7/
0,
4 0, 7-6
-
4 m/
M 7 3, 2
10
3) for 87 Hz delta operation
4) 6/1 rope reeving only for EZDR 10
5

DR-Com F-/EKDR 3 - F-/EK-/EZDR 5, 10
The size of the hoist is determined by the load
spectrum, average operating time per working day,
SWL and reeving.
The load spectrum
(in most cases estimated) can be evaluated in
accordance with the following definitions:
1 Light
Hoist units which are usually subject to very small
loads and in exceptional cases only to maximum
loads.
SWL
Operating time
2 Medium
Hoist units which are usually subject to small loads
but rather often to maximum loads.
SWL
SWL
SWL
Operating time
Operating time
Operating time
Small partial load
Small dead load
Heavy partial load
Medium partial load
Medium dead load
3 Heavy
Hoist units which are usually subject to medium
loads but frequently to maximum loads.
Heavy dead load
4 Very heavy
Hoist units which are usually subject to maximum or
almost maximum loads.
Selection table
Very heavy dead load
1. What are the operating conditions?
2. What is the specified safe working load?
3. To what height must the load be lifted?
4. What is the required lifting speed?
The
Load
g
roup
is
spectrum
determined
from
the
operating
time
and
load
spectrum
5. Do the loads need to be lifted and lowered with
high precision?
6. Is horizontal load travel necessary?
7. How is the hoist to be controlled?
G roup
of
mechanisms
to
FEM/
ISO
1) 1 Am/
M 4
Rope reeving
arrangement
4/
1
Range SWL
in
t
DR 3
3,
2
DR 5
5
DR 10
10
Average
operating
time
per
day
in
hours
1 Light 2-4
2 Medium 1-2
3 Heavy 0,
5-1
4 Very heavy
up
to
0,
5
Group
of
mechanisms
to
FEM 1 Am
ISO M 4
Example
SWL 5 t
Load spectrum “medium” from table
Hoist speed 4.5 m/min
Creep hoist speed 0,8 m/min
Reeving 4/1
Average hook path 3 m
No. of cycles/hour 10
Working time/day 8 hours
The average operating time per working day is estimated or calculated as follows:
Operating time/day
Operating time/day
For the “medium” load spectrum and an average daily operating time of 1,7 hours,
the table shows group 1 Am . For a load capacity of 5 t and 4/1 rope reeving, the
table indicates hoist size DR 5 - 5.
Range Group
of
mechanisms
to
FEM/
ISO
F-/
EKDR
3
F-/
EK-/
EZDR
5
=
2 x average hook path x no.
of
cycles/h x working
time/day
60 x lifting speed
2 x 3 x 10 x 8
=
=
60 x 4,5
SWL Hook path
Lifting
speed
m/
min
t m
4/
1
V1
6,
3
F-/
EK-/
EZDR
10
8
6; 10
4/
0,
7
10
6 1) Gearbox service life 20 % above the FEM value
20364044.p65/081105
1 Am/
M
4
1,
7
hours
2
2,
5
3,
2
4
5
6; 10
4,
5/
0,
8
6; 10
4,
5/
0,
8

20364044.p65/081105
7

Key data pole-changing hoist drives DR 3 – DR 5 – DR 10
Design is in accordance with the VDE regulations and the design rules of the FEM, to meet the high demands made on
electric hoists.
Main/creep lifting F6
Range DR
3 No.
of
poles
Required supply cable conductor cross sections and fuse links
Code P % CDF
n Starts/ h Rated current
INand
starting
current
IA
for
50
Hz
cos cos
400 V
ϕN ϕA Motor size
kWrpm IN ( A)
IA ( A)
ZBR
100
C 12/
2 - B050
ZBR
100
D 12/
2 - B050
12
0, 55
20 430 240 4, 6
7 0, 53
0,
72
V1
2 3, 4 40 2800 120 8, 5
40 0, 78
0,
88
12
0, 8 20 410 240 5, 7
9 0, 55
0,
75
V2
2 5, 3 40 2780 120 11 55 0, 88
0,
85
Range
DR
3
Mains connection
delay
fuse
for
50
Hz
1)
Supply lines
for
5%
voltage
drop
∆U and
starting
current
IA
for
50
Hz
2)
4 00
V
400 V ( ∆ U 20
V)
Motor size
A mm² m
ZBR 100
C 12/
2
201, 5
25
ZBR 100
D 12/
2
251, 5
19
Range DR
5 No.
of
poles
Code P % CDF
n Starts/ h Rated current
INand
starting
current
IA
for
50
Hz
cos cos
400 V
ϕN ϕA Motor size
kWrpm IN ( A)
IA ( A)
ZBR
100
D 12/
2 - B050
ZBR
132
D 12/
2 - B140
12
0, 8 20 410 240 5, 7
9 0, 55
0,
75
V1
2 5, 3 40 2780 120 11 55 0, 88
0,
85
12
1, 4 20 400 240 9, 6
15 0, 54
0,
68
V2
2 8, 9 40 2870 120 18 120 0, 89
0,
85
Range
DR
5
Mains connection
delay
fuse
for
50
Hz
1)
Supply lines
for
5%
voltage
drop
∆U and
starting
current
IA
for
50
Hz
2)
4 00
V
400 V ( ∆ U 20
V)
Motor size
A mm² m
ZBR 100
D 12/
2
251, 5
19
ZBR 132
D 12/
2
502, 5
15
Range DR
10
No.
of
poles
Code P % CDF
n Starts/ h Rated current
INand
starting
current
IA
for
50
Hz
cos cos
400 V
ϕN ϕA Motor size
kWrpm IN ( A)
IA ( A)
ZBR
132
D 12/
2 - B140
12
1, 4 20 400 240 9, 6
15 0, 54
0,
68
V1
2 8, 9 40 2870 120 18 120 0, 89
0,
85
Range
DR
10
Mains connection
delay
fuse
for
50
Hz
1)
Supply lines
for
5%
voltage
drop
∆U and
starting
current
IA
for
50
Hz
2)
4 00
V
400 V ( ∆ U 20
V)
Motor size
A mm² m
ZBR 132
D 12/
2
502, 5
15
1) Fuse links also apply in conjunction with a cross travel motor.
8 2) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ.
20364044.p65/081105

