4_Chapter 1 Product Presentation DR3-DR10

EKDR product presentation

Product presentation DR 3 - DR 5 - DR 10

1 DR Pro

1.0 DR Com

1

2


Contents 1 Mechanical equipment of DR 3, 5 and 10 rope hoists 4 1.1 Components of the EKDR monorail hoist 5 1.2 C design 6 6 1.2.1 Hoist unit side 1.2.2 Travel unit side 6 1.3 Hoist motor – cylindrical rotor brake motor 7 7 1.3.1 Motor selection table 1.4 Hoist brake 8 8 1.4.1 Assignment of brake to the motor 1.5 Hoist gearbox 9 1.6 Rope guide 10 1.6.1 Coupling 10 1.6.2 Rope anchorage 10 1.6.3 Rope guide, standard and acid resistant 10 1.7 Rope retaining crosshead, top block and bottom block 11 11 1.7.1 Rope retaining crosshead 1.7.2 Top block 11 1.7.3 Bottom block 11 1.8 Securing the EKDR on the girder flange 12 12 1.8.1 Thrust rocker 1.8.2 Counterweight plates 12 1.9 Travel wheels and travel drive 13 13 1.9.1 Integrated gearbox for cross travel unit Notes 14

1.10

1.11 1.12 1.13 1.14

1.15

1.16

1.17

1.18 1.19 Notes 1.20

1.21 1.22

1.23

Integrated electrical equipment of DR 3, 5 and 10 rope hoists 1.10.1 Power supply and control cable 1.10.2 Enclosure overview 1.10.3 Rope drum – geared limit switch connection Slot arrangement of PCB, left-hand side Slot arrangement of PCB, right-hand side ISS Intelligent contactor control Control 1.14.1 Cable-connected control system 1.14.2 Radio control system 1.14.3 Joystick control unit Electrical equipment concept for refurbishment 1.15.1 Parallel transmission 1.15.2 Serial BUS transmission 1.15.3 Wireless transmission 1.15.4 Integration concept for refurbishment Crane bridge enclosure with pole-changing long travel motors 1.16.1 Plug-in connections 1.16.2 Plug-in long travel drives 1.16.3 Plug-in connections 1.16.4 Parallel Out 1.16.4 Parallel In Hoist inverter 1.17.1 Travelling hoist inverter 1.17.2 Frequency-controlled long travel Large load display Reserve control Double-rail crab 1.20.1 EZDR10-H20-4/1 1.20.2 EZDR10-H20/H40-6/1 FDR foot-mounted hoist Product definition 1.22.1 DR Pro 1.22.2 DR Com DR crane set for single-girder overhead travelling crane

17 17 17 17 18 19 20 21 21 21 21 22 22 22 22 22 23 23 23 23 23 23 24 24 24 25 26 27 30 30 30 31 32 32 32 33

3

The DR rope hoist Optimised for crane applications, the new Demag DR rope hoist meets all the requirements for state-of-the-art hoists for tomorrow‘s needs. Besides the space-saving design and particularly long service life, it also offers a higher lifting speed for faster handling rates – comprehensive standard features at an attractive price. Higher hoist speed for faster handling Most sub-assemblies of the Demag DR rope hoist have a lifting speed of at least 6 m/min with 4/1 reeving as standard. A frequency inverter provides infinitely variable cross travel speeds up to 30 m/min for low-sway travel motions, fast and exact positioning and gentle handling of sensitive loads. This also results in a significant reduction of the mechanical load on the crane installation. Greater efficiency thanks to higher availability The hoist unit is supplied with FEM classification 2m+. The rope reeving components are classified in 2m, the gearbox service life is rated at 1900 hours at full load instead of the 1600 hours at full load specified for the 2m classification. The generous dimensioning of all components also ensures constant availability. The modular design of the rope hoist facilitates simple and rapid maintenance and repair of individual components, thus cutting any downtime to a minimum.

