Operating instructions Demag SpeedHoist D-SH 42374245.
Translation of original operating instructions Manufacturer Demag Cranes & Components GmbH P.O. Box 67 · 58286 Wetter (Germany) Telephone +49 (0) 2335 92-0 · Telefax +49 (0) 2335 92-7676 www.demagcranes.com Please fill in the following table before first putting the unit into service. This provides you with a definitive documentation of your manipulator and important information if you ever have to contact the manufacturer or his representative. Owner Where in use Size Serial number Ident. no.
© Demag Cranes & Components GmbH 21115144_en_310310 3.2.5 Rocker switch connection assignment 28 3.2.5.1 Emergency stop 28 3.2.5.2 Rocker switch interface 28 3.2.6 Manulift handle connection assignment 29 3.2.6.1 Emergency stop 29 3.2.6.2 Interface of the DSM Manulift handle 29 3.3 Oil and grease filling of gearbox 30 3.4 Operating conditions 30 3.5 Noise emission 30 3.6 Paint finish 30 4 Design and function 31 4.1 Design 31 4.2 Drive 31 4.3 Gearbox 31 4.
4 Starting operation 44 6.9 Putting into operation 45 6.9.1 Grip height adjustment 45 6.9.2 Connecting the rope to the grip 45 6.9.3 Shortening the wire rope 46 6.9.4 Putting the unit into operation 46 6.10 D-Grip button assignment 46 6.11 Circuit diagrams 48 6.11.1 D-SH circuit diagram 48 6.11.1.1 D-SH with D-Grip 48 6.11.1.2 D-SH with rocker switch 50 6.11.1.3 D-SH with DSM Manulift 52 7 Operation 54 7.1 Safety instructions 54 7.
© Demag Cranes & Components GmbH 21115144_en_310310 7.7.3 Documentation of parameters 73 7.7.4 Control of the PLC 73 8 Maintenance 75 8.1 Safety instructions 75 8.2 Basic principles for maintenance 76 8.3 Routine inspections 77 8.3.1 Specified inspections 77 8.3.2 Service life of the contactor 78 8.4 Maintenance schedule 78 8.5 Display of operating hours / statuses 80 8.6 Wire rope 81 8.6.1 Construction, application and reeving of wire ropes 81 8.
1 General 1.1 Information on the Demag Speedhoist D-SH You have purchased a Demag product. This Demag SpeedHoist D-SH was manufactured in accordance with the relevant European standards and regulations. The Demag SpeedHoist D-SH complies with the statutory regulations e.g. EC machinery directive 2006/42/EC. The D-SH is of modular design.
1.2 Information on the operating instructions These operating instructions are designed to provide the owner with appropriate instructions for safe and correct operation and for maintenance. These operating instructions are an integral part of the D-SH hoist.
1.3 Symbol/signal words Important safety information and instructions are marked by corresponding symbols and signal words. The safety instructions must be followed. Please exercise particular caution to ensure that accidents, injuries and damage are avoided in such cases. The relevant local accident prevention regulations for the application and general safety instructions must also be complied with.
Wearing parts are not subject to liability for defects. We reserve the right to incorporate technical modifications within the scope of improving the operating characteristics and further development of the machine. 1.5 Copyright These operating instructions must be treated confidentially. They are only intended to be used by people who work with or on the machine.
1.7 Terms and definitions Owner Owners (employer, company) are defined as persons who own D-SH hoists and who use them appropriately or allow them to be operated by suitable persons. Operating personnel/operator Operating personnel or operators are defined as persons entrusted by the owner of the D-SH with operation and/or transportation of the equipment.
1.8 Test and inspection booklet A test and inspection booklet filled in with all details must be available for every D-SH hoist. The results of the regular tests and inspections must be entered into the test and inspection booklet and must be certified by the inspector. Test and inspection booklet order no.: see page 5 “Accompanying documents”. 1.9 After-sales service Our after-sales service will provide you with technical information on the D-SH hoist, etc.
2 Safety 2.1 General The “Safety” chapter provides an overview of all important safety aspects for optimum protection of personnel as well as safe and trouble-free operation of the machine. At the time of its development and manufacture, the machine was built according to generally accepted engineering standards and is considered to be safe to operate. The machine may still be a cause of danger if it is not used correctly or appropriately by trained personnel.
DANGER By electrical current. Electrical energy may cause very severe injuries. • Before carrying out maintenance, cleaning and repair work, switch off the unit and secure it against switching on again. • Do not remove any safety equipment or render it inoperative by modifications. The D-SH is industrial equipment to be used with a rated voltage (see type plate). Power is fed via power supply lines (mobile cables, open or enclosed power conductor systems, cable drums).
Use of the control unit Lifting and lowering motions are controlled by means of the corresponding control elements on the control unit. The slow speeds are intended for attaching the load, lifting it free and depositing it. Loads can be precisely positioned at slow speeds. Short transport times can be achieved at higher speeds. They are suitable for motion sequences with a safely suspended load if no hazard can be caused by the faster motion sequences.
Certain work and practices are prohibited when using the D-SH hoist as they may involve danger to life and limb and result in lasting damage to the D-SH hoist, e.g.: • Do not handle the load in an unsafe manner (e.g. swinging the load). • Do not handle suspended loads above people. • Do not pull or drag suspended loads at an angle. • Do not pull free any fixed or obstructed loads. • Do not exceed the maximum permitted load and permitted load dimensions. • Do not leave suspended loads unsupervised.
• the safety devices are always kept freely accessible and are checked regularly. • the national regulations for the use of the D-SH hoist are observed. • the specified regular checks and inspections are carried out on time and are documented. • the operating/travel area is adequately illuminated. • suitable and tested load handling attachments are provided and used.
