DEMAG DR Series Manuale di istruzioni

720 IS 800

214 912 44

201204 EN

DR crane set

Standard cranes with EKDR

Technical data and instructions for assembly

21491244.p65/201204

Manufacturer:

Operating instructions

EKDR Com rope hoist

(Technical data and spare parts) 214 916 44 720 IS 813

DRS 112 – 200 wheel block system 214 276 44 720 IS 845.5

DFW-L-L travel units 214 331 44 720 IS 845.1

DFW-L-E travel units 214 362 44 720 IS 845.1

Demag EKDR Pro rope hoist 214 725 44 720 IS 813

DRC-10 radio remote control systems 214 920 44 720 IS 975

DRC-J radio remote control systems 214 975 44 720 IS 975

DSE-8R, 16 R control pendants 214 940 44 720 IS 975

Technical data

EKDR Pro rope hoist 203 520 44 714 IS 813

Demag DRS travel unit components 203 352 44 714 IS 845

KBK 0, KBK 25, KBK 100 power supply

via trailing cables 202 617 44 714 IS 963

KP-A / T clamp-type buffer 203 313 44 714 IS 888

Assembly instructions

KP-A / T clamp-type buffer 214 354 44 720 IS 888

Accompanying documents

Demag Cranes & Components GmbH

P.O. Box 67, D-58286 Wetter

Telephone (+2335) 92-0 · Telefax (+2335) 927676

www.demagcranes.com

21491244.p65/201204

Page

0 Foreword 4

0.1 Copyright 4

0.2 Customer service 4

0.3 Liability for defects 5

0.4 Limitations of liability 5

0.5 Definitions 6

1 Safety instructions 7

1.1 Symbols 7

1.2 Intended use 7

1.3 Inappropriate use 8

1.4 Basic information on safety 8

1.5 Selection and qualification of operating personnel 9

1.6 Safety instructions for assembly and disassembly 10

1.7 Safety instructions when first putting the unit into service

after completing assembly 10

1.8 Safety instructions for operation 10

1.9 Safety instructions for maintenance 11

2 Scope of delivery 13

3 Overview of DR rope hoist assembly 14

3.1 Adjusting the EKDR Pro/Com 3 - 5 – 10 low-headroom monorail hoist,

4/1, 2/1 and 4/2 rope reeving 14

3.1.1 Assembling trolleys of the DR 3, 5 and 10 range 14

4 Manufacturing tolerances of crane runways 16

5 Technical Description DFW travel unit 17

5.1 DFW-L-E overview 17

5.2 DFW-L-L overview 19

6 Crane set 21

6.1 Crane set with DFW travel unit 21

6.1.1 Design of the travel unit 21

6.1.2 Changing the span 22

6.2 KP-T16 clamp-type buffer 23

7 Electrical components 24

7.1 Illustration of the scope of supply of the flange clamps 26

7.2 Connector overview 27

7.3 Plug-and-socket connection for motors of the KB and Z series 28

7.3.1 Safety instructions 28

7.3.2 General 28

7.4 Electrical design and connector insert 29

7.4.1 ZBF two-speed motor with brake 29

7.4.2 GF combined brake module 29

8 Crane anti-collision device 30

9 Geared limit switch for the DR rope hoist 33

9.1 Geared limit switch 33

9.1.1 Determining the cut-out points for the geared limit switch 33

9.2 Instructions for adjusting the geared limit switch 35

These instructions are no operating instructions for the end user, but assem-

bly instructions for the company being responsible for assembly and erection

of the rail-guided handling equipment.

Special operating instructions for the overall installation must be prepared by

the corresponding crane manufacturer.

Table of contents

21491244.p65/201204

0 Foreword

You have purchased a Demag product.

This rail-guided handling equipment was manufactured in accordance with German

and European standards and regulations, e.g. EC Machinery Directive 98/37/EC,

and state-of-the-art engineering principles.

