Demag DR 3 - 10 Rope Hoist

Transcription

Demag DR 3 - 10 rope hoistwithout electrical control42576444.eps42382544.eps42349444.eps310708 enGB203 640 44714 IS 813

ManufacturerDemag Cranes & Components GmbHP.O. Box 67, D-58286 WetterTelephone ( 2335) 92-0 · Telefax ( 2335) 927676www.demagcranes.comPlease fill in the following table before first putting the chain hoist into service.This provides you with a definitive documentation of your Demag rope hoistand important information if you ever have to contact the manufacturer or hisrepresentative.OwnerWhere in useRangeSerial numberMain hoist motor numberOperating voltageControl voltageFrequencyWiring diagram numberAccompanying documents2Demag FDR 3 - FDR 5- FDR 10 (PRO) rope hoist214 932 44720 IS 813Demag EKDR 3 - EKDR 5- EKDR 10 (PRO) rope hoist214 725 44720 IS 813Demag EZDR 5- EKDR 10 (PRO) rope hoist214 961 44720 IS 813Demag FDR 3 - FDR 5- FDR 10 (COM) rope hoist214 990 44720 IS 813Demag EKDR 3 - EKDR 5- EKDR 10 (COM) rope hoist214 916 44720 IS 813Demag EZDR 5- EKDR 10 (COM) rope hoist214 965 44720 IS 813Dedrive Compact DIC214 708 44720 IS 922CD Dedrive Compact DIC213 136 44716 IS 922External pulse encoder214 372 44720 IS 919Z motor range214 228 44720 IS 91920364044.indd/310708Operating instructions

ContentsIntroduction4Design overview5Explanation of size designation / type assignment5DR-Pro selection criteria6Selection table7DR-Com selection criteria8Selection table9Key data of pole-changing hoist drives DR 3 – DR 5 – DR 1010Key data of cross travel drives DR 3 – DR 5 – DR 1011Key data of inverter-controlled cross-travel drives11Key data of pole-changing cross-travel drives EKDR 3 and 511Key data of pole-changing cross-travel drives EKDR 1011Key data of inverter-operated hoist drives DR 3, DR 5, DR 1012Parameter settings for the recommendedDemag DIC Dedrive Compact frequency inverter14Connection plate with terminal strip for 2-/12-pole DR hoist motor16Connection plate with terminal strip for 4-pole DR hoist motorand hoist inverter operation18Cable entry20Block diagrams21Example for the connection of a hoist motor21Example for the connection of a cross-travel motor22EG integrated encoder22Brake release contact22Temperature sensor for hoist and cross-travel motor22Brake control23SGG geared limit switch24Load detector26MKA-2 front panel/connection diagram/dimensions27Block wiring diagram28Overload protection ZMS, FGB-2, FWL29Calculation and setting of the overload switching pointFWL load spectrum recorderApplication20364044.indd/31070826MGS electro-mechanical overload protection293030Mode of operation30Calculation of the elapsed safe working period (SWP)31Cross-travel limit switch32Optional packages333

IntroductionThis document contains information on rope hoists without electrical control. Itapplies for DR-Pro, EKDR-Pro, EZDR-Pro, FDR-Pro, EKDR-Com, EZDR-Com andFDR-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 contact and mechanical mounting device forAG 1 - 3 external pulse generators- GS and VE brake modules- 4-pole cross-travel motor with Microtherm contact- 8/2-pole cross-travel motor for EKDR- GF and VE brake modules- Base plate in the rope hoist electrical enclosure for connecting the hoist motorand sensors- SGG geared limit switch- MGS overload cut-off device, for double-groove design with ZMSPay attention to the following when designing the electrical equipment forDR rope hoists not supplied with electrical equipment:Pole-changing motors are rated for intermittent duty. The basis for this isFEM 9.683, issue 10/1995Derived from this document, we provide values for the duty factor and switchingfrequency for these motors in our documentation.The specified values must not be exceeded. In order to ensure this, we recommend that timing elements be incorporated in the control system to prevent toofrequent switching or too fast restoration of the supply to the two-pole winding.The value should be set to at least 1 second.420364044.indd/310708For setting up the electronic circuit, we recommend that the SGDM hoist unit relaybe used for this function.

Design overviewTravel motorExample EKDREKDR low-headroom monorail hoistThrust rockerElectrical equipment coverwith terminal stripand geared limit switchGearbox with hoist motor4/1 bottom blockFig. 142577844.epsExplanation of size designation / type assignmentEKDR-Pro3-3,24/1 -6Z-6/1 -400 -00 -50 -30300 45Rail head width in mmonly EZDRTrack gaugeMaximum cross-travel speed in m/minFrequency [Hz]Electrical equipment code 1)Operating voltage [V]Hoist speed in m/minMotor type: Z cylindrical rotorHook path in mReevingSWL in tSeries 3; 5; 10Demag rope hoistK Low-headroom monorail hoistZ Double-rail crabF Stationary20364044.indd/310708E Electric travel unit1) Code 00Prepared for electrical equipment supplied by the customerCode 01DR with internal electrics for application on a crane Including crane bridge housing and DSE-8R or DSE-10R control pendant with control cable.Code 02DR with solo electrical equpment for application as a solo travelling hoist. Including DSE-8R or DSE-10R control pendant with control cable.Code 03Like code 01 but control via DRC radio control systemCode 04Like code 02 but control via DRC radio control systemCode 05DR fitted with parallel “in“ interface5