2.7 Emergency stop device Emergency stop 42707744.jpg 40215745.eps WARNING Unauthorised, negligent or accidental switching-on. Danger to life and limb. Check to ensure that the reason for the emergency stop has been eliminated before the D-SH hoist is switched on again. The emergency-stop device must not be used to switch the D-SH hoist off in normal operation. To prevent damage and injuries, the D-SH hoist is fitted with an emergency-stop device. This is located on the control unit.
3 Technical data 3.1 Mechanical equipment 3.1.1 Design overview 1 3 2 4 5 6 8 5 7 9 10 11 12 42584645.eps 3.1.
3.1.3 Dimensions 215 105 M8 355 1) Rope outlet highest hook position Rope outlet lowest hook position 39 150 203 45 ø20 70 15 105 15 188 164 143 152 307 © Demag Cranes & Components GmbH 93 M8 215 366 21115144_en_310310 640 1) Load bar, optional, part no.: 851 195 44 42586146.
D-SH hoist with two KBK I or KBK II trolleys and manual force control 1/1 reeving Load bar, part no.: 851 195 44 SWL 80 kg KBK I 355 850 853 150 45 90 93 Load bar Rope travel m = highest m/n n = lowest hook position 42586247.
D-SH hoist with two KBK I or KBK II trolleys and rocker switch 1/1 reeving Load bar, part no.: 851 195 44 SWL 80 kg KBK I 355 C C 150 45 90 93 Load bar Rope travel m = highest m/n n = lowest hook position 42772844.
D-SH hoist with two KBK I or KBK II trolleys and DSM Manulift handle 1/1 reeving Load bar, part no.: 851 195 44 SWL 80 kg KBK I 355 823 755 150 45 90 93 Load bar m/n Rope travel m = highest n = lowest hook position 42772944.eps D-SH 80 1/1 D-SH 160 3.1.4 Selection table Hook path Size SWL Lowest hook position m m n 2,2 39 93 FEM Hoist speed m/min kg 3.1.5 Hoist motor data 80 1 Am max. 70 D-SH 160 160 1 Am max.
3.2 Electronic components 3.2.1 Control board Multiple connector X13 (8) Operating LED (7) Steady flashing Unit ready for operation Unsteady flashing Unit fault 1. No voltage LED dark 2. Electronics defective PIN 1 1 2 5 6 7 8 3 4 10 11 12 9 13 14 15 9 42686146.jpg i RJ45 connector Note Pin assignment 10 9 8 7 6 5 4 3 2 1 21115144_en_310310 © Demag Cranes & Components GmbH For any changes of the jumper position, the unit must be de-energized.
3.2.1.1 D-SH with frequency inverter 4 2 3 5 1 42686245.
3.2.2 EEPROM hardware protection 1 2 3 4 5 6 7 8 10 11 12 9 42686146.jpg Jumper strip X11 is used for this purpose. The jumper strip is structured as follows. 6 5 4 3 2 1 Pin 1 is located on the right-hand side at the micro-controller. As a protection against re-initializing, a jumper must be applied between pins 5 and 4. The bridge of X13 can be used. If re-initializing is now tripped, for example, by a detected EEPROM error, this is displayed by error E22 in the 7-segment display.
No. Colour Signal 1 Bk, black Digital output GND 2 Br, brown Forward 3 Bu, blue Backward 4 Ye, yellow Emergency stop 5 Or, orange AC supply 6 Wh, white 24 V DC ext. 7 Vt, violet GND ext. 8 Rd, red Right 9 Gn, green Left Gr, grey Digital output signal, 0 / 24 VDC 10 Conductors 5 and 6 must be connected with each other, as well as 7 and 9. The output signal can be tapped at conductors 1 and 10.
3.2.4 D-Grip connection assignment The following diagram shows the right-angle plug socket assignment, viewed from the soldering side and the plug assignment in the grip viewed in the direction of the pins. Connection assignment of the right-angle plug Power consumption Max. approx. 70 mA Pin no. Colour Assignment 1 BN 24 V DC 2 BU GND 3 WH Manual force analogue 4 PK Button left 5 YE Switch right 6 GY Grip occupied 7 GN Status LED (not used) 8 --- --- No load: approx.
3.2.5 Rocker switch connection assignment DANGER by electrical current Electrical energy may cause very severe injuries. Work on the electrical equipment may only be carried out by specialists or by trained personnel. The rocker switch is supplied with the helical cable connected. The diagram below shows the connector assignment in the rocker switch. Connection assignment of plug on helical cable 1 2 3 4 5 6 7 8 9 42776044.eps Connection assignment of socket on switch Pin no.
3.2.6 Manulift handle connection assignment DANGER by electrical current Electrical energy may cause very severe injuries. Work on the electrical equipment may only be carried out by specialists or by trained personnel. The DSM Manulift is supplied with the helical cable connected. If a helical cable has to be replaced, the 8 or 9 conductors must be connected as shown in the circuit diagram. 3 4 2 1 Undo the four screws (2) to remove cover (1). Tighten diagonal pairs of screws when refitting the cover.
3.3 Oil and grease filling of gearbox Oil grades Gear oil with a viscosity of 220 mm²/s at 40 °C with mild high-pressure additives should be used for ambient temperatures of approx. -10 °C to +50 °C. DIN 51 502 CLP 220, e.g. BP ENERGOL GR–XP 220, Esso Spartan EP 220, SHELL Omala Oil 220, Mobilgear 630 or Aral Degol BG 220. At higher or lower ambient temperatures, the type of oil used should be adapted to the specific conditions.
4 Design and function 4.1 Design 1 2 4 3 5 6 8 5 7 9 10 11 12 1 Electrical equipment cover 2 Gearbox housing 8 Lifting limit switch 3 Bracket 9 Rope drum 4 Analogue PWM converter 10 Drum axle 5 Frame 11 Cover plate 6 Fan cover 12 Switching rod 7 Rope guide 42584645.eps 4.2 Drive The hoist motor is a 2-pole Demag motor with a cylindrical squirrel-cage rotor and integrated brake.
