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DEMAG DC-Com 1, Operating Instructions Manual

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DEMAG DC-Com 1 Operating Instructions Manual Download Page 108

214802ET

.indd/291

113

108

12.5 Hook assembly

42764045.eps

 Item  Part 

no. 

Qty.  Designation 

 

Material 

Standard

 

     18 

71778033 

1 

Hook 

fi

 ttings set  DC-Com 2 

6,8 Nm 

 

 

     18 

71878033 

1 

Hook 

fi

 ttings set  DC-Com 5 

9,5 Nm 

 

 

     18 

71578033 

1 

Hook 

fi

 ttings set  DC-Com10 

25 Nm 

 

 

     21 

71851633 

1 

Hook safety catch set  DC1-5 

 

 

 

     21 

71551633 

1 

Hook safety catch set  DC10 T04 

 

 

21480106.tbl

Summary of Contents for DC-Com 1

Page 1: ...instructions accessories component parts Demag DC Com 1 10 chain hoist 291113 en GB 214 802 44 720 IS 817 Distributed by Ergonomic Partners Sales ErgonomicPartners com www ErgonomicPartners com Tel 31...

Page 2: ...19 3 Serial no calendar week year of manufacture 4 Load capacity group of mecha nisms Model code Page 18 Selection table Page 19 5 Chain type hook path Available hoist chains Page 77 Model code Page 1...

Page 3: ...gn overview 17 Model code 18 Selection table 19 Electric key data 20 Hoist motor data 20 Mains connection delay fuse links 23 Supply cables 23 Hook dimension C 24 Noise emission sound pressure level 2...

Page 4: ...endant 49 General 49 Meaning of the buttons 49 Meaning of the parameters 49 Starting parameter programming mode 50 Adjusting the lower hook position 52 Putting into service for the first time 53 Safet...

Page 5: ...ntry plate 74 Checking the hoist chain 74 Chain set scope of supply 76 Available hoist chains 77 Replacing the chain set 78 Lubricating the hoist chain 82 Load hook 83 Checking the load hook 83 Hook s...

Page 6: ...101 Assemblies 101 Spare parts 102 Overview 102 Motor 103 Parts on the gearbox 104 Chain drive 106 Hook assembly 108 Bottom block with internal cut off springs standard 109 Bottom block with external...

Page 7: ...Wind chain hoist 211 010 44 PGS parallel gripper 214 095 44 Assembly Adjustment Dimen sions Crane hook adapter 211 240 44 KDDC UDDC articulated trolley 211 159 44 E11 E34 DC travel drive I 214 810 44...

Page 8: ...e safety regulations and the oper ating instructions The machine may only be operated by personnel who are fully familiar with the operating instructions In particu lar they contain the Safety section...

Page 9: ...ce These instructions must be read carefully before starting any work on and with the chain hoist especially before it is put into service for the first time The manufacturer assumes no liability for...

Page 10: ...owing to their technical training knowledge and experience of electric machines as well as knowledge of the relevant valid standards codes of practice and regulations are able to assess the tasks give...

Page 11: ...load capacity plate on the crane for any correspondence or spare part orders Specifying this data ensures that you receive the correct information or the required spare parts Demag Cranes Components G...

Page 12: ...ot be exceeded The maximum permitted load capacity of the chain hoist includes the load and any load handling attachment The machine may only be installed used operated maintained and removed by train...

Page 13: ...on this analysis corresponds to state of the art engineering principles However residual risks remain DANGER Live components Danger to life and limb Electric energy may cause very severe injuries Dang...

Page 14: ...places are specified in operating procedures personnel who work with or on the machine are provided with appropriate first aid equipment Personnel must be trained in the use of the first aid equipment...

Page 15: ...rength no loose sleeves no rings or any other jewellery etc Safety shoes to protect against falling parts and against slipping Safety helmet to be worn by everybody in the danger zone 2 8 Emergency st...