20364044.p65/081105
Key data cross travel drives DR 3 – DR 5 – DR 10
The cross travel drives of the DR without electrical control are designed for operation with a Demag frequency inverter in the
120 Hz range. We recommend that Demag DIC Dedrive Compact frequency inverters be used. Owing to the large input voltage
range of the Dedrive Compact, the DR without electrical control can be operated with mains voltages of 380...480 V with
50...60 Hz. At 380 V, the max. frequency must be reduced by 5 Hz.
Key data of inverter-controlled cross travel drive DR 3, DR 5, DR 10 - 2/1 - 4/1 - 4/2
Range DR
3-10
No. of
poles
% CDF
Output
Current
cos ϕ n
Recommended
P
at
220
V
for
50
Hz
inverter
type
Motor size
k W
I ( A)
rpm Dedrive
Compact
ZBA 71
B4
- B003
4 60 0, 37
2, 6
0, 54
1375 DIC-4-004-E
Key data of inverter-controlled cross travel drive EZDR 10 -Pro 6/1
Range DR
10
No. of
poles
% CDF
Output
Current
cos ϕ n
Recommended
P
at
220
V
for
50
Hz
inverter
type
Motor size
k W
I ( A)
rpm Dedrive
Compact
ZBA 90
A4
- B007
4 60 1, 1
5, 1
0, 74
1400 DIC-4-007-E
Example for calculating the cross sections
of the conductors of cables exceeding
the length indicated in the table:
ZBR 100 C 2/12, 400 V required length 25 m
Known cross section x requiredlength
2,5 x 25
=
= 4
Known cable length
16
2
mm
9

Key data of inverter-operated hoist drives DR 3, DR 5, DR 10
Design is in accordance with the VDE regulations and the design rules of the FEM, to meet the high demands made on
electric hoists.
The hoist drives of the DR without electrical control are designed for operation with a Demag frequency inverter in the 87 Hz
range. We recommend that Demag DIC Dedrive Compact frequency inverters be used. Owing to the large input voltage range of
the Dedrive Compact, the DR without electrical control can be operated with mains voltages of 380...480 V with 50...60 Hz. At
380 V, the max. frequency must be reduced by 5 Hz.
Range DR
3
No. of
poles
Code FEM classification
% CDF
Output
P
Current
at
220
V
cos ϕ n
for
50
Hz
Recommended
inverter
type
Motor size
k W I ( A)
rpm Dedrive
Compact
ZBR
100
B 4 - B050
2m
DIC-4-017
ZBR 100
B 4 - B050
4 V3
3m 604, 2 16, 9 0, 85
1350
DIC-4-014
ZBR 100
B 4 - B050
4m DIC-4-014
Range D R 3
Mains connection
delay
fuse
for
50
Hz
1)
Supply lines
for
5%
voltage
drop
∆U ) 2
4 00
V
400 V ( ∆ U 20
V)
Inverter type
A mm² m
DIC-4-017 161, 5
58
DIC-4-014 161, 5
70
Range DR
5
No. of
poles
Code FEM classification
% CDF
Output
P
Current
at
220
V
cos ϕ n
for
50
Hz
Range D R 10
Mains connection
delay
fuse
for
50
Hz
1)
Supply lines
for
5%
voltage
drop
∆U ) 2
4 00
V
400 V ( ∆ U 20
V)
Inverter type
A mm² m
Recommended
inverter
type
Motor size
k W I ( A)
rpm Dedrive
Compact
ZBR
132
B 4 - B140
2m
8, 3 29, 0 0, 87
1420 DIC-4-025
ZBR 112
A 4 - B140
4 V3
3m
60
DIC-4-025
5, 3 18, 7 0, 84
1430
ZBR 112
A 4 - B140
4m DIC-4-017
Range D R 5
Mains connection
delay
fuse
for
50
Hz
1)
Supply lines
for
5%
voltage
drop
∆U ) 2
4 00
V
400 V ( ∆ U 20
V)
Inverter type
A mm² m
DIC-4-025 352, 5
65
DIC-4-017 161, 5
58
Range DR
10
No. of
poles
Code FEM classification
% CDF
Output
P
Current
at
220
V
cos ϕ n
for
50
Hz
Recommended
inverter
type
Motor size
k W I ( A)
rpm Dedrive
Compact
ZBR
132
C 4 - B140
2m
10, 2 38, 0 0, 84
1425 DIC-4-040
ZBR 132
B 4 - B140
V2
3m
60
DIC-4-032
8, 3 29, 0 0, 87
1420
ZBR 132
B 4 - B140
4m DIC-4-025
4
ZBR
132
C 4 - B140
2m50 13, 1 46, 5 0, 83
1410 DIC-4-040
ZBR 132
C 4 - B140
V3
3m
DIC-4-040
6010, 2 38, 0 0, 84
1425
ZBR 132
C 4 - B140
4m DIC-4-032
20364044.p65/081105
DIC-4-040 506, 0
97
DIC-4-032 354, 0
80
DIC-4-025 352, 5
65
1) Fuse links also apply in conjunction with a cross travel motor.
10 2) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ.