4


Components of the EKDR monorail hoist

1.1 5

6 7 9

1 2

10

3 11 4

12

1

2 3 4 5 6 7 9 10 11 12 13

Electrical enclosure with integrated electronics, electrical equipment and geared limit switch Flange width retaining elements with cable guide Rope drum Hoist motor with brake Travel motor with brake Travel gearbox Retaining ring

13

Thrust rocker 4/1 top block Rope retaining crosshead with SGS or optionally ZMS overload protection Three-stage offset gearbox Bottom block with protective cover and 2 handle recesses

5

C design Compact design for optimum utilization of space The design of the Demag DR rope hoist provides outstanding approach dimensions for better utilization of the space served by the crane. This means that either a larger area can be served or new buildings can be designed smaller. This cuts new construction and subsequent costs.

1.2

Hoist unit side The gearbox and the electrical enclosure are bolted together to form the hoist unit frame by means of three connecting rods.

1

2

3

1 Three-stage, helical hoist gearbox lubricated for life 2 Hoist motor with cylindrical rotor and DC brake 3 Rope drum 4 Bolted frame

4

Travel unit side The travel unit side consists of two legs, with one of the legs being designed as the gearbox housing for the travel drive. The travel motor is of direct input design.

1.2.2

5 6

5

6

6

Travel motor with brake Connection of the wheel legs


Hoist motor – ZBR cylindrical rotor brake motor 1

2

3

4

1.4

5

6

7

The low-vibration and low-noise ZBR cylindrical rotor motor is available as 12/2 or 4-pole motor with phase insulation, IP55 type of enclosure and optionally also with IP65 type of enclosure. 1 Aluminium housing 2 Position of the integral pulse generator (not visible in the figure) for detecting the speed and direction of rotation. The information is sent to the electronic system for evaluation 3 Plastic fan cover (must not be loaded mechanically) 4 Optional: External pulse generator 5 Thermal contact, temperature class F (The control switches off the motor at excessive heat within a short time) 6 Brake system (ventilated DC brake) 7 Plastic fan

Motor selection table (yellow = inverter-controlled motors)

3,2 t

ZBR 100C 12/2 0,57/3,4 kW 20/40% CDF 240/120 S/h Brake B050

ZBR 100D 12/2 0,8/5,3 kW 20/40 % CDF 240/120 S/h Brake B050

ZBA 100B4 7,1 kW with FI 60 % CDF

5t



ZBA 132AL4 11 kW with FI 60 % CDF


ZBA 132B4 16 kW with FI 60 % CDF

ZBA 132C4 22,2 kW with FI 60 % CDF

Brake B140

Brake B140

10 t

Brake B050

Brake B140

Hoist speed with 4/1 reeving 3,2 t 5t 10 t

V1 6 m/min 6 m/min 5 m/min



7

DC brake of the ZBR hoist motor Brake-side motor end cap

As standard, the EKDR hoist brake is provided with a brake release monitoring function. When the brake is switched off, braking is mechanical down to standstill. Brake spring Wear on the brake is checked by measuring the run-on revolutions and the wear Electro-magnet on the brake which can be calculated on this basis. The brake is additionally Armature disk equipped with a visual wear indicator and stop plate which should be checked every time the brake is adjusted. As standard, the motor is equipped with an integral pulse generator. The main processor monitors releasing Microswitch of the brake and start-up of the motor. In for function the event of any discrepancies, the lifting axis is automatically de-energized. check Covering tape IP55

Friction plate

Carrier

Brake disk with brake linings Wear indicator

Adjusting nut Distance spring

Collared pin 1.5

The GS module with 2,5 fold overexcitation is used as brake module.

Assignment of brake to the motor

1.6

B140, 23 Nm ZBR 132D 12/2 ZBR 132AL4 ZBA 132B4 ZBA 132C4

8

B050, 8,3 Nm ZBR 100C 12/2 ZBR 100D 12/2 ZBA 100B4


Hoist gearbox with with 2m+ classification

1

1.7

2

The three-stage helical gearbox has shown such a good performance that the 1600 full load hours necessary in 2m have been exceeded by far. Therefore the gearbox is rated as 2m+ with 1900 full load hours which means 20 % more service life. The gearbox is lubricated for life with commercially available CLP 220 mineral oil so that the oil must only be changed at the time of a general overhaul or after 10 years. 1 2

Oil filling opening Oil drain screw

3 4

Output shaft in enclosed bearing First and second intermediate shaft with open bearing Pinion fixed to the motor by means of a conical bonded press fit

5 3

4

5

1.8

The 2m+ classification only applies to the gearbox! The other components of the monorail hoist are classified in 2m with 1600 full load hours!