4.6 Frame The frame of the D-SH consists of two end caps on both drum ends and two crossbeams fitted in-between which are positively connected and bolted to each other via the drum axle. The gearbox housing is also connected positively and bolted to one end cap. In addition, the end caps are provided with two M8 threaded bore holes on the upper and lower sides, for foot or ceiling mounting and for fitting to trolleys. 4.7 Electrical equipment 4.7.
4.7.3 Inverter The inverter is the power section and provides infinitely variable speed control of the D-SH motor. 4.7.4 External emergency stop (only D-Grip) With the emergency-stop device, the lifting or lowering motions can be stopped in the event of a hazard. The emergency-stop switch must be fitted externally, for example on the load handling attachment or the crane pillar. 4.7.5 Control board The control board contains the “intelligence” of the D-SH hoist.
4.8 Trolley The load capacity of the D-SH hoist must not exceed the load capacity of the trolley. KBK I and KBK II trolleys as well as Aluline 120 and 180 trolleys can be used. The D-SH hoist is fitted to the trolley via a separate frame. 4.8.1 Runways When selecting a track, we suggest you specify our KBK and KBK Aluline crane construction kit track section (fig. 1) of special design. They feature a low deadweight.
5 Transportation, packing, storage 5.1 Safety instructions WARNING Suspended load. Falling parts. Danger of injury by falling parts Secure the components during transport. Do not step under the suspended load. CAUTION Danger by inappropriate transport Risk of injury and damage to the machine. Lift loads only on the marked lifting points. Only use suitable hoisting equipment with sufficient load capacity. 5.2 Transport inspection D-SH hoists are shipped as a complete unit, i.e.
6 Installation and putting into operation for the first time 6.1 Safety instructions DANGER By electrical current. Electrical energy may cause very severe injuries. Work on the electrical equipment may only be carried out by specialists or by trained personnel. Before starting work, switch off the electrical supply and secure against restoration. WARNING Danger of injury by assembly errors Inappropriate installation can lead to severe injury and/or damage to property.
6.2 Assembling the trolley 6.2.1 KBK I, KBK II, Aluline classic 120 and 180 trolleys KBK II trolley with pin KBK I trolley with pin 1 1 41401044.eps 41400944.eps Aluline classic 120 trolley with pin Aluline classic 180 trolley with pin 1 1 42589744.eps 42589844.eps 1 1 2 9 5 3 4 2 6 2 7 Tightening torque 25 Nm 3 © Demag Cranes & Components GmbH 9 3 8 8 21115144_en_310310 42783044.eps 1 Trolley with pin 6 Hex.
6.2.2 CF 5 trolley, flange width 50 – 91 mm with load bar 1 2 3 4 5 8 6 7 1 1 7 41665545.eps 9 8 1 CF 5 click-fit trolley 7 Head pin 12H11 x 30 slot 2 Retaining clip SL 10 SXN08 8 Retaining clip SL 12 SXN08 3 CF5 retaining elements 9 CF5 trolley crossbar 4 Head pin 10 x 64,8 slot 10 Hex. socket screw M 8 x 22 5 Tube 16 x 2,8 x 29 11 Washer 8 x 16 x 2 6 CF5 suspension eye bracket 38 21115144_en_310310 42783144.
6.2.3 RU trolley, flange width 50 – 90 mm with load bar Tightening torque 50 Nm Tightening torque 50 Nm 41665744.eps 2 Tightening torque 25 Nm 12 3 13 21115144_en_310310 © Demag Cranes & Components GmbH 2 42783244.eps 2 Side cheek travel wheel univ. no toothed rim 8 Washer 16,5X 25 X 4 3 D-SH load bar 9 Load bar RU 3 cpl. (item 7, 8, 10, 11) 4 Load capacity plate 450kg 10 Pin RU 3 load bar 5 RU 3DK travel wheel universal 11 Tube 26,9 x 2,65 x 31 6 Sleeve 12,1 x 27 x 9 12 Hex.
6.3 Electrical connection DANGER Live components Danger to life and limb. All wiring and connection work may only be carried out by an instructed and qualified electrician according to the specifications of the electrical connection diagram included in the supply. Every D-SH hoist is provided with a wiring diagram showing details of the control system. The wiring of the D-SH hoist complies in all respects with current DIN VDE and accident prevention regulations.
Mains connection Plug control unit • First check whether the voltage and frequency specified on the data plate match your mains supply. Ensure that the mains connection cable is at zero voltage and secured against accidental restoration of the power supply. • Remove the cover to connect the supply cable. • Use the mains connection set included in the delivery to produce the plug-in connection for the mains connection cable. • Cut the sleeve to suit the geometry of the mains cable.
6.4 Putting into operation for the first time 6.4.1 Checks before putting the hoist into operation for the first time The owner is obliged to carry out the following checks before putting the hoist into operation for the first time, see section 2.8 “Regular inspections”. Activity Section Check oil level in the hoist gearbox of the D-SH hoist 3.3 “Oil and grease filling of gearbox” Check rope securing devices and rope guide After-sales service x Check electrical switchgear and wiring 6.
6.4.1 Emergency stop connection Setup (D-grip) For operation of the D-SH hoist with the D-Grip, an external emergency-stop device must be fitted. It is applied on terminals X2.1 and X2.2 of the analogue PWM converter (see section 7.6). If no emergency-stop switch is used, terminal X2.1 and X2.2 must be jumpered. Commercially available emergency stop switches or the switches offered as an option (mushroom-head pushbutton/trip-wire switch) may be used.