These assembly instructions are designed to provide the crane manufacturer with

appropriate instructions for safe and correct assembly and installation. The operat-

ing and assembly instructions of the corresponding products stated in the individual

sub-chapters form parts of these assembly instructions.

Every individual given the task of transporting, installing, commissioning, operating,

maintaining and repairing our rail-guided handling equipment and additional equip-

ment must have read and understood

• the assembly instructions

• the operating instructions,

• the safety regulations and

• the safety instructions in the individual chapters and sections.

The assembly instructions must be available to the assembly personnel at all times

in order to prevent assembly errors and to ensure smooth and trouble-free opera-

tion of our products.

These assembly instructions must be treated confidentially. They should only be

used by authorized personnel. They may only be entrusted or made available to

third parties with the prior written consent of Demag.

All documents are protected within the sense of copyright law.

No part of this documentation may be reproduced, utilized or transmitted without

specific prior consent. Infringements are an offence resulting in obligatory compen-

satory damages.

All industrial rights reserved.

For technical information on Demag products and their systematic application,

please refer to one of our after-sales service stations, the relevant representative

or to our main office in Wetter.

Our after-sales service will provide you with all technical information on Demag

products and their systematic application.

Should you have any questions regarding our products, please refer to one of our

after-sales service stations, the relevant representative or the manufacturer.

Kindly quote the serial or order number (see test and inspection booklet, load

capacity plate on the crane) in any correspondence or for spare part orders.

Specifying this data ensures that you receive the correct information or the required

spare parts.

The relevant after-sales service station of Demag is specified for example on the

back page of the hoist unit test and inspection booklet.

0.2 Customer service

0.1 Copyright

21491244.p65/201204

These operating instructions must be read carefully before installing and putting the

rope hoist into operation.

We assume no liability for any damage and malfunctions resulting from failure to

comply with the operating instructions.

Any liability claims for defects must be made by quoting the order number immedi-

ately on detecting the defect.

Any liability claims for defects are void in the event of:

• inappropriate use,

• faulty devices or equipment connected or attached to the system which are not

part of our scope of supplies and services,

• use of non-genuine spare parts and accessories,

• refurbishment or modification of the product unless approved in writing by

Demag.

Wearing parts are not subject to liability for defects.

All technical information, data and instructions for operation contained in these

operating instructions were up-to-date on going to print and are compiled on the

basis of our experience and to the best of our knowledge.

We reserve the right to incorporate technical modifications within the scope of fur-

ther development of the rope hoists which are the subject of these operating in-

structions.

The information, illustrations and descriptions contained in these operating instruc-

tions are therefore only intended for information purposes.

The descriptions and illustrations contained in this documentation do not necessari-

ly correspond to the scope of delivery or any subsequent spare part delivery, either;

the drawings and illustrations are not to scale.

Only documentation belonging to the actual order is valid.

We assume no liability for damage and malfunctions caused as a result of operating

errors, non-compliance with these operating instructions or inappropriate repairs

and maintenance.

We expressly point out that only genuine Demag spare parts and accessories ap-

proved by us may be used. Accordingly, this also applies to other manufacturers’

parts supplied by us.

For safety reasons, the fitting and use of spare parts or accessories which have not

been approved and unauthorized modification and conversion of the product are

not permitted and exempt Demag from any liability for damages resulting therefrom.

With the exclusion of any further claims, we are liable for any defects or omissions

on our part in the products or documentation supplied within the scope of the liabil-

ity obligations entered into in the original contract. Any further claims, in particular

any and all claims for damages, are excluded with the exception of legal claims in

accordance with product liability legislation.

0.3 Liability for defects

0.4 Limitations of liability

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0.5 Definitions Owner

Owners (employer, company) are defined as persons who own the rail-guided

handling equipment and who use it appropriately.

Operating personnel/operator

Operating personnel or operators are defined as persons entrusted by the owner

of the rail-guided handling equipment with operation of the equipment.