20364044.p65/081105
Parameter settings for recommended Demag DIC Dedrive Compact frequency inverter
Please refer to the table below for the required parameter settings.
For the hoist drives, rotary encoder feedback on the motor is required. We recommend that the Demag AG 2 external pulse generator
be used together with the EM-ENC-02 extension module for the Demag Dedrive Compact frequency inverter.
After entry of the rated motor values, it is absolutely necessary to perform parameter identification.
No. Name Unit ZBA ZBR
71B4 90A4 100 B4
112 A4
132 B4
132
C4
6 0%
5 0%
60%
030 Configuration - 410 210
370 Rated voltage
V 220
371 Rated current
A 2, 6
5, 1 16, 9 18, 7 29, 0 46, 5 38,
0
372 Rated speed
rpm 1375 1400 1350 1430 1420 1410 1425
373 No. of
pole
pairs
- 2
374 Rated cosine
phi
- 0, 54
0, 74
0, 85
0, 84
0, 87
0, 83
0,
84
375 Rated frequency
Hz 50
376 Mech. rated
output
kW 0, 4
1, 1 4, 2
5, 3
8, 3 13, 1 10,
2
417 Frequency switch-off
limit
Hz 250 100
418 Min. frequency
Hz 5 8
419 M ax.
frequency
1) Hz120 84 85 86
420 Acceleration Hz/ s
25 42 42, 5
43
421 Deceleration Hz/ s
50 42 42, 5
43
490 Operating mode
encoder
1
- 0 4
491
Pulse
number
per
revolution
of
encoder
1
- - Depending
on
rotary
encoder
used
721 Amplification speed
controller
- 3 10
722
Integral
action
controller
time
speed
ms200 100
For further details regarding commissioning, the many control possibilities, the various hoist functions and the selection of further
additional components of the DIC Dedrive Compact, refer to the operating instructions 214 708 44 and 214 716 44. The permissible
ambient conditions must be complied with.
1) At 380 V, the max. frequency must be reduced by 5 Hz.
11

Connection plate with terminal strip for DR with 2-/12-pole hoist
Fig. 2
1
Top-hat rail, 200 mm long
5
PE
J
EG
PE
123456
3 4
42354944.eps
12 20364044.p65/081105
2-pole 2 pol. hoist HUB
2
PE PE
PE
12VE A 1A B 1B GDNE
12-pole 12 pol. HUB hoist
K
9
6 7 8
11 12
10
X52
L
Cross1
Kreuz1 Cross2 Kreuz2
2 3 PE 1 2 3 PE
SGS SGG
U V W
U V W
1
8
7
6
5
4
3
2
1
PE
2
1
ThH ThH Brg Brg BrH BrH SGS SGS PE SGG1SGG2 SGG3SGG4
SGG5SGG6SGG7SGG8
X161 X162 X163 PE X418 X482 X483 PE
X11
X48
X16
X5
X53
A
PE
PE
X9
B C D E F G H I

20364044.p65/081105
Customer connections
1 Top-hat rail
2 12-pole hoist motor connection
3 2-pole hoist motor connection
4 EG integrated pulse generator
5 Protective earth conductor PE
6 Thermo-switch hoist motor
7 Brake release contact hoist motor
8 Brake hoist motor
9 SGS overload protective device, electro-mechanical
10 SGG geared limit switch
11 Cross travel cut-out system, general
12 Cross travel cut-out system, preliminary (v2 → v1)
All terminals must be connected with up to 4 mm² Cu cross section, except
2-pole hoist and PE which must be connected with up to 16 mm² Cu cross
section.
Factory connections
A Terminal X11 (12-pole hoist motor)
B Terminal X9 (2-pole hoist motor)
C Terminal X10 (signals hoist motor)
D Terminal X53 (SGS)
E Protective earth conductor PE
F Terminal X5 (SGG)
G Terminal X16 (cut-out)
H Terminal X48 (prel.)
I Protective earth conductor PE
J Protective earth conductor PE
K Protective earth conductor PE
L Connection X52 (integrated pulse generator hoist motor)
13

Connection plate with terminal strip for DR with 4-pole hoist motor
Fig. 3
1
Top-hat rail, 200 mm long
5
PE
J
EG
PE
123456
3 4
42356144.eps
14 20364044.p65/081105
2-pole 2 pol. HUB hoist
2
PE PE
PE
12VE A 1A B 1B GDNE
12-pole 12 pol. HUB hoist
K
9
6 7 8
11 12
10
X52
L
Kreuz1 Cross1
Cross2
Kreuz2
SGS SGG
U V W
U V W
PE
3
2
1
PE
3
2
1
8
7
6
5
4
3
2
1
PE
2
1
ThH ThH Brg Brg BrH BrH SGS SGS PE SGG1SGG2 SGG3SGG4
SGG5SGG6SGG7SGG8
X161 X162 X163 PE X418 X482 X483 PE
X11
X48
X16
X5
X53
A
PE
PE
X9
B C D E F G H I