6.5 Inspection before putting the unit into operation The inspections specified in section 11.3, table 1 must be carried out when the unit is put into operation for the first time. 6.6 Instructions relating to safety at work All fitting and assembly work must be completed in accordance with the operating instructions and the rope must be greased.
6.9 Putting into operation CAUTION Cutting and tearing injuries When working with and on wire ropes, cutting and tearing injuries may be caused by broken wires on the wire rope. Always wear robust working gloves when working with or on wire ropes. 6.9.1 Grip height adjustment Set the control grips to the required working height. Make this adjustment and connect the rope to the grip at the place where the D-SH is used based on the description of the following section 6.9.2. 6.9.
6.9.3 Shortening the wire rope Cut any excessive rope length to the required length with wire rope scissors. If, in exceptional cases, it is necessary to shorten the wire rope, this must be done in compliance with engineering standards and only with the consent of the manufacturer of the machine. Slide heat-shrinkable sleeve part no. 343 706 44 over the shortened end of the rope. 42343244.eps 6.9.
Symbols of the adhesive symbol sheet 1 2 3 4 5 6 7 8 9 10 11 12 13 A Dummy without symbol B Dummy without symbol C Dummy without symbol D 42540144.
6.11 Circuit diagrams 6.11.1 D-SH circuit diagram 48 63180246L1.eps 21115144_en_310310 © Demag Cranes & Components GmbH 6.11.1.
21115144_en_310310 63180246L3.eps 63180246L2.
63180146L1.eps 21115144_en_310310 © Demag Cranes & Components GmbH 6.11.1.
21115144_en_310310 63180146L2.
63180446L1.eps 21115144_en_310310 © Demag Cranes & Components GmbH 6.11.1.
21115144_en_310310 63180446L2.
7 Operation 7.1 Safety instructions WARNING Inappropriate operation Inappropriate operation may result in severe injury or damage to property. The machine may only be operated by authorised and instructed personnel in compliance with all accident-prevention and safety regulations. - National regulations for the use of cranes and lifting appliances must be observed and complied with.
CAUTION Danger due to premature wear/corrosion Corrosion on plastic (identifiable by dull, sooty or brittle surfaces) and metal components in enclosed switchgear housings can be caused by too frequent inching. Corroded parts must be replaced in good time. i NOTE 21115144_en_310310 © Demag Cranes & Components GmbH Advise operators to avoid inching (i.e. giving short pulses to the motor to obtain small movements) as far as possible, e.g. when attaching a load.
7.2 Description of the control unit 7.2.1 Control switches D-Grip Right-angle plug (5) Display “Button left” (4) Button left (1) “Grip occupied” display (3) “Switch right” display (2) Switch right (7) “Grip occupied” sensor Quick-change coupling 42534244.eps The grip includes the following control and signal devices: • “Grip occupied” sensor with LED signal display. If the grip is covered by the operator’s hand, this is indicated by LED (1) lighting up.
7.2.2 Control switches Rocker switch Emergency stop Lifting Rocker 1) 2) Lowering 42707744.jpg i 42707844.jpg NOTE The operating element of the rocker switch is designed with IP 34 type of enclosure. In the following, the design and functioning of the rocker switch are described. The switch includes the following command devices: Emergency stop button Used to stop the lifting motion in the event of hazardous situations.
7.2.3 Control switches DSM Manulift 2 1 DSM Manulift 2 Top cover 3 1 3 Emergency-stop switch 4 4 4 Actuating rockers 5 Quick-change coupling 5 40215744.eps 7.2.3.1 DSM Manulift quick-change coupling Mechanical interlocking of the switching elements prevents movement in opposite directions being switched on simultaneously. The shock and impact-resistant housing of the is of high quality thermoplastic, it is resistant to fuels, salt water, grease, oil and alkaline solutions. IP65 type of enclosure.
7.3 Switching on 7.3.1 Checks when starting work The operator is obliged to carry out the following checks when starting work (see section 2.8 “Regular inspections”): Activity Section Check Check operation of limit switch 4.5 “Checking the limit switch” 6.4.2 “Emergency limit switch” x Check operation of the slipping clutch 7.3.3 “Checking operation of the gearbox and slipping clutch” x Check hook safety catch and load hook 8.
7.4 Switching off 1. When the work has been completed, position the unloaded bottom block and the control grip outside the travel area. 2. Press emergency-stop button (1). The emergency-stop button is unlocked by turning it. 3. Switch off the power supply at the mains connection or isolating switch. (1) 42707744.jpg 7.5 Stopping operation in the event of an emergency 40215745.eps 1. Press emergency-stop button (1). 42707744.jpg 40215745.
7.6 Analogue PWM converter 7.6.1 Function The analogue PWM converter is used for converting the analogue voltage signal of the D-Grip into the appropriate PWM lifting or PWM lowering signal for the D-SH hoist. The basic frequency of the PWM signal is 1 kHz. The mark-to-space ratio varies depending on the analogue voltage in the range of min. 10% and max. 90%. The converter is supplied with 24 V DC provided by the D-SH hoist. 42768744.
43406044.tif Pin line J1 The pin line is only used for programming the controller and is of no significance for normal operation. Pin line J2 When the converter is used on the D-SH hoist, the jumper position 2-3 must be selected. DIP switch S1 Meaning S1.1 With/without trimming S1.2 With/without mid voltage S1.3 Lifting/lowering only one enable signal or separate enable signals S1.4 Selection range input voltage 0…10VDC or 0…5VDC Switch Position Meaning S1.
7.6.2 Diagnosis LEDs The converter is provided with three diagnosis LEDs which are fitted next to each other. Colour Meaning Red Outputs a specific flash code in the case of an error Yellow Indicates whether electronics voltage is available (permanently lit) Green Indicates whether the controller is working (flashes regularly) If the yellow LED is not lit, please check whether the 24 V DC supply voltage (terminals 1, 2) is available.