Specialist personnel

Specialist personnel are defined as persons assigned by the owner of the rail-

guided handling equipment to carry out special tasks such as installation, setting-

up, maintenance and fault elimination.

Qualified electrician

Qualified electricians are defined as persons who, owing to their technical training,

knowledge and experience of electrical installations as well as knowledge of the

relevant standards, codes of practice and regulations, are able to assess the tasks

given to them and to identify and eliminate potential hazards.

Trained person

Trained persons are defined as persons who have been instructed and trained for

the tasks assigned to them and on the possible hazards resulting from incorrect

handling and who have been informed about the required protective devices,

protective measures, relevant regulations, codes of practice, accident prevention

regulations and operating conditions and who have proven their qualifications.

Experienced technician

Experienced technicians are defined as persons, who, owing to their technical

training and experience, have sufficient knowledge of rail-guided handling equip-

ment and are familiar with the relevant national industrial safety regulations, codes

of practice, accident prevention regulations, directives and generally accepted

engineering standards enabling them to judge the safe operating condition of rail-

guided handling equipment.

Assigned expert engineer (in the Federal Republic of Germany according to

BGV D8, § 23, for determining the S.W.P.)

An assigned expert engineer is defined as an experienced technician specifically

assigned by the manufacturer to determine the remaining duration of service

(service life) of rail-guide handling equipment (S.W.P. = safe working period) and

to carry out a general overhaul of rail-guided handling equipment.

Authorized expert engineer (in the Federal Republic of Germany according to

BGV D6, § 28)

In addition to the expert engineers of the Technical Supervisory and Inspection

Board, an authorized expert engineer for the inspection of rail-guided handling

equipment is defined as an expert engineer authorized by the Industrial Employers’

Mutual Insurance Association.

Rail-guided handling equipment

Rail-guided handling equipment are systems used for lifting and moving loads, such

as cranes, crabs and travelling hoist units, rail systems.

21491244.p65/201204

1 Safety instructions

1.1 Symbols The following symbols and recommendations indicate potential safety hazards or

causes of damage or provide useful information.

Hazard warning

This symbol appears in the assembly instructions next to all instructions relating to

safety at work wherever a potential hazard to life and limb exists if the instructions

are not complied with.

Follow these instructions at all times and be particularly vigilant and cautious.

Pass on safety instructions to all persons entrusted with working on the equipment

including the track and power supply.

In addition, observe all general safety regulations at all times.

Warning against dangerous electrical voltage

Contact with live parts can result in immediate death. Protective covers (e.g. covers

and enclosures) of electrical assemblies or those marked with this sign may only be

opened by qualified electricians. Before opening, all relevant operating, control, feed

or other voltages must be disconnected.

Warning against suspended load

Any person remaining in this danger zone may suffer serious injury or death.

Operating hazard for the installation

This symbol in the assembly instructions indicates all warnings which, if not com-

plied with, may result in damage to the rail-guided equipment or the load.

Rail-guided handling equipment is only intended for lifting and moving loads and

may be used as stationary or travelling units.

Rail-guided handling equipment may only be operated when in perfect working

order by trained personnel in accordance with the relevant safety and accident

prevention regulations. This also includes compliance with the operating and main-

tenance conditions specified in the assembly and operating instructions.

Rail-guided handling equipment is industrial equipment operated with a rated volt-

age of up to 1000 V from high-voltage supply systems.

Power feed is via power supply lines (mobile cables, open or enclosed power con-

ductor systems, cable drums). These systems lead up to the terminals of the main

switch (mains connection switch, isolating switch).

The relevant isolating switches must be switched off and secured when performing

maintenance/repair work. During operation or when the main switch is not switched

off, electrical components inside enclosures, motors, switchgear cabinets, terminal

boxes, etc., carry dangerous voltages.