9

EKDR rope guide The EKDR monorail hoist is available with wire rope diameters of 7, 9 or 13 mm; the rope guide is similar to the one of the DH hoist. The rope anchorage for the 2/1 and 4/1 rope reeving is an aluminium bushing and a rope insert. The rope is secured with a clip. An acid-resistant rope guide is available as an option. The rope drum and the drive are connected by a drive flange and coupling elements.

1

1

2

3

4

2

2

1 2 3 4 5 6

1.9

Rope drum Coupling elements Insert Aluminium bushing Clip Drive flange with involute splining

1.11 1.10 6

6

4

1

1.12

1.13

6

1 2 3 4

Insert Aluminium bushing Coupling elements Clip

1

2

1.14 1 2 2

10

3

4

Standard rope guide Acid-resistant rope guide, optional

2

1

1

2

As standard, the rope retaining crosshead is equipped with an electro-mechanical overload protection (SGS). Evaluation is via the central electronic unit. As an option, it may also be equipped with a strain gauge carrier link (ZMS). 1 2 3

1.17

1

1

2

Top block 4/1 Compensating sheave 4/2 Rope retaining crosshead

2

3

1


1

1.16

Rope retaining crosshead ZMS strain gauge carrier link bore hole SGS overload cut-out Dished washers Limit switch

2

Top block 4/1 Compensating sheave 4/2 Rope retaining crosshead 2/1 Rope lead-off protection

The bottom block is provided with covers and 2 handle recesses. 1 2

Bottom block 4/1 with protective cover Handle recess

1.17 2

1.18

11

Securing the EKDR on the girder flange 1 2 3

Glued setscrews with cup point Trolley secured by setscrew with cup point Thrust rocker

1.19 1

3

1.20

The weight of the EKDR for standard flange widths of 200 – 420 mm is counterbalanced by a thrust rocker with thrust rollers for travelling gently on the rail. The contact pressure of the thrust rocker can be adjusted and depends on the type of EKDR. For smaller flange widths of 73 – 200 mm, counterweight plates are used for counter-balancing. 1 2 3

1

2

2

Table of flange thicknesses The following flange thicknesses apply: DR 3 = min. 10 mm DR 5 = min. 12 mm DR 10 = min. 15 mm

Spacer sleeves as flange width retaining elements with cable guide Thrust rollers with plastic tyres Tension spring

3

1.21 Counterweights A compensating weight is necessary to increase the wheel load of the driven wheel when the travelling hoist is used with small lower flange widths. These plates are pushed onto the connecting rod, positioned at the end of the rod and fixed into place using the existing retaining spacer sleeves, washers and seeger rings. The retaining spacer sleeves also have to be fitted to the second connecting rod. The thrust rocker is maintained.

12


Travel wheels and cross travel drive The travel wheels of the EKDR are of universal design suitable for parallel or sloping runways. The cross travel drive is via direct drive on one travel wheel by means of a 4-pole ZBA motor with frequency inverter for cross travel up to 30 m/min. 1 2 3

4

Guide rollers Non-driven travel wheel 4-pole ZBA 71B4 cross-travel motor, 0,37 kW, 1400 rpm, 100 % CDF with brake Directly driven travel wheel

1.22 1 2

1.23

4

3

Travel drive: • fully integrated gearbox oil-lubricated • no intermediate stage • directly driven travel wheel without flange • guide rollers • 4-pole ZBA motor with frequency inverter Cross travel speed 1,5 – 30 m/min

13

Notes

14


Notes

15

Notes

16


Overview – integrated electrical equipment 1.24

1

2

3

1

The EKDR electrical equipment features PCB design and is integrated in the cover of the electrical enclosure. All connections are of plug-in design and provided with encoded plugs. The DR can either be operated via a cable-connected DSE control pendant featuring micro-switch elements or by means of a radio transmitter. Both control units are provided with a bi-directional interface. As standard, the enclosure cover features an appropriate slot for the radio control card. Additionally, an optimised cost variant is available for a solo DR travelling hoist with an external 48 V control transformer. 1 Enclosure cover hinge 2 Control signals 3 Power supply system 4 Lock of the electrical equipment enclosure

4

2

3

4

5

6

1 2 3 4 5 6

Enclosure cover PCB Cabling via encoded plugs Trolley inverter Braking resistor Geared limit switch with 4 contacts