20364044.p65/081105
Customer connections
For the DR with 4-pole hoist motor, the connection is made directly in the motor
terminal box
1 Top-hat rail
2 -
3 -
4 -
5 Protective earth conductor PE
6 -
7 -
8 -
9 SGS overload protective device, electro-mechanical
10 SGG geared limit switch
11 Cross travel cut-out system, general
12 Cross travel cut-out system, preliminary (v2 → v1)
All terminals must be connected with up to 4 mm² Cu cross section, except
2-pole hoist and PE which must be connected with up to 16 mm² Cu cross
section.
Factory connections
A Terminal X11 (12-pole hoist motor)
B Terminal X9 (2-pole hoist motor)
C Terminal X10 (signals hoist motor)
D Terminal X53 (SGS)
E Protective earth conductor PE
F Terminal X5 (SGG)
G Terminal X16 (cut-out)
H Terminal X48 (prel.)
I Protective earth conductor PE
J Protective earth conductor PE
K Protective earth conductor PE
L Connection X52 (integrated pulse generator hoist motor)
15

Cable unions
1
1
Fig. 4
DR 3 cable unions DR 5 cable unions
2
DR 10 cable unions
3
3
2
42355044.eps
42355244.eps
1 Round cable union M25 1)
2 Round cable union M20 1)
1) Screw-type unions must have long threads (approx. 15 mm)
e.g. cable union Schlemmer-Tec, manufacturer no. 5307620 (M20 x 1,5)
16 cable union Schlemmer-Tec, manufacturer no. 5307125 (M25 x 1,5)
20364044.p65/081105
1
Cable unions, DR 3, DR 5, DR 10 cover
3 Twist-type cable entry gland for cable glands up to max. 12,5 mm
4 Round cable union M25
3
2
42355144.eps
4
42355344.eps

20364044.p65/081105
Connection diagrams
Hoist motor connection diagrams
Pole-changing hoist drive
low
speed
PE
Fig. 5
1L1 1L2 1L3
1U
2U
PE
U U U
1V
1W
M
3~
U U
2V 2W
U
CW
1L1 1L2 1L3
~ ~
U V W
high
speed
U1 V1W1
M 3~
U2
V2
W2
CCW
Switchgear
cabinet
Motor
TB1
TB2
1S2
1S1
VE
RD BU WH
RD
BD2 BD1
Hoist drive with frequency inverter
VE
RD BU WH
RD
X1
X1
U
Frequency
inverter hoist
Thermo-switch
Brake monitoring
Switchgear
cabinet
2L1 2L2 2L3
BD2 BD1
Motor
7
6
5
4
3
2
1 + -
GS
~
~
~
2L1 2L2 2L3
Re-start block min.
250 ms!
6
5
4
3
2
1
7
GS
TB1
TB2
1S2
1S1
42356044.eps
~
~
~
+ -
Brake monitoring
Thermo-switch PCB in DR
Re-start block min.
250 ms!
Motor
terminal box
42355944.eps
Y/Y
Y/D
ZBR 100 motor terminal block
1U
T1
1V
T2
U U U
1SP1 1SP2 1SP3 2SP1 2SP2 2SP3
U2
U1
1U
T1
1SP1
1W
T3
1V
T2
1SP2
2U
T11
1W
T3
1SP3
2V 2W
T12 T13
U U U
2U
T11
2SP1
2V
T12
2SP2
BD1 BD2
2W
T13
2SP3
BD1
SP1
1L1 1L2 1L3 1L1* 1L2* 1L3* L+ 1L-
1U
Motor terminal board
V2
V1
W2
W1
W2 U2 V2
U1 V1 W1
1L1 1L2 1L3
X1
RD
VE+ GS1 BD1
VE
- +
WH BU RD
4 3 X1
GS
BD1 BD2
U
SP1 SP2 TB1 TB2
BD2
SP2
ZBR 132 motor terminal block
1U
T1
1V
T2
U U U
U U U
1SP1 1SP2 1SP3 2SP1 2SP2 2SP3
T1
1SP1
1L1 1L2 1L3 1L1* 1L2* 1L3* L+ 1L-
TB1 TB2
4 2 1
wh gn bn
1S3 1S2 1S1
TB1 TB2 1S3 1S2 1S1
SP1 SP2 TB1 TB2
1W
T3
2U
T11
2W
T13
BD1 BD2
1V
T2
1SP2
1W
T3
1SP3
2V
T12
2U
T11
2SP1
2V
T12
2SP2
2W
T13
2SP3
BD1
SP1
U
BD2
SP2
GS
- +
7 6 5 4 3 2 1
WH BU
2L3 2L2 2L1 BD2 X1
VE
4 2 1
wh gn bn
1S3 1S2 1S1
TB1 TB2 1S3 1S2 1S1
4 2 1
wh gn bn
1S3 1S2 1S1
41003284.eps
41004384.eps
03800784.eps
17