DR-Pro selection criteriaThe size of the hoist is determined by the loadspectrum, average operating time per working day,SWL and reeving.2. What is the specified safe working load?5. Do the loads need to be lifted and lowered withhigh precision?3. To what height must the load be lifted?6. Is horizontal load travel necessary?4. What is the required lifting speed?7. How is the hoist to be controlled?1. What are the operating conditions?The load spectrum(in most cases estimated) can be evaluated inaccordance with the following definitions:The group is determined by the load spectrum and operating time.1 Light1Light2-44-88-16over 16Hoist units which are usually subject to very smallloads and in exceptional cases only to 4-84Very heavySWLSmall partial loadSmall dead loadLoad spectrumAverage operating time per working day in hoursGroup of mechanisms ing time2 MediumHoist units which are usually subject to small loadsbut rather often to maximum loads.Group ofmechanisms toFEM/ISO 1)Reevingarrangement1AmM42mM53mM64mM71AmM42mM52/1, 4/2 2)3mM64mM72mM54/1Range3mM74mM76/1 2)SWL in tSWLHeavy partial loadMedium partial loadDR 3---1,61,251---3,22,52---Medium dead loadDR 53,22,521,66,3543,2---DR 106,3543,212,51086,31612,510Operating time3 HeavyHoist units which are usually subject to mediumloads but frequently to maximum loads.SWLHeavy dead loadOperating timeExampleSWLLoad spectrumHoist speedCreep hoist speedReevingAverage hook pathNo. of cycles/hourWorking time/day5t“medium” from table6 m/min1 m/min4/13m208 hoursThe average operating time per working day is estimated or calculated as follows:4 Very heavyHoist units which are usually subject to maximumor almost maximum loads.Operating time/day 2 · average hook path · no. of cycles/hour · working time/day60 · hoist speed SWLVery heavy dead loadOperating time/day Operating time2 · 3 · 20 · 860 · 6 2,66 hours1) Gearbox service life 20 % above the FEM full load service life62) 4/2 reeving only for DR 5 and DR 10, 6/1 only for EZDR 1020364044.indd/310708For the medium load spectrum and an average daily operating time of 2,66 hours,the table shows group 2m. For a load capacity of 5 t and 4/1 rope reeving, thetable indicates hoist size DR 5 - 5.

Selection tableRangeGroup of mechanismsFEM1)SWL [t]Hoist speed [m/min]V1V2V3 2)12/218/31-25 3)6/19/1,50,5-12,5 3)9/1,512/20,8-16 3)12/218/31-25 3)4,5/0,86/10,4-8 3)6/19/1,50,5-12,5 3)9/1,512/20,8-16 3)12/218/31-25 3)8,0/1,40,4-9 2)1-18 3)10/1,71-18 2) 3)1-25 3)4,0/0,70,2-4,5 2) 3)0,5-9 3)5/0,80,5-9 2) 3)0,5-12,5 3)8,0/1,40,4-9 2) 3)1-1810/1,71-18 2) 3)1-25 3)2,7/0,40,7-6-2/1DR 3F- / EK-Hook path M43,22mM52,53mM624mM71,612; 204/1F- / EK-2/1DR 5F- / EK-F- / EK- / EZ-6; 1012; 20; 304/1F- / EK-F- / EK- / EZ-6; 10; 154/2F- / EK-F- / EK- / EZ-2/1DR 10F- / EK-F- / EK- / 03mM684mM76,312; 20; 304/1F- / EK-F- / EK- / EZ-6; 10; 154/2F- / EK-F- / EK- / 8; 11,35; 18,46/120364044.indd/310708EZ-6,7; 13,31) Gearbox service life 20 % above the FEM value2) Loads weighing up to one third of the rated load are moved at 1,5 times the rated speed using Prohub3) for 400 V, 87 Hz delta operation7