Serious personal injury or damage to property may occur in the event of:

• unauthorized removal of covers,

• inappropriate use of rail-guided handling equipment

• incorrect operation

• insufficient maintenance,

• exceeding the maximum permitted load (The rated load capacity/S.W.L. is the

maximum permitted load. Pay attention to the sum of the load to be lifted and

the load handling attachment.)

• Working on live parts.

1.2 Intended use

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1.3 Inappropriate use Certain work and practices are prohibited when using rail-guided handling equip-

ment as they may involve danger to life and limb and result in lasting damage to

rail-guided handling equipment, e.g.:

• Unsafe load handling (e.g. swinging the load)

• Handling suspended loads above persons

• Pulling or dragging suspended loads at an angle

• Pulling free fixed or obstructed loads

• Exceeding the maximum permitted load and permitted load dimensions

• Leaving suspended loads unsupervised

• Running load-supporting means (chains and ropes) over edges.

• Using load-supporting means (chains and ropes) as a load bearing sling.

• Subjecting the control pendant to inappropriate mechanical loads

• Allowing loads to drop when the load-supporting means are in a slack condition

• Failing to pick up loads from a solid base, but, for example, from a load handling

attachment

• Transporting persons, unless lifting devices are specifically approved for trans-

porting persons

• Manipulating electrical equipment

Persons under the influence of drugs, alcohol or medicines which affect reactions

must not install, operate, put into service, maintain, repair or disassemble rail-guid-

ed handling equipment.

Any conversions and modifications to the installation must comply with the technical

safety requirements. Work on electrical equipment of rail-guided handling equip-

ment may only be carried out by qualified electricians in accordance with electrical

regulations. In the event of malfunctions, rail-guided handling equipment must be

stopped, switched off and the relevant main switches locked immediately. Defects

must be rectified immediately.

National accident prevention regulations and codes of practice and general safety

regulations must be observed when operating our products. Important information

and instructions are marked by corresponding symbols. Follow these operating and

safety instructions to avoid personal injury and damage to machinery.

The operating instructions must be kept available at the place where rail-guided

handling equipment is in use at all times.

They include significant aspects and appropriate excerpts from the relevant guide-

lines, standards and regulations.

The owner must instruct his personnel appropriately.

If the safety instructions given in these operating instructions are not observed in

any way, personal injury or even death can result.

Observe general statutory and other obligatory regulations relating to accident pre-

vention and environmental protection and basic health and safety requirements in

addition to those included in these operating instructions.

Such requirements may relate, for example, to the handling of hazardous materials

or the provision/wearing of personal protection equipment.

Comply with these regulations and general accident prevention regulations relevant

for the place at which rail-guided handling equipment is used and follow the instruc-

tions therein when working with the equipment.

Rail-guided handling equipment may still constitute a danger to life and limb if it is

not installed, operated, maintained or used appropriately by personnel which have

not been trained or specially instructed.

The operating instructions must, if required, be supplemented by the owner with

instructions and information (e.g. factory regulations) relating to organization of

work, working procedures, operating personnel, etc. Supervising and reporting

obligations as well as special operating conditions must also be taken into

consideration.

1.4 General safety

information

21491244.p65/201204

Personnel assigned to working with rail-guided handling equipment must have read

and understood the operating instructions and, in particular, the section on safety

information.

All activities relating to rail-guided handling equipment which are not described in

these operating instructions may only be carried out by specialist personnel

specifically trained for rail-guided handling equipment.

The owner must ensure that personnel work in a safety and hazard-conscious

manner in compliance with the operating instructions.

The owner must ensure that rail-guided handling equipment is only operated when

in proper working order and that all relevant safety requirements and regulations are

complied with.

Rail-guided handling equipment must be taken out of service immediately if func-

tional defects or irregularities are detected.

In the event of a stoppage (e.g. if defects regarding safe and reliable operation are

detected, in emergency situations, in the event of operating malfunctions, for repairs

and maintenance purposes, if damage is detected or after finishing work) the opera-

tor/experienced technician must carry out all prescribed safety measures (e.g. for

cranes operating outdoors, ensure wind drift safety catch is fitted) or observe that

they are automatically carried out.