Cross travel motor connection diagram
Cross-travel drive with frequency inverter
Fig. 6
PE
1L1 1L2 1L3
U1
~ ~
M 3~
V1 W1
TB1
TB2
EG integrated pulse
generator
Brake release contact
Temperature sensor, hoist
and cross travel motor
Thermo-switch
Switchgear
cabinet
VE
RD BU WH
RD
Motor
X1
BD2 BD1
Brake
2L1 2L2 2L3
U
6
5
4
3
2
1
7
GE
~
~
+ -
Motor terminal
block
Motor terminal block
18 20364044.p65/081105
U1
T1
V1
T2
U1
T1
W1
T3
V1
T2
L1 L2 L3
W1
T3
U
SP1 SP2 TB1 TB2
BD1
SP1
L+ L-
BD1 BD2
42355844.eps 41003384.eps
BD2
SP2
TB1 TB2
See operating instructions for Motors, type Z, ident. no. 214 228 44
See operating instructions for Motors, type Z, ident. no. 214 228 44
See operating instructions for Motors, type Z, ident. no. 214 228 44

20364044.p65/081105
Brake control
Various control modules are available for controlling Demag B003 to B680 disk
brakes with DC magnets.
All modules can also be fitted inside the switchgear cabinet.
In this case, the brake coil must be protected against switching voltage peaks by
means of a varistor, part no. 260 898 84, in the motor terminal box.
All rectifiers feature varistor protection against overvoltage at the AC input and on the
switching contact terminal as standard.
The braking rectifiers are approved for a max. AC voltage of 500 V AC.
Brake cut-out in the AC or DC circuit is possible with GE rectifiers (cross travel) and
GS rectifiers (hoist) depending on the connection.
Brake application times are highly dependent on the way in which the brake is
switched off.
For the DR without electrical control system, cut-out in the DC circuit by using the
VE module is necessary.
Operation with frequency inverters
If ZB cylindrical rotor brake motors are operated together with inverters, the
brake must be provided with a separate power supply and control.
Brake control modules
GE brake rectifiers (normal excitation)
GE brake rectifiers are used for the cross travel drive of the DR as standard.
They mainly consist of a half-wave rectifier with integrated free-wheeling circuit.
GS brake rectifiers (high-speed excitation)
GS brake rectifiers are used for the ZBR motors of the DR hoist drives as
standard.
The GS module includes a reversible rectifier which overexcites the brake for approx.
0,3 seconds to release it and supplies it with the appropriate holding voltage
from a half-wave rectifier (overexcitation factor of 2,5 with 3-phase connection).
Important: When used with a pole-changing motor, GS modules must always
be provided with a separate power supply.
To ensure perfect functioning for cut-out of the GS and VE modules, i.e. switching
with overexcitation, min. 250 ms must expire between cut-out and switching on
again.
VE voltage relays (voltage-dependent high-speed trip relay)
VE voltage relays can be combined with GE, GS and GP brake rectifiers. VE
voltage relays must only be used for brakes with a separate power supply.
These modules are preferably used for inverter-fed motors. They are used for
high-speed demagnetization of the brake to achieve fast brake application times
without the need for additional wiring for brake cut-out in the DC circuit. VE
voltage relays are connected to the brake power supply. The contact in the DC
circuit is opened when the brake is switched off.
19

SGG geared limit switch
Fig. 7
Adjusting instructions for SGG
Operating principle
Adjust
Setting the contacts for individual
adjustment:
Setting the contacts for adjustment in
blocks:
Adjusting screw, black Adjusting screw, white
For adjusting the geared limit switch, a hexagon socket key, 4 mm, is required.
42589444.eps
SGG/terminal strip connection
SGG Switch contacts
20 20364044.p65/081105
1
2
3
4
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
Before setting the switching points, make sure that live contacts are provided with a
touch guard in order to protect them against accidental contact.
Allow for run-on!
Each contact is allocated to a cam disk which is infinitely adjustable.
The cam disks can be adjusted independently by means of the white adjusting
screws.
When turning the white adjusting screw clockwise, the cam disk is also turned clockwise.
The switching point is shifted upwards in accordance with the hook path.
When turning the screw anti-clockwise, the switching point is shifted downwards.
Standard cam disks are designed in such a way that a max. useful path and a run-on
path are available.
The geared limit switch is already permanently connected with the control system via
the system connector cable. For setting the contacts, turn the white adjusting screw
until the contact maker opens the contact.
If the run-on path is exceeded, the contact either opens or closes.
The contacts are adjusted in blocks by means of the black adjusting screw. All cam
disks are adjusted together, while the relative adjustment of the individual contacts
remains unchanged. When turning the black adjusting screw clockwise, the cam
disks are also turned clockwise.
Approach cut-out points several times to check the limit switch functions are
operating correctly!