1.25

1.10.3

1

2

3

4

Connection between rope drum and geared limit switch 1 Rope drum 2 Supporting flange 3 Engaging element crown wheel 4 Crown wheel 5 Geared limit switch with 4 contacts

5

17

Slot arrangement in the enclosure cover X8 ZMS2

Electrical connection reciever card

X7 ZMS1

Direction relay Lifting/lowering (no-load switching)

Speed relay for pole-changing hoist motor

1.11

X15 FI card

X34 Overspeed brake Rotary coding switch

X11 Hoist 12-pole

DIL switches

X9 Hoist 2-pole

X10 Hoist brake and thermal contact microswitch X16 Cross 1 final cut-off X53 SGS

Plug-in data memory

X5 Geared limit switch X37 Holding brake

18

X54 Horn

X52 EG pulse gen.

X66 Crane contactor


Circuit breaker

K1 Contactor

1.27

Attention! Blade contacts carry 400 V line voltage!

X1 400 V

PE

X13 Line trolley inverter

X27 Control voltage 48 V AC

X14 Cross-travel brake

X2 CAN bus

X44 D-Sub CAN bus

X48 Cross 2 Fast-to-slow

X49 UniInput (not ass.)

X47 Uni input

19

No-load switching with intelligent contactor control K3 direction relay

K2 pole-changing relay

K1 contactor

The intelligent contactor control of the DR prevents damage in the electrical equipment due to overvoltage by so-called “noload switching”. The contactor switches off immediately before each “lifting” or “lowering” control operation. The relays switch with a time delay due to the buffer voltage. The minimum difference in time between the switching operations prevents that an overvoltage is applied to the relay contacts, e.g. by contact-breaking sparks in the contactor.

1.28

At rest K1 contactor is OFF

K1 contactor OFF

K3 direction relay

The service life of contactor K1 is monitored by counting the cut-off operations. A warning in the display of the control element signals on time, when the end of the service life has been reached. Since the contactor is mounted on a top-hat rail, it can be easily replaced. After replacement, the counter must be reset by means of IDAPSY. Normally, the service life of the contactor corresponds to the service life of the entire hoist unit.

K2 pole-changing relay

~~

1.13.1

20

1U 1V 1W 2U 2V 2W

In the case of a power failure, the intelligent contactor control (ISS) additionally ensures that K1 always drops first. Contactor K1 is an AC contactor. However, the print relays are DC relays with a large amount of accumulated magnetic residual energy and a small moved mass. In addition, a buffer voltage from a buffer capacitor prevents the relays from dropping for a defined period of time.


Control units and radio controls DSE 8 R and DSE 10 R control pendants The DR can optionally be controlled by means of the cable-connected DSE control pendant or via the DRC or DRC-J radio control system. The DSE R for two-stage and infinitely variable control is equipped with standard key-operated switches for easily checking the correct functioning of the emergency limit switch. The display shows the specific installation status information as well as the load range when an electronic load detector is used. An IRDA interface allows direct data transfer with the laptop (with DSE 8 R only downloading, with DSE 10 R, the CAN bus remains active so that downloading as well as uploading is possible.)

1.29

1.32

1.30

DRC 10 radio remote control The DRC 10 is a hand-held transmitter with proportional pushbuttons for precise and smooth travelling with a range of up to approx. 300 m. Wireless log-on of the hand-held transmitter is fast and easy by means of the keypad menu. No further measures are necessary on the receiver side. The transmitter is powered by exchangeable standard AA rechargeable batteries for approx. 10 days transmitter operation and a high level of availability thanks to fast charging. The classic memory effect is avoided successfully owing to the intelligent charging technology. Signals

1

8

2

3

4 5 6

7 1.31 1 Battery capacity 2 Crane number 3 Radio link 4 Maintenance symbol 5 Overload warning 6 Load display for ZMS application 7 Bar display for load 8 Trolley selection Other symbols Initialisation Error with number Warning with number

are transmitted bidirectionally, i.e. information is acknowledged by the receiver, simultaneously adaptive frequency management (frequency hopping) guarantees trouble-free operation. The display shows the specific installation status information and the load range. The emergency stop for the DRC 10 is implemented by transmitting an emergency stop telegram.