Personal protective clothing must be worn

as necessary or as required by regulations.

Personnel must not wear loose clothing, jewellery including rings or long hair loose.

Injury may occur, for example, by being caught or drawn into the mechanism.

All safety and hazard warnings on rail-guided handling equipment, their access

routes and their mains connection switches must be preserved completely and in

legible condition.

Inching (i.e. giving short pulses to the motor) must always be avoided.

Emergency limit stop devices (e.g. slipping clutch or emergency limit switch) must

not be approached in normal operation.

Modifications, additions to and conversions of rail-guided handling equipment

which may impair safety in any way must not be carried out without the approval

of Demag. This also applies to the fitting and adjusting of safety devices as well as

for performing welds on load bearing parts.

Safety devices must not be rendered inoperative.

Only genuine Demag spare parts may be used.

Observe prescribed deadlines or those specified in the operating instructions for

routine checks/inspections.

For independent operation or maintenance of rail-guided handling equipment, the

owner may only employ persons

• who are at least 18 years of age,

• who are mentally and physically suitable,

• who have been instructed in the operation and maintenance of rail-guided han-

dling equipmentand have proven their qualification to the owner in this respect

(in addition to theoretical training, instruction also includes sufficient practical

operating experience as well as acquiring the ability to identify defects which are

a hazard to safe operation),

• who can be expected to carry out the work assigned to them reliably.

The owner must assign operating and maintenance personnel to their relevant

tasks.

1.5 Selection and qualifi-

cation of operating

personnel

21491244.p65/201204

• Installation and disassembly work may only be performed by experienced techni-

cians.

• Installation and disassembly work must be co-ordinated by the person carrying

out the work and the owner within the scope of their responsibility.

• The danger zone must be made safe.

• The installation must be isolated in accordance with the relevant electrical regula-

tions.

• Customer-specific regulations must be observed.

• Only appropriate, tested and calibrated tools and equipment may be used.

• The electrode holder and earth must be connected to the same assembly when

welding work is carried out. If the current flow is returned via protective conduc-

tors, screening elements or anti-friction bearings, serious damage may be

caused to these or other components.

• The working area must be made safe.

• First check that the voltage and frequency specified on the data plates match the

owner’s mains power supply

• All clearance dimensions and safety distances (see approval drawing) must be

checked before putting the unit into service.

• In the course of putting the product into service, it may be necessary to render

safety devices or features inoperative when carrying out adjustments or function

checks.

• When putting the unit into service, it may be necessary to perform work in the

danger zone, therefore, it must be ensured that only appropriately trained per-

sonnel are employed for this work.

The operator must check the function of the brakes and emergency limit stop de-

vices before starting work.

All instructions and measures described in the assembly and operating instructions

with regard to safe operation and items concerning general safety and accident

prevention which have to be observed before, during and after putting into service

must be strictly complied with. Any failure to comply can lead to accidents resulting

in fatalities.

Rail-guided handling equipment must be taken out of service immediately or not put

into operation if any defects relating to operating safety and reliability are detected.

Safety devices must not be rendered inoperative or modified in contradiction to their

intended use.

Only operate rail-guided handling equipment when all protective devices and safety-

relevant equipment, e.g. movable protective devices and emergency-stop devices,

are fitted and fully functioning.

Anybody who identifies an immediate danger of personal injury must actuate the

emergency stop button without delay. This also applies in the case of damage oc-

curring to parts of the installation and equipment which makes immediate stoppage

necessary. After an ”emergency-stop”, the operator must not switch on and restart

rail-guided handling equipment until an experienced technician is satisfied that the

cause which led to actuation of this function has been rectified and that continued

operation of the installation constitutes no further hazard.

1.6 Safety instructions for

assembly and disas-

sembly

1.7 Safety instructions

when first putting the

unit into service after

completing assembly

1.8 Safety instructions for

operation

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