20364044.p65/081105
Technical data
Transmission ratio:
Switch contacts:
Contact type:
Cam disc:
Switching point repeat accuracy:
Electrical connection:
Technical features:
Compliance with standards
Ambient temperature
Type of enclosure
Insulation class
Approvals
Technical features of
switching elements:
Positive opening to rated operating voltage
Ui Thermal continuous current Ith Category acc. to VDE 0660:
Mechanical service lives in switching
cycles
Terminal identification
Approvals
Current load to plug connector
Outer dimensions:
Length up to pinion cover
Enclosure dimensions
Overall height
i = 205 with block setting of all cam disks designed for min. >1x10 6 switching
operations
4
Change-over contact, snap-action contact, NC with automatic disconnection,
contact material: silver/silver
with 15° leading cams
approx. +/-15 mm on hook, least favourable case for 2/1 reeving and hook path
12 m. In this case, the 47 revolutions on the drive shaft result in an adjusting angle
of 79,71° on the cam shaft for i = 205.
Terminal strip direct connection on PCB.
EN 60204-1 IEC 947-5-1 EN 60947-T5-1
EN 60529 EN 50013 IEC 536
Continuous operation -40 °C to +80 °C
IP 54
Class II
CE and CSA
VDE 0660 part 200 from 7/92
250 V AC and 24/80 V DC
6 A
AC-15, 230 V AC/1,5 A
DC-13, 60 V DC/0,5 A
10 x 106 switching operations
Acc. to EN 50013
CE-UL/CSA
6 A / 85 °C 250 V AC
approx. 165 mm
approx. 91 x 72 mm
approx. 95 mm
21

Load detector
SGS overload cut-out,
electro-mechanical
Fig. 8
Position switch
Receptacle with tab, 6,3-2.1
Socket connector, 2-pole
42355444.eps
Depending on the design, the SGS overload switch is set to the rated load of the DR
and integrated in the DR hoist. The SGS contact must be evaluated in addition to
avoid any vibration in the system caused by switching off and on again.
We recommend the use of MKA-2 contact evaluators for standard applications.
This unit prevents premature enabling of the lifting motion and the resulting vibration
processes by means of signal filtering. The unit is available for three control voltage
ranges, it is included in the supply depending on the order.
In combination with the SGS, only the ‘overload cut-out’ function can be used.
SGS Load link
Input voltage: 24 V, 9600 Hz
Output signal: Load limit contact NC -X53
V switching capacity: 4 A/230 V AC; 1 A/24 V DC
Ambient temperature: -30° C to +80° C
Type of enclosure: IP 67
Mounting position: Any
22 20364044.p65/081105

20364044.p65/081105
MKA-2 front plate/connection
diagram/dimensions
Fig. 9
A1 13 14 23 24
O.K CLK
MGS
Dematik
46953144
gn br/ws ge
1 2 3 4 A2
Jumper positions
1)
®
MKA-2
Overload protection
Position 1 (not
SGS)
Position 2
Overload cut-out
41873344.eps
1) Jumpers for crane acceptance test.
Remove jumpers after acceptance test.
MKA-2 dimensions
MKA-2 front plate
45,0 113,0
Dematik ® MKA-2 contact evaluator
Part no.: For control voltage 220...240 V, 50/60 Hz 469 531 44
110...120 V, 50/60 Hz 469 532 44
42...48 V, 50/60 Hz 469 533 44
24 V, 50/60 Hz 469 534 44
Other voltages in special designs:
Possible contacts: 2 NO contacts
Rated cut-out capacity: 230 V; 5 A AC11, 4 A conditional nominal short-circuit current
Operating voltage range: 90 to 100 % of the nominal value
Nom. consumption: max. 4 VA
Ambient temperature range: -20° C to +70° C
Mode: Suitable for continuous operation
Type of enclosure: IP 40 to DIN 40050
Conductor connection: max. 2 x 2,5 mm² with self-releasing washers
Mounting position: Any
Mounting: Quick mounting for carrier rail 35 mm
Weight: 390 g
71
40995644.eps
23

Block wiring diagram
Dematik ® SGS/MKA-2 as overload cut-out
Fig. 10
L4
L5
L1,L2,L3 PE
S2 S1
S1 S2
U1
23
24
S3 S3
K4 K3
K3 K4
Lifting Lowering
Function: SGS / MKA-2 as overload
cut-out
F2
K3 K4
U1
M
3
M2
A1
Dematik MKA-2
A2 2 3
SGS1 SGS2
Brown
Yellow
SGS
21 22
Jumper in position 2
= Overload cut-out
(see page 23, fig 9)
42356644.eps
Equipment designation
B1 = SGS limit switch
F2 = Fuse ‘main hoist motor’
K3 = Contactor ‘Main lifting’
K4 = Contactor ‘Main lowering’
M2 = Main hoist motor
S1/S2 = Pushbutton lifting/lowering
S3 = Emergency limit switch lifting/lowering
U1 = MKA-2 contact evaluator
The SGS load link is plugged into position SGS on the PCB (SGS 1, SGS 2, PE).
The outgoing terminal connections are connected to the MKA-2 contact evaluator.
DR terminal SGS 1 on MKA terminal 2 and DR terminal SGS 2 on MKA terminal 3.
Plug the jumper behind the front plate of the MKA-2 into position 2, i.e. between the
pins in the middle and at the bottom.
(see also description of MGS/MKA-2 load detectors (206 689 44))
When SGS and MKA are used in combination, only the ‘overload cut-out’ function
can be used.
Only use contacts 23 - 24 of the MKA.
24 20364044.p65/081105