7.7 Parameter setting set The default parameters are selected to provide optimum performance for most applications. In addition, the D-SH features two different possibilities of setting parameters to adapt the hoist to specific applications. • By means of the control unit, dynamic factors such as speed, acceleration and deceleration can be set or functions can be switched on and off (see “Setting the parameters with a laptop” section 7.7.2).
7.7.1 Setting the parameters with the manual terminal The operating unit features the following keys: Manual operating terminal type UPBT2-A00 • Arrow up (↑) • Arrow down (↓) • Arrow right (→) • Arrow left (←) • Return (↵) • Escape (F). RUN The meaning of the keys is described below. ERROR Open the electrical equipment cover of the D-SH to connect the operating unit. DANGER Live components F Danger to life and limb. Electrical energy may cause very severe injuries.
7.7.1.1 Cables and connection On the control board, a 6-pole RJ socket is provided for connecting the modular cable (see “Cables and connection”, section 7.7.2.1). On the other end, the adapter (red dot) and the operating terminal are connected. 7.7.1.2 Putting the manual operating terminal into operation 1. Switch off the D-SH power supply; 2. Open electrical equipment cover; 3. Connect the operating terminal type UPBT2-A00 with modular cable and adapter to the RJ socket; 4.
7.7.1.3 Navigating with the manual operating terminal Navigate to menu items on the same menu level (vertical direction) with (↑) (↓). To change from a menu to a sub-menu (horizontal direction), actuate the (↵) key. You can return to the next higher level with the (F) key on every level. To return to the original item, it may be necessary to actuate the (F) key several times.
7.7.2 Setting the parameters with a laptop/PC (software terminal) 7.7.2.1 Cables and connection A PC or a laptop is required. Windows 3.10/95/98/NT/ME/2000/XP are supported as operating systems. The modular cable with RJ12-DSUB9 adapter (blue dot) from the parameter setting set is used to connect the control system to the PC/laptop. For connection to the control system, the electrical equipment cover on the D-SH must be opened. One end of cable is plugged onto the RJ socket of the control board.
Using the mouse Using the keyboard Meaning Esc or F like hand-held terminal Return or Enter on num. block like hand-held terminal Arrow keys like hand-held terminal Alt X or select the window with the tab key and actuate the space bar Exit program Select with the tab key and actuate the space bar Select interface Select the COM interface to which the cable is connected to start communication. Then actuate the F or the Esc key.
7.7.2.4 Menu structure and parameters DEMAG D-SH Ver.: x.yz The diagram below shows the menu tree and the available parameters and diagnosis variables.
7.7.2.
7.7.2.7 Operating parameters Parameter name Unit Value Minimum Range Remark Maximum Type of hoist Displays the type of hoist. Maximum speed rpm 800 5200 100 The maximum speed can be set here. These speeds correspond to the speeds listed in the table (approx.). For maximum speeds < 2500 the Pro-Hub function is no longer active. Minimum speed rpm 0 200 1 Accelerating time ms 300 5000 100 The acceleration time is changed here.
7.7.3 Documentation of parameters The factory setting is restored by a reset of the parameters in the “Functions” menu item. Parameter name Factory setting Value: Operating parameters D-SH type D-SH Maximum speed [rpm] Minimum speed [rpm] 1 Accelerating time [ms] 400 Braking time [ms] 200 Fast-to-slow limit switch activated 4800 No – Yes Yes Position fast-to-slow limit top [mm] 70 Position fast-to-slow limit bottom [mm] 70 Assignment digital output Factor speed lowering 7.7.
Max. speed Example 1 Example 2 Min. speed = Max. speed – Min. speed 80 (PPV – 10) + Min. speed PPV = 10 ... 90% 74 n Motor speed in rpm Max. speed Max. speed parameter Min. speed Min. speed parameter PPV Mark-to-space ratio of the PWM signal in % 42738244.
8 Maintenance 8.1 Safety instructions In the following sections, the maintenance work required for optimum and troublefree operation of the machine is described. DANGER By live components There is a danger to life and limb due to electric current. Work on electrical equipment may only be carried out by qualified personnel in compliance with the safety regulations. Before starting work, switch off the electrical supply.
CAUTION Lubricants/oils Risk of injury resulting from contact with the body/skin. Oils and lubricants are extremely harmful to health. Contact with these media may result in serious damage to health (poisoning, allergies, skin irritation, etc.) Pay attention to the manufacturer’s safety data sheets and instructions. CAUTION Danger of injury. Danger of slipping. Leaking oils and lubricants are hazards due to the increased risk of slipping.
Instructions for maintenance work in the course of operation If maintenance work on the D-SH hoist must be carried out in the course of operation, special safety precautions are necessary, depending on the operating situation. In each individual case, the owner or the person assigned by him must check whether the maintenance work may be carried out in the course of operation without risk of personal injury and, taking into account the local conditions, implement all necessary safety precautions.
8.3.2 Service life of the contactor The switchgear is subject to wear during operation of the D-SH hoist. Its service life has been rated for the specified loading group. In the case of extreme switching frequencies, premature wear is possible. D-SH 80/160 Reeving Display value C for Unom 380 - 575 V Display value C for Unom 220 - 240 V 1/1 80 80 The display value C indicates the service life of the contactor to be expected multiplied by 100.000.
Check during operation Activity Read operating hours for determining the remaining duration of service See section Before first putting into operation When starting operation Every 6 months 8.5 and 9 During the annual inspection X Read the C switching cycles 8.3.2 X Check operation of the slipping clutch 8.13 X - X Lubricate rope 8.9 X Check trolley, load bar and status of buffers 6.2 X Check load hooks for cracks, deformation and wear 8.