The DRC-J joystick control has infinitely-variable joystick elements instead of proportional pushbuttons and offers the same features as the DRC 10.

1.33

21

DR electrical equipment concept for refurbishments The electrical equipment concept of the EKDR provides for parallel as well as for serial and wireless transmission of the control signals. The parallel interface makes it possible to use DR trolleys and crabs on a crane with conventional controls (parallel wiring). An electrical equipment enclosure accommodating a transformer, a crab switch contactor and industrial relays is fitted on the hoist. The following signals can be transmitted via these inputs at 48 V control voltage (the DR signal level is adapted to the crane control voltage via coupling relays): Lifting, lowering, fast and left, right, fast. In addition to the normal axis motions, the functions “Taring”, “Check emergency limit switch” and “Emergency stop” can also be connected. Feedback information is provided via a floating contact. One of 16 information variants is assigned to this contact by means of parameters for the trolley.

Parallel transmission Groups of bits are transmitted on parallel channels

Serial bus transmission Consecutive transmission of bits via one channel

Wireless transmission via radio

Integration of the new rope hoist into a conventional crane 1.15.4 Strain gauge carrier link

Geared limit switch

Cr. travel limit switch Power Trolley interface

Data Additional inputs Hoist and trolley

FI trolley

Trolley motor

HW1 or HW2 Bus

Hoist motor

No-load switching Power

Assignment of the parallel inputs see annex

Parallel wiring

Crane motor

Conventional crane electrical equipment Power

HW1: For no-load switching at small currents or FI connection HW2: For no-load switching at higher currents

22

Crane limit switch


Crane bridge enclosure with pole-changing long travel motors 1 Plug-in connections Long travel drive 2 Isolator switch (located in the control cabinet door) 3 PCB 4 Plug-in connections Bus / control cable

1.34

1

2

3

4

1 2

1.35

3 4 1

2

3 4

Plug-in long travel drives 1 Long travel drive 1 2 Long travel drive 2

1.36

1

2 1 2 3 4 5

1.37 1

2

Power supply to trolley Control cable to trolley Control voltage Mobile control system Large load display or another CAN device

3

4

5

6

6

1.38

Power supply of trolley 2 Power supply of trolley Control system of trolley 2 Control system of trolley Control voltage + CAN Mobile control system DSE-CAN for 2 trolleys Large load display or another CAN device

Parallel Out Parallel In 1 Cicuit breaker 2 Terminal strip 3 Transformer

1.39

New Parallel-In enclosure 2

1

3

3

2 1 23

Travelling hoist inverter and frequency-controlled long travel 1.41

1.40

1.43

1.42

External heat sinks and braking resistors

24

1.44

Hoist inverter The EKDR hoist inverter is accommodated in a separate enclosure with possible connection to the hoist motor. The Dedrive Compact is used as hoist inverter. The functions that underline the particular suitability of the inverters as hoist inverters do not only include the outstanding control characteristics, but also the ProHub or performance optimisation and load spectrum recorder functions. This makes it possible to operate the motor in field-weakening mode with a partial load. Integrated torque calculation enables the motor to be operated safely close to the output limit with a partial load, without subjecting the motor to overload. This function is mainly used for hoist drives and makes it possible to reduce handling cycle times.

Frequency-controlled long travel Depending on the application, two inverter series are used for long travel. Whereas Dedrive Pro units are installed in a special housing variant for IP55, Dedrive Compact units (without a heat sink and of cold-plate design) are installed in a control cabinet with IP54 enclosure. The required heat sink is fitted to the Dedrive Compact unit through a recess on the rear of the control cabinet. Heat generated within the frequency inverter power stage in normal operation can be dissipated directly to the surroundings by natural convection without the need of ventilation.


Large load display The hoist can be equipped with an optional large load display for reading the load at a distance of up to 40 m. The particularly bright LEDs with automatic brightness control are even suitable for outdoor use. The IP 55 type of enclosure has threaded bore holes for fastening brackets providing for easy retrofitting, if required. The control/signal cable to the large load display is connected via a distributor box.