DR-Com selection criteriaThe size of the hoist is determined by the loadspectrum, 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:2. What is the specified safe working load?5. Do the loads need to be lifted and lowered withhigh precision?3. To what height must the load be lifted?6. Is horizontal load travel necessary?4. What is the required lifting speed?7. How is the hoist to be controlled?1. What are the operating conditions?The group is determined by the load spectrum and operating time.Average operating timeper working day in hoursLoad spectrum1 Light1Light2-4Hoist units which are usually subject to very smallloads and in exceptional cases only to maximumloads.2Medium1-23Heavy4Very heavySWLSmall partial loadSmall dead loadOperating time0,5-1up to 0,5FEM1AmISOM4Group of mechanisms to2 MediumHoist units which are usually subject to small loadsbut rather often to maximum loads.Group of mechanisms acc. to FEM/ISO1Am / M4Reeving arrangementHeavy partial load4/1RangeSWL in tMedium partial loadSWLMedium dead loadOperating time3 HeavyHoist units which are usually subject to mediumloads but frequently to maximum loads.SWLHeavy dead loadOperating timeDR 33,2DR 55DR 1010ExampleSWLLoad spectrumHoist speedCreep hoist speedReevingAverage hook pathNo. of cycles/hourWorking time/day5t“medium” from table4.5 m/min0.8 m/min4/13m108 hoursThe average operating time per working day is estimated or calculated as follows:4 Very heavyHoist units which are usually subject to maximum oralmost maximum loads.Operating time/day 2 · average hook path · no. of cycles/hour · working time/day60 · hoist speed Very heavy dead loadOperating time82 · 3 · 10 · 860 · 4,5 1,7 hoursFor the medium load spectrum and an average daily operating time of 1,7 hours,the table shows group 1Am. For a load capacity of 5 t and 4/1 rope reeving, thetable indicates hoist size DR 5 - 5.20364044.indd/310708SWLOperating time/day

Selection tableRangeGroup of mechanismsFEMSWL [t]Hook path [m]ISOHoist speed[m/min]V14/1DR 33,2F- / EK-1AmM42,56; 104,5/0,86; 10;4,5/0,86; 10;4/0724/1DR 55F- / EK- / EZ-1AmM443,24/1DR 1010F- / EK- / EZ-1AmM4820364044.indd/3107086,39

Key data of pole-changing hoist drives DR 3 – DR 5 – DR 10Design is in accordance with the VDE regulations and the design rules of the FEM, to meet the high demands madeon electric hoists.Main/creep lifting F6No. ofpolesDR 3 rangeHoistspeedMotor size12ZBR 100 C 12/2 - B05012/2; /hRated current IN and startup current IA for 50 Hz400 VcoscosIN [A]IA 405,790,550,7540278012011550,880,8518/3; 9/1,5ZBR 100 D 12/2 - B0502Required supply cable conductor cross sections and fuse linksDR 3 rangeMains connection delay fuse for 50 Hz 1)Supply lines 2) for 5% voltage drop U and start-up current IA for 50 Hz400 V400 V ( U 20 V)Motor sizeAmm²mZBR 100 C 12/2201,525ZBR 100 D 12/2251,519Main/creep lifting F6No. ofpolesDR 5 rangeHoistspeedMotor sizePNCDFn[kW][%][rpm]Starts/hRated current IN and startup current IA for 50 Hz400 VcoscosIN [A]IA [A]φNφA129/1,5; 12/20,8204102405,790,550,7524,5/0,8; 6/15,340278012011550,880,851212/2; 18/31,4204002409,615,00,540,6826/1; 9/1,58,940287012018,0120,00,890,85ZBR 100 D 12/2 - B050ZBR 132 D 12/2 - B140Required supply cable conductor cross sections and fuse linksDR 5 rangeMains connection delay fuse for 50 Hz 1)Supply lines 2) for 5% voltage drop U and start-up current IA for 50 Hz400 V400 V ( U 20 V)Motor sizeAmm²mZBR 100 D 12/2251,519ZBR 132 D 12/2502,515Main/creep lifting F6DR 10 rangeNo. ofpolesHoistspeedMotor size12ZBR 132 D 12/2 - 1,4204008,9402870Starts/hRated current IN and startup current IA for 50 Hz400 VcoscosIN [A]IA [A]φNφA2409,615,00,540,6812018,0120,00,890,85DR 10 rangeMains connection delay fuse for 50 Hz 1)Supply lines 2) for 5% voltage drop U and start-up current IA for 50 Hz400 V400 V ( U 20 V)Motor sizeAmm²mZBR 132 D 12/2502,5151) Fuse links also apply in conjunction with a cross-travel motor.102) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ.20364044.indd/310708Required supply cable conductor cross sections and fuse links

Key data of cross travel drives DR 3 – DR 5 – DR 10The inverter-fed cross-travel drives of the “DR without electrical control” are designed for operation with a Demag frequencyinverter in the 120 Hz range. We recommend that Demag DIC Dedrive Compact frequency inverters be used. Owing to thelarge input voltage range of the Dedrive Compact, “DR rope hoists without electrical control” can be operated with mainsvoltages 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 drivesDR 3, DR 5, DR 10 - 2/1 - 4/1 - 4/2No. of polesDR 3 - 10 range%CDFMotor size4ZBA 71 B4 DR B00360OutputPCurrentat 220 VkWI (A)0,372,6cos φ0,54nat 50 HzRecommendedinverter typerpmDedrive Compact1375DIC-4-004-Enat 50 HzRecommendedinverter typerpmDedriv

Demag rope hoist K Low-headroom monorail hoist Z Double-rail crab F Stationary E Electric travel unit. 6 20364044.indd/310708 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 .File Size: 1MBPage Count: 36