8.5 Display of operating hours / statuses The 7-segment display is located on the bottom of the D-SH hoist in the electrical equipment cover behind a semi-circular window. The following operating information can be displayed. For further displays of warning messages and error statuses, see sections 10.2. 42777544.eps Software version Every time, power is switched on or after an emergency-stop, the software version is first displayed (from software version 1.44). Example: Software version 1.
8.6 Wire rope RH = right-hand ordinary lay rope RH = right-hand ordinary lay rope 8.6.1 Construction, application and reeving of wire ropes Figure 1 Figure 2 92069044.eps Range D-SH Wire rope diameter See figure 11,0 m rope length part no. 1) 8.7 Discarding the wire rope 42579544.
Critical points are, e.g.: 1. Rope zones subject to the highest number of alternating bending cycles and in particular to alternative deflection. This also applies to rope zones on compensating sheaves which are subject to a very high number of reversed bending cycles due to rope swing or uneven winding on rope drums. These rope sections show increased abrasion and a higher number of broken wires. 2. The zones at which loads are picked up, i.e.
8.8 Removing/fitting the rope 8.8.1 Unwinding the rope Before a rope is reeved, the whole length of the rope should be rolled out on the ground as shown in fig. 2. Any twisting of the rope should be strictly avoided. Correct Incorrect Fig. 2 41116144.eps WARNING Pre-stressed components Danger to life and limb.
42586544.eps 42586644.eps 42586744.eps 42586844.eps 42586944.eps 84 42587044.eps 42587144.eps 42587244.eps 21115144_en_310310 © Demag Cranes & Components GmbH 42586444.
21115144_en_310310 © Demag Cranes & Components GmbH 42587344.eps 42587444.eps 42375244.eps 42375344.eps 42375444.eps 42375544.eps 42587944.eps 42588044.eps 42588144.
8.8.3 Fitting the rope Secure the rope end with rope clamps fitted at the beginning of the drum. (rope end protrudes approx. 3 cm from the clamp). For construction, application and reeving of wire ropes for the D-SH, see section 8.6.1. Secure the rope end with rope clamps fitted at the beginning of the drum. (rope end protrudes approx. 3 cm from the clamp). Tightening torque 2,8 Nm 42374644.eps 42374744.eps CAUTION Danger by loose connections Loose connections are a danger to life and limb.
Tightening torque 5 Nm Grease the internally toothed rim of the rope drum before assembly (part no.: 011 058 44, 60 g). 42587744.eps 42587644.eps 42588544.eps CAUTION Danger by loose connections Loose connections are a danger to life and limb. Apply the tightening torques specified in the following. © Demag Cranes & Components GmbH Tightening torque of the drum fastening 5 Nm 21115144_en_310310 42588644.eps 42587344.eps 42588744.
Tightening torque 40 Nm 42587044.eps 42588844.eps 42586844.eps CAUTION Danger by loose connections Loose connections are a danger to life and limb. Apply the tightening torques specified in the following. Tightening torque of flange fastening 40 Nm © Demag Cranes & Components GmbH Tightening torque 25 Nm 42586544.eps CAUTION Danger by loose connections Loose connections are a danger to life and limb. Apply the tightening torques specified in the following.
1 1 1 2 42374844.eps 42374944.eps 42375044.eps CAUTION Danger by loose connections Loose connections are a danger to life and limb. Make sure that split pins, retaining rings, split sleeves etc. are appropriately fitted. Apply the tightening torques specified in the following. 21115144_en_310310 © Demag Cranes & Components GmbH Tightening torque of rope clamp 3 Nm 8.9 Shortening the wire rope See section 6.9.3 8.10 Lubricating the wire rope The rope must be lubricated with gear oil ELP 220.
8.11 KDP 63 hoist motor brake 8.11.1 Measuring the brake displacement Functioning of the brake on the hoist motor can be tested by interrupting the “Grip occupied” detection of the D-Grip. When the “Grip occupied” detection is interrupted, the brake is released, when the “Grip occupied” detection is enabled, the brake is applied. WARNING Danger by brake failure A brake displacement which is too large > 1,2 mm may result in failure of the brake.
8.11.2 Replacing the brake disc i NOTE This work may only be carried out by specialist personnel. Observe relevant safety regulations and codes of practice and the instructions contained in chapter 2 “Safety”. Loosen and remove the 4 nuts. Remove brake cover. 40991044.eps 41106544.eps Pull cables out slowly until resistance is felt. © Demag Cranes & Components GmbH 40990944.eps Remove armature disc. Remove friction plate with lip seal. 40991444.
Fit armature disc. Fit friction plate with lip seal. i NOTE Ensure correct fit of lip seal. The cable duct must lie in the recess of the lip seal. 40991444.eps 40991244.eps Seal 40990744.eps Fit brake casing. Keep cables pulled tight during assembly. Then remove assembly guide. Cable duct i NOTE Seal in brake enclosure must always be in contact with the cable duct. Use two 6 mm dia. bolts or pins (as assembly aid) to guide the brake spring. 40991544.eps 40990844.
8.12 Oil change 8.12.1 Safety instructions CAUTION Danger of injury. Danger of slipping. Leaking oils and lubricants are hazards due to the increased risk of slipping. Spilt oils and lubricants must be absorbed immediately by means of sawdust or oil absorbent and disposed of in an environmentally compatible way. CAUTION Leaking oil endangers operation Oil leaks/loss of oil in the course of operation may cause damage to or total failure of the machine. In such a case, stop the machine and notify Service.
8.13 Adjusting the slipping clutch Under normal operating conditions, the slipping clutch does not need to be adjusted. The clutch runs in the oil bath and the linings are virtually wear-free. The slipping clutch is initially set in the factory. Adjustment of the slipping clutch may only be carried out by authorized specialists. An increase of the tripping torque which exceeds the factory setting is not permitted. i NOTE A new locknut must be fitted each time the clutch lining is replaced. 8.