1.45

Distributor box

1 2 3

1

Signal cable from crane Signal cable to large display Signal cable to trolley

2 2 3 1.46

1.46

25

DSE 8 R and DSE 10 R control pendants as reserve control A radio control system of a DR hoist can be replaced by cable-connected DSE 8 R or DSE 10 R control pendants as reserve control in the case of radio control failure. The EKDR can be quickly converted for this purpose.

1.47

Standard wiring

1.47

Removing the cover

1.47

Plugging in a DSE 8 R / DSE 10 R control pendant as reserve control

1.47

1.47

Disconnecting the plug-in connection of the radio receiver processor card

26

Mounting plate with strain relief for reserve control


Notes

27

Notes

28


Notes

29

Double-rail crab up to 10 t EZDR10 – H20 – 4/1 – 1400 mm 1.48

1 1 2 3 4

2

1.48

3

4

Derailment protection Top block DRS Wheel block system Thrust rocker

Double-rail crab up to 16 t EZDR10 – H20 and H40 – 6/1 1.48 1 2 3 4

2 rope sheaves under cover, special cover for operation outdoors Rope retaining crosshead H12 with SGS or ZMS Thrust roller 2 x 150 kg Driven travel wheel DRS 160

1

30

2

3

4


FDR foot-mounted hoist up to 10 t 1 2 3 4

Connection for side mounting Connection for ceiling mounting Connection for foot mounting With H40 (DR10) drum lengths an additional squared section is needed between the foot brackets (as for EZDR)

1.49 1

2

3

4

1.50

• •

•

Hoist gearbox and motor in standard mounting position Angle of deflection to fixed return sheave with specified rope distance is to be kept as small as possible A double-groove drum is only available for the DR 10

31

Product definition DR Pro and DR Com 1.0

1

DR Pro

DR Com

Features

- Design for operation on a crane or as a solo travelling hoist - Control via CAN bus or parallel control - Available options: Radio control, double load hook, load spectrum recorder, longer rope, load range display

- Design for operation on a crane or as a solo travelling hoist - Control via CAN bus or parallel control - Available options: Radio control, double load hook, load spectrum recorder, longer rope, load range display

Reeving

2/1 / 4/1 / 4/2 (DR 10)

4/1

2m+ (1900 h)

1 Am (800 h)

1,6 / 2 / (2/1 reeving) 3,2 t / 4 t / 5 t / 6,3 t / 8 t / 10 t

3,2 / 4 / 5 / 6,3 / 8 / 10 t

FEM group Load capacity Hoist speed

Pole-changing: DR3 / DR5: v0: 4,5/0,8 m/min DR10: v0: 4/0,7 m/min

5 - 30 m/min

5 - 20 m/min

6 / 10 m

6 / 10 m

-10 °C - +45 °C

-10 °C - +45 °C

Type of enclosure

IP55

IP55

Control pendant

DRC, DSE 8 R, DSE 10 R, DSE 16 R

DRC, DSE8 R, DSE 10 R, DSE 16 R

Contactor control with electronic monitoring (bus system) or frequency-controlled lifting

Contactor control with electronic monitoring (bus system)

Cross-travel speed Lifting height Temperature range

Type of control Safety function

32

Pole-changing: DR3 / DR5: v1: 6/1 m/min v2: 9/1,5 m/min Frequency-controlled: DR3 / DR5: v3: -12,5 m/min DR10: v2: -9 m/min v3: -12,5 m/min

- Speed monitoring of hoist motor - Brake release monitoring - Load spectrum value - Contactor switching operations

- Speed monitoring of hoist motor - Brake release monitoring - Load spectrum value - Contactor switching operations


DR Crane Set single-girder overhead travelling crane with DLC or DRC DR Crane Set package overview Demag crane sets offer outstanding quality, efficiency and reliability at the highest level. Every component reflects decades of expertise in all aspects of crane design. You are supplied with complete, tailored component packages for efficient single or double-girder and suspension crane solutions that save you time. 1.51

1 2 3 4 5

Solo trolley with drive Crane girder * Crane carriage Crane drive Control pendant or radio remote control 6 Crane electrical equipment 7 Hoist electrical equipment - with lifting limit switch - with load detector 8 Clamp-fitted buffers 9 C-rail assembly 10 Power supply 11 Hoist power supply

1.51

10 11

* not included in the crane set

9 4

2

3

4 3 8 6

8

1

7 5

5

33

4_Chapter 1 Product Presentation DR3-DR10

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