Page 16: ...fy that the machine must be inspected before it is put into operation the machine must be inspected regularly the elapsed share of the theoretical safe working period must be calculated a record of te...

Page 17: ...ook assembly with load capacity plate 2 4 Window 2 14 Slipping clutch 24 Motor shaft 5 Pulse wheel for speed monitoring 15 Dished washer pack 25 Winding head cap 6 Magnet brake 16 Slipping clutch adju...

Page 18: ...e Manulift DC ProCC 2 stage chain hoist for conventional contac tor control DCS Pro Variable speed chain hoist DCMS Pro Variable speed Manulift DC ProFC Variable speed chain hoist for control by means...

Page 19: ...Lifting speeds until 09 2008 no longer available Load ca pacity Size Reeving Group of mecha nisms Chain size Lifting speed Standard hook path 6 Motor size 7 Max weight for hook path Chain hoist DIN E...

Page 20: ...m 5 ZNK 80 A 8 2 8 0 18 20 665 240 1 10 1 10 1 25 2 50 0 46 2 0 72 40 2745 120 2 10 2 70 3 20 4 70 0 49 DC Com 10 ZNK 100 A 8 2 8 0 27 20 690 240 1 60 1 80 2 10 1 90 0 48 2 1 10 40 2745 120 2 00 2 30...

Page 21: ...2 1 80 40 3555 120 7 30 8 90 10 00 5 10 0 48 440 480 V 60 Hz 3 CE CCSAUS 15 DC Com 1 ZNK 71 B 8 2 8 0 06 20 870 240 0 96 1 15 1 15 1 45 0 47 2 0 22 40 3525 120 1 15 1 55 1 55 2 75 0 45 DC Com 2 ZNK 7...

Page 22: ...17 DC Com 2 ZNK 71 B 8 4 8 0 11 15 815 240 2 50 2 70 3 00 1 25 0 51 4 0 22 25 1705 120 2 50 2 50 2 90 2 30 0 55 DC Com 5 ZNK 80 A 8 4 8 0 22 15 860 240 3 10 3 50 4 00 1 70 0 48 4 0 43 25 1755 120 3 80...

Page 23: ...Size Motor size A A A A A A A DC Com 2 ZNK 71 B 8 4 6 6 6 6 6 6 6 DC Com 5 ZNK 80 A 8 4 Tab 12 3 4 3 Supply cables Supply cables 18 for 5 voltage drop U and starting current IA Voltage 220 240 V 380...

Page 24: ...362 395 425 400 435 465 DC Com 10 ZNK 100 A 8 2 460 493 582 493 526 615 ZNK 100 B 8 2 582 615 2 1 ZNK 100 B 8 2 552 632 585 665 Size Reeving Trolley at right angles to the girder Parallel to girder DC...

Page 25: ...ordered or the latest technical modifications are incorporated the ac tual scope of supply may differ from the data and information as well as from the illustrations described here If you have any que...

Page 26: ...n a damp location the equipment must be packed tight and protected against corrosion use desic cant 3 8 Materials 3 8 1 Linings We only use asbestos free slipping clutch and brake linings 3 8 2 Housin...

Page 27: ...may occur in the following applications for example Galvanising or electroplating facilities Hygiene areas Low or high temperature applications On request suitably optimised equipment and important i...

Page 28: ...ective requirements for a load control device for load capacities as of 1000 kg The brake arranged on the load side prevents the load from slowly dropping when the unit is at rest Monitoring of the sl...

Page 29: ...controlled DC chain hoists half wave evaluation Demag control pendants are connected via plug in connectors for manual control Compact DSC control units which are optimised for for Demag DC chain hois...

Page 30: ...hours of operation The display appears after 3 seconds without any lifting motion If the control board has to be replaced we recommend if technically possible that the details for the number of operat...