8.16 Replacing the helical cable on the DSM operating handle 3 4 2 1 Undo the four screws (2) to remove cover (1). Tighten diagonal pairs of screws when re-fitting the cover. 41104644.eps Disconnect electrical leads (4). Only connect according to the circuit diagram, see section 6.11. 41104744.eps 9 4 4 13 12 11 10 5 42782044.eps © Demag Cranes & Components GmbH 7 8 6 42375044.eps 42781944.eps Loosen rope socket (9) from control switch.
8.17 General overhaul GO Upon reaching the theoretical duration of service, the owner is obliged to carry out a general overhaul (see “Regular inspections”, section 2.8). WARNING Operating safety at risk Failure to carry out the general overhaul or carrying it out inapproprietely can lead to severe injury and/or damage to property. Prescribed general overhaul intervals must be strictly complied with.
9 Measures for achieving safe working periods S.W.P. The safety and health provisions of EC directive 2006/42/EC make it a legal requirement to eliminate special hazards which may be caused, for example, by fatigue and ageing. This requirement is also reflected in the third supplement to German accident prevention regulations BGV D8 of 1.4.1996.
9.1 Calculating the actual duration of service S The actual duration of service S of the D-SH hoist can be determined as follows: S = kmi x Ti x f kmi : Actual load spectrum factor Ti : Number of operating hours f 9.1.1 Estimating the load spectrum factor kmi (by the owner) : Factor depending on the type of recording To simplify estimation, each type of load can be grouped together into km load spectrum modules. The types of load are simplified and quoted as 1/4, 1/2, 3/4 load and full load.
9.2 Example: D-SH – 80 in 1Am Lifting speed : 50 m/min 1) No.
10 Fault finding and elimination 10.1 Error messages No. Error event Cause and elimination of the error 1 Load drifts when the “Grip occupied” detection in the grip is activated - Take hand from the grip, wait approx. 5 seconds and repeat the test. If the same effect occurs again, start new zero balance by switching the unit on/off 2 Manual force does not return to the value 0 again (deviates significantly) - Check whether the swivel cover is fitted correctly.
10.1.2 D-Grip error messages Fault Possible cause Remark Lifting and lowering do not function, brake does not release Display 8 Ext.
10.2 Warning messages and error statuses Warnings are indicated by means of the lightning symbol and the subsequent figures (see instructions for finding faults). The current direction of movement is stopped. Movement in the opposite direction is possible, the current warning is then deleted automatically. Error messages are indicated by means of the letter E and the subsequent figure (see instructions for finding faults). No further movement is possible.
11 Accessories Part no.: Plug protection for D-Grip 773 235 44 The operating terminal is used to display and program the SpeedHoist parameters. UPBT2-A00 Operating terminal 537 414 84 Item 1 Rocker switch component up to 250 kg The complete rocker switch component with 2,8 m or 4,3 m helical cable can be retrofitted to a D-SH (incl. quick-change coupling and material for fitting the helical cable on the D-SH hoist housing). Part no.: 773 299 44 (2,8 m) Part no.: 773 298 44 (4,3 m) Item 1 42777644.
Original Declaration for fitting partly completed machinery according to Machinery Directive 2006/42/EC, Annex IIB Ident. number / Language 19962444 / EN Issue Page 0110 1/ 1 Hereby we, Demag Cranes & Components GmbH Ruhrstraße 28, 58300 Wetter declare that the electrically driven hoist for lifting loads Demag Speedhoist Serial no.
Original EC conformity declaration for a machine according to Directive 2006/42/EC, Annex IIA Ident. number / Language 19962344 / EN Issue Page 0110 1/ 1 Hereby we, Demag Cranes & Components GmbH Ruhrstraße 28, 58300 Wetter declare that the electrically driven hoist for lifting loads Demag Speedhoist with rocker switch / Demag Speedhoist with Manulift switch Serial no.
Original EC conformity declaration for a machine according to Directive 2006/42/EC, Annex IIA Ident. number / Language 19962244 / EN Issue Page 0110 1/ 2 Hereby we, Demag Cranes & Components GmbH Ruhrstraße 28, 58300 Wetter declare that the electrically driven hoist for lifting loads Demag Speedhoist with manual force control Serial no.
Original EC conformity declaration for a machine according to Directive 2006/42/EC, Annex IIA Ident. number / Language 19962244 / EN Issue Page 0110 2/ 2 Demag Speedhoist with manual force control Serial no.: xxx xxx xx ----------------------------------------------------------------------------------------------------------For assembly / first putting into service including function check ...................................., date ................................................
12 Spare parts 108 21115144_en_310310 © Demag Cranes & Components GmbH 12.
12.1 Gearbox with KDP 63 B motor Item 4 6 7 8 14 15 16 21 24 27 31 32 33 34 38 39 43 48 61 62 63 64 65 66 67 Part no. 83410644 34149999 83413933 83414833 82641844 83426033 82641744 34264844 82641444 82641644 34251199 82641144 82640444 15245399 12439584 75269833 12418984 12485533 82643444 31882599 15245699 15245599 12496484 82643244 32168599 Qty. 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 4 4 1 1 4 Designation DK 1 T.
21115144_en_310310 © Demag Cranes & Components GmbH 12.
12.2 Rope drum/frame Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 22 23 24 25 26 27 30 31 31 32 33 34 36 37 40 41 42 43 44 45 Part no. Qty.
12.3 Trolleys with load bar: KBK I, KBK II and Aluline classic 120, 180 1, 2 1, 2 3 4 6 4 5 3 7 3 8 4 42783344.eps 98061044 98211044 34045499 34064399 34064399 83005744 85119544 32147199 33950599 Qty. 2 2 4 4 1 2 1 4 4 Designation Trolley with pin KBKI Trolley with pin KBKII Washer A21 x 37 x3 Washer 20 X 32 X 4 Washer 20 X 32 X 4 Tube 20 X 2 X 22 D-BE / DS1 load bar Hex. socket screw M 8 X 22 Washer 8 X 16 X 2 Material Standard 140HV A2F St A2F St A2F DIN 125 DIN 1440 DIN 1440 10.