20364044.p65/081105
ZMS, FGB-2, FWL overload protection
Fig. 11
ZMS
Calculating and setting the
overload switching point
Calculation example for FWL overload
cut-out
Example:
DR 10-Pro, 8 t in 4/1
ZMS = 1,25 t
A/B = 0,5
Rope hoist
A/
B
DR3and 10
0,
5
DR50, 64
FGB-2 with PVC module
For a detailed description: see document 206 880 44
Screening over outer sheath
42355544.eps
Rope
F EM
Nominal load
[ t]
Lever ZMS 2/ 1
4/ 1
6/ 1
4/ 2
LF
[ x10-
3]
hoist
2/ 1 4/ 1 6/ 1 4/ 2 A/ B Nom.
load
[ t]
Value S1to S7
Value S1to S7
Value S1to S7
Value S1to S7
2/ 1 4/ 1 6/ 1 4/
2
2m1, 6 3,
2
751101001 75 1101001
1,
0596
DR
3 3m1, 25
2, 5
0, 5 0,
625
60 0011110 60 0011110 - - - - 2,
2222
- -
4m1 2 49 1000110 49 1000110 4,
3403
2m2, 5 5
751101001 75 1101001
1,
0596
DR
5 3m2 4 0, 64
1,
25
61 1011110 61 1011110 - - - - 2,
0696
- -
4m1, 6 3, 2
50 0100110 50 0100110 4,
0422
2m5 10 16 5
110 1100111 115 1100111 122 0101111 115 1100111 0, 2778
0, 2289
0,
2778
DR
10
3m4 8 12, 5 4 0, 5 1,
25
93 1011101 93 1011101 115 1100111 93 1011101 0, 5425
0, 4800
0,
5425
4m3, 2 6, 3 10 3, 2
75 1101001 74 0101001 78 0111001 75 1101001 1, 0596
1, 1109
0, 9375
1,
0596
Nominalload
x A/B x 110 8 t x 0,5 x 110
FWL switch value =
+ 5 =
+ 5 = 93
No. of ropes x nominalload
ZMS 4 x 1,25 t
25

FWL load spectrum recorder
Application
Mode of operation
The service life of hoist units mainly depends on the selection of the appropriate
group of mechanisms, i.e. the correct estimation of operating time and load spectrum.
Over long periods of utilization, however, operating conditions may change at
a later date which may result in a longer or shorter service life. The conversion from
single to double-shift operation for a production crane, for example, results in doubling
daily utilization and, therefore, results in correspondingly faster wear of the drive
mechanisms.
Since hoist units are designed for specific periods of operation based on the rules of
fatigue strength, failures must be expected after the end of the theoretical service life
has been reached.
FWL units record all loads on the hoist unit during operation, in a power-failure safe
and long-term memory. The load spectrum recorder indicates experienced utilization.
It therefore continuously provides information on the operating conditions and the
calculated remaining service life of the hoist unit.
The load spectrum recorder measures the lifted load and the hoist motor operating
period.
The measured load is compared with the SWL and a relative load is calculated. Since
wear on the moving parts of the hoist unit increases disproportionately with rising
load, the value for relative loading is evaluated accordingly. Owing to this evaluation,
operation of the hoist unit with half the rated load only creates (1/2) 3 = 1/8 of the load
spectrum value (LK value) which is reached by operation with rated load.
For ¼ rated load, therefore, the LK value is (1/4) 3 = 1/64, etc.
The operating time of the hoist unit is measured as the duty time of the lifting and
lowering motions. Since wear can be assumed proportionally to the operating time,
the measured value is integrated as a proportion of time in the displayed LK value.
Double the operating time with identical load as a consequence corresponds to a
doubled LK value.
The load spectrum recorder collects the measured loading of the hoist unit, continuously
for any load and duty intervals. The LK value therefore corresponds to the sum
total of loads experienced so far. In contrast to the elapsed operating time counter, it
is not the pure duration of operation of the hoist unit that is displayed but the load on
the hoist unit is recorded, which is of far greater importance for wear, and evaluated
according to its influence.
The counter in the load spectrum recorder is calibrated so that when the strain gauge
carrier link is loaded with the SWL in group of mechanisms 1 Bm, the LK value
counts +1 per second.
This makes the load spectrum recorder an effective instrument for monitoring hoist
units.
Based on continuous recording of the displayed LK value, in particular in conjunction
with maintenance work, the owner of the hoist unit can easily obtain important information
for cost-effective planning of maintenance and preventive maintenance work.
It is possible to analyse utilization of hoist units on the basis of the recorded LK values
to appropriately plan any extension or modernisation measures.
The loading and operating time class to FEM can be verified at any time in conjunction
with the elapsed operating time counter.
26 20364044.p65/081105