Page 31: ...ns of a self locking clamp mechanism The control pendant can be adjusted to a different suspension height by unlocking the clamp mechanism The strain relief hose for the control pendant consists of an...

Page 32: ...ructed personnel who are familiar with the principle of operation of the machine in compliance with all safety regulations Ensure sufficient working clearance before starting assembly work Secure and...

Page 33: ...ing elements must correspond to the direction of movement Electric safety The chain hoist operating instructions must be referred to when Demag chain hoists are used These operating instructions only...

Page 34: ...nly used for Demag chain hoists Self locking nuts must not be replaced by other types of nut 5 4 Installation procedure 1 Unpack and dispose of the packing material in an environmentally compatible wa...

Page 35: ...ins 2 Then pull bend protection sleeve 1 off the control pendant 3 Slide bend protection sleeve 1 onto the control cable Plug the control cable into the control pendant and turn the bayonet lock until...

Page 36: ...and DST C or DSE C control pendants Ergonomic workplace The suspension height can be adjusted by means of a self locking mechanism at any time to suit individual re quirements Adjust the suspension h...

Page 37: ...n place At the same time pull the control cable until the correct height has been reached for the control pendant 6 If the control pendant is positioned too low pull on the control cable hose behind t...

Page 38: ...ocket insert 4 Cable collector 720 065 45 5 DSE 10C control pendant 773 352 45 6 Control cable locking mechanism Tab 25 H4 H5 H8 H11 height adjustable standard control cables are used to gether with t...

Page 39: ...214 802 44 291113 39...

Page 40: ...N EN 14492 2 DC Com chain hoists are used with a slipping clutch which directly acts as overload protection The slipping clutch must be adjusted according to the load capacity of the chain hoist For i...

Page 41: ...suspension brack et can be ordered to achieve an improved C dimension Assembly 1 Remove the retaining clip and pin on one side 2 Attach the suspension bracket DC 10 according to the reeving arrangeme...

Page 42: ...able in Hoist motor data Page 20 is required for the power supply Please note that the length of the supply cable specified for a given cross section must not be exceeded in order to avoid excessive v...

Page 43: ...after the mains cable has been connected and before the chain hoist is put into operation The mains connector must never be disconnected under load Phase sequence for connection to the AC power netwo...

Page 44: ...5 9 Circuit diagrams and control boards 5 9 1 DC Com 1 10 solo hoist circuit diagram Fig 20 44 214 802 44 291113...

Page 45: ...Fig 21 214 802 44 291113 45...

Page 46: ...Fig 22 46 214 802 44 291113...

Page 47: ...e 7 E11 E34 DC travel drive assembly in structions I For further information on cross travel limit switch part no 716 663 45 see Tab 3 Page 7 E 11 E 34 DC travel drive assembly instructions I 5 9 3 Co...

Page 48: ...ber Label with Serial no SN Modification version MV Production date calendar week year Tab 28 Fig 24 Pin 1 1 RJ45 connec tor Function assignment PIN Control cable X3 14 Trolley X5 13 1 Special F1 Spec...

Page 49: ...eter pro gramming changes are saved Tab 31 5 10 3 Meaning of the parameters From software version SW 2 10 the following parameters can be programmed Display of parameter no Parameter name Display of p...

Page 50: ...P disappears after approx 2 seconds Press the Lifting button again and hold it down until o for O K is displayed 5th step Release the button Parameter programming mode is now active When parameter pr...

Page 51: ...meters Page 49 8th step To set a different value press the Lowering button until the required value is shown in the display 9th step The value is again selected by using the Lift ing button the system...

Page 52: ...imit stop 4 0 4 3 Tab 38 To reduce the hook path proceed as follows 1 Position the hook as shown in the diagram 2 Stop the chain hoist by actuating the emergency stop or the mains connection switch an...

Page 53: ...carried out work may need to be performed in the danger zone when the installation is first put into operation 6 2 Inspection regulations WARNING Non compliance with operating and maintenance regulat...