12.4 KBK I, KBK II, Aluline classic 120, Aluline classic 180 trolleys KBK I trolley KBK II trolley 1 1 41401044.eps 41400944.eps KBK I trolley Item 1 Part no. 98061044 Qty. 1 Designation Material Standard Trolley with pin KBKI 22266418.tbl KBK II trolley Item 1 Part no. 98211044 Qty. 1 Designation Material Standard Trolley with pin KBKII 22266419.tbl Trolley Trolley Aluline classic 120 Aluline classic 180 © Demag Cranes & Components GmbH 1 1 42589744.eps 42589844.
12.5 CF 5 trolley with load bar, flange width 50 – 91 mm 1 2 3 4 Part no. Qty. 84020544 32147199 33950599 41686646 2 4 4 1 Designation CF 5 click-fit trolleys, azure blue Hex. socket screw M 8 X 22 Washer 8 X 16 X 2 CF5 trolley crossbar 1) 25 Nm Material Standard 10.9 A2F!L St A2F DIN- 912 DIN 1440 H7 21475506.
12.6 CF 5 trolley, flange width 50 – 91 mm Flange width 50 – 91 mm 21115144_en_310310 © Demag Cranes & Components GmbH Item 1 2 3 4 5 6 7 8 Part no. 84020544 34287544 84001544 84002244 84002744 84002544 84002144 34287644 Qty. 1 1 1 1 1 1 1 1 Designation CF 5 click-fit trolleys, azure blue Retaining clip SL 10 SXN08 CF5 retaining elements Head pin 10 X64,8 slot Tube 16 X 2,8 X 29 CF5 suspension eye bracket Head pin 12H11X 30 slot Retaining clip SL 12 SXN08 Material Standard cpl.
12.7 RU trolleys with load bar, flange width 50 – 90 mm Item 1 2 3 4 5 Part no. Qty. 83961044 83961944 83005244 32147199 33950599 4 2 1 4 4 Designation Side cheek travel wheel univ. no toothed rim RU 3 DS 1 load bar DS1-H 7 load bar KBK Hex. socket screw M 8 X 22 Washer 8 X 16 X 2 Material Standard 10.9 A2F!L St A2F DIN- 912 DIN 1440 1) 1) 25 Nm 116 1) Component parts, see page 95 21115144_en_310310 © Demag Cranes & Components GmbH 21475508.
12.8 RU trolleys, flange width 50 – 90 mm Item 2 5 7 8 9 10 11 Part no. 83961033 83961533 33460199 56302344 83961944 83961644 83961844 Qty. 1 2 2 12 1 1 2 Designation RU 3 side cheek set Travel wheel set univ. 4xOZ Hex. nut M16 X1,5 Washer 16,5X 25 X 4 RU 3 DS 1 load bar Pin RU 3/DS1 load bar Tube 26,9X 2,65X 31 50 Nm Material Standard 8 DIN 985 A2F cpl. (items 7, 8, 10, 11) 21115144_en_310310 © Demag Cranes & Components GmbH 22266412.
21115144_en_310310 © Demag Cranes & Components GmbH 12.
12.9 DSM-CS control unit Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 34 34 35 36 Part no. 15183733 77206833 77203933 77202144 77204733 77207533 77200133 77207933 77220744 77202333 77207633 77201833 82646444 83575144 34657299 31921899 36400399 83566644 34244799 83566744 31921799 15056399 87350344 75270333 75270433 77347833 83566544 Qty.
21115144_en_310310 © Demag Cranes & Components GmbH 12.
12.10 Rocker switch Item 1 2 2 3 4 5 6 7 8 9 Part no. 77203933 75270933 75271033 77206833 77327633 77328933 82646533 77324533 77327333 77326233 Qty. 1 1 1 1 1 1 1 1 1 1 Designation Material Standard Helical cable union Helical cable D-SH 2800 Helical cable D-SH 4300 Cap DSM 5 set Electronic module set Emergency-stop button Housing set sub-assembly Coupling connection set Fittings C hook set Swivel set 21115144_en_310310 © Demag Cranes & Components GmbH 21115002.
12.11 D-Grip and accessories 77325544 77323544 77323433 77325133 77322533 15183733 77206833 77326233 77324633 77322433 Qty. 1 1 1 1 1 1 1 1 1 1 Designation Material Standard Sub-assembly D-Grip 1D Solo Protective plate Sensor D-Grip + rear part Helical cable set D-BP Housing D-Grip set Rope socket D-BP Set Cap DSM 5 set Swivel set Coupling set Cover foil set 21475510.tbl 122 © Demag Cranes & Components GmbH 1 2 3 4 5 6 8 11 14 19 Part no.
12.12 Electrical components Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part no. Qty. 72094533 15282799 72003445 75271333 71511445 74949646 71903845 82640944 82640244 1 4 1 1 1 1 1 1 1 72005345 15265599 2 4 75271444 1 Designation DCS 10 hoist inverter Hex. socket screw M 6 X110 Connector set 4P D-SH control system Sealing electrical equipment cover DC Flange D-SH 80/DC-10 Cable union compl.
The current addresses of the sales offices in Germany and the subsidiaries and agencies worldwide can be found on the Demag Cranes & Components homepage at www.demagcranes.com/Contact and Demag worldwide Demag Cranes & Components GmbH Telephone +49 (0) 2335 92-0 · Telefax +49 (0) 2335 927676 www.demagcranes.com Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, 58286 Wetter (Germany) Subject to change. Not liable for errors or omissions. Printed in Germany P.O.