20364044.p65/081105
Calculation of the elapsed
safe working period (SWP)
Example: DR 3 3m
Counter LK = 10014
LF = 0,5425 x 106 L1, L2, L3, PE
L4
U3
L5
S1
S3
K1
K1
S2 S1
U1
K2
13
14
S3
K3
F1
M
3
M1
A1 1 2 3
A2 4 5 6 7
U1
S3
S4
K3
23
24
S3
K2 K3
K2
K2
The FWL load spectrum recorder makes is possible to determine the past duration
of service and, as a consequence, also the remaining duration of service.
For measuring, the nominal load of the ZMS is used as the reference nominal load.
This means that the FWL counts the full load seconds of the ZMS. If the ZMS is not
to be loaded with its own nominal load (for hoist unit nominal load), the displayed
value needs to be corrected by a specific factor. This correction factor must be entered
into the crane test and inspection booklet when the unit is put into operation.
The duration of service S in hours (to FEM 9.755) is calculated by means of the
following formula:
S = LK × LF
S = Duration of service in full load hours
Full load hours S = 10014 x 0,0005425 = 5,43 hours
U1
K3
A1
A2 1 2 3
U2
B1
ZMS
FGB-2
FWL
K2 K3
16
10
P1
LK = FWL counter reading
LF = Load spectrum factor
FGB-2/FWL as overload protection and load spectrum recorder for hoist units with pole-changing motors
Switch 8 ON = overload protection
Fig. 12
Creep Main
Lifting Lowering Lifting Lowering
Green
Brown
White
Screen
Screen
Green
Brown
White
Yellow
Equipment designation
B1 = Strain gauge
F1 = Fuse ‘Hoist motor’
K1 = Contactor ‘Creep lifting/creep lowering’
K2 = Contactor ‘Main lifting’
K3 = Contactor ‘Main lowering’
M1 = Creep – main hoist motor
P1 = Elapsed operating time counter
S1/S2 = Pushbutton lifting/lowering
S3 = Emergency limit switch lifting/lowering
S4 = Preliminary limit switch ‘Main lifting’
U1 = Frequency evaluator/load spectrum
recorder, overload
U2 = FGB-2 frequency generator
U3 = Hoist unit control (e.g. 250 ms re-start
block)
42356544.eps
27

Cross travel limit switch
Position switch XCK-MR
Fig. 13
Position switch
2 x switching in steps with rotating stop
Switching crossbar positions with
contact arrangement
Contact block
‘A’
Connection of cable on
switch:
Type XCK-MR54D1
With rotating stop
Key data:
Housing: Zinc die-cast
Type of enclosure: IP66
Mechanical service life: 2 million switching cycles
Actuating speed: max. 90 m/min
Min. moment for actuation: 0,5 Nm
Positive opening: 0,75 Nm
Cable unions: 3 x M20
Contact block
‘B’
Screw-type union M20 with long
thread (approx. 15 mm)
+180° +90° 0° -90° -180°
Rated operating data: AC-15: 240 V; 3 A
DC-13: 125 V; 0,55 A
Connection/cross section: Flat terminal with washer M3,5/max. 2 x 1,5 mm²
Earth lead connection/cross section: Flat terminal with washer M3/max. 1,5 mm²
Short-circuit protection: Fusible link 10 A, gG (gL)
A11 A12
B21 B22
B11 B12
Positive lock connector 6,3 mm with lock
Connector, 3-pole
Connector -X16
Connector, 3-pole
Core 1 on pin 1
Core 2 on pin 2
Core 3 on pin 3
Core 4 on pin 1
Core 5 on pin 2
Core 6 on pin 3
5 mm offset without
connector -X48
42355444.eps
Contact type: No snap function, positive opening of NC contact 21-22
28 20364044.p65/081105

20364044.p65/081105
Option packages
Cross travel inverter
DR PRO and DR COM
Package 1
Cross travel limit switch
DR PRO and DR COM
Package 2
Selection via logic
Fitted in the factory
Overload cut-out, F series
Only for DR PRO
Package 3
Selection via logic
Fitted in the factory
Accessories for parameter
programming
Package 1. 1
1.
2
Inverter DIC-4-004 DIC-4-007
537 713
84
537
715
84
Braking
resistor
120
Ohm
0,
4 KW
- 537
732
84
Braking
resistor
220
Ohm
0,
2 KW
537 730
84
-
Order cable between trolley motor and FI separately, e.g. 4 x 1,5 + 2 x (2x0,5),
part no.: 719 096 45
EKDR 3 - 10
With mech.
fittings
Cross
travel
limit
switch
719
074
45
EZDR 5 - 10
With mech.
fittings
719
174
45
Package 3. 1
3. 2
3. 3
3. 4
3. 5
3.
6
Rope hoist
DR3 DR5, 10
DR3 DR5, 10
DR3 DR
5,
10
ZMS
0, 625
t
491 390
44
1, 25
t
491 391
44
0, 625
t
491 390
44
1, 25
t
491 391
44
0, 625
t
491 390
44
1,
25
t
491
391
44
FGB-2 ( terminals)
469
674
44
FWL
469 669
44
469 668
44
469
667
44
42-48 V
110-120 V
220-240
V
Order cable LIYCY 3 X 0,5 mm² between FGB-2 and FWL separately,
part no. 464 495 44
For programming the parameters, order an operating unit (key-pad, see table 1) or an
interface module and the ‘Parcom Compact’ parameter programming software (see
table 2).
Table 1
KP500 operating
unit
537
722
84
Table 2
KP232 interface
module
537
769
84
RS232 module
CM
- 232
537
723
84
Data line
PC
1,
8 m
537
237
84
Parcom
Compact
parameter
programming
software
537
752
84
29

Notes
30 20364044.p65/081105

20364044.p65/081105
Notes
31

Demag Cranes & Components GmbH
P.O. Box 67, D-58286 Wetter
Telephone (+49 2335) 92-0 · Telefax (+49 2335) 927676
www.demagcranes.com
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Subject to change. Not liable for errors or omissions.
Printed in Germany Basse/081105/5H