Page 54: ...cked for compliance with the corresponding acci dent prevention regulations By means of suitable measures carried out by the owner or on his behalf the owner must ensure that the load handling attachm...

Page 55: ...danger zone when the load is set down WARNING Risk of burns There is a risk of burns from contact when the chain hoist is in operation Do not touch hot motor housings WARNING Suspended load Falling pa...

Page 56: ...pplies if damage occurs to parts of machinery or equipment which makes an immediate stoppage nec essary If the chain hoist has been stopped by an emergency stop due to safety related defects it must b...

Page 57: ...Take the machine out of service immediately if functional defects or irregularities are detected The operator is obliged to check the machine for any visible damage at least once per shift and to rep...

Page 58: ...above persons Do not pull or drag suspended loads at an angle The chain drive mechanism may be damaged at angles of 4 or more Do not pull free fixed or obstructed loads with the chain hoist Do not le...

Page 59: ...t is already suspended can be safely deposited by actuating the lowering button When the lowering motion has been completed lifting is possible again If the slipping clutch already trips at rated load...

Page 60: ...the relevant documents for operation of the control pendant and button assignments see Tab 3 Page 7 7 5 Taking the equipment out of operation 7 5 1 Taking the equipment out of service when faults occ...

Page 61: ...the load has been removed 4 Stop all moving parts and ensure that they cannot start moving while maintenance work is being carried out 5 Observe the relevant accident prevention regulations instructio...

Page 62: ...ed for maintenance work only use appropriate attachments for the lifting of persons which ensure that work is carried out in a safe and stable position Only suitable tested and calibrated tools and ac...

Page 63: ...work on the chain hoist when the load has been removed 5 Ensure that there is sufficient freedom of movement Keep the working area clean and tidy Loose parts or tools left lying around may cause acci...

Page 64: ...ices Regular inspections must be carried out in accordance with BGV D6 and BCG 905 Principles for the inspection of cranes in Germany It may be necessary to remove parts in order to inspect wearing pa...

Page 65: ...chain hoists are designed for specific periods of operation Premature failure cannot however be ruled out The following items have been taken from FEM rule 9 755 with reference to the electric chain...

Page 66: ...not considered Estimating load spectrum factor kmi by the owner To simplify estimation each type of load can be grouped together into km load spectrum modules The types of load are simplified and quot...

Page 67: ...sification in FEM group of mechanisms 1Am see DC Com data plate with a theoretical duration of serv ice of 800 hours see table below the hoist has a theoretical remaining duration of service of With o...

Page 68: ...UVV accident prevention regulations and BGV D8 are satisfied The equipment may continue to be used when an expert engineer has entered the conditions for further utilisation into the test and inspecti...

Page 69: ...secured X Check the chain for deformation damage cracks pitting reduc tion in the thickness of the links or increase in pitch due to wear elongation caused by deformation Checking the hoist chain Pag...

Page 70: ...t min dimen sion e mm 15 3 14 4 25 2 24 3 Tab 50 Suspension ring Fig 37 Chain hoist DC 1 2 5 DC 10 Suspension ring turned 90 chain hoist parallel to girder min dimen sion e mm 17 55 24 3 Tab 51 8 5 2...

Page 71: ...emove retaining spring 4 from pin 5 and remove the pin While doing so hold the chain collector Place chain collector box 6 on the ground 8 5 4 Operating limit switches standard for DC Com 10 with 2 1...

Page 72: ...unit has switched off 2 1 reeving It must only be possible to compress the upper part of a bottom block with internal cut off springs onto the lower part by a small amount so that approx 20 mm of the...

Page 73: ...d degreased to enable the chain sprocket to be inspected properly If the chain sprocket shows signs of wear from the chain or chipping on its sides the chain set must be replaced without delay 8 5 5 2...

Page 74: ...ting the correct hoist unit for the given application owners of chain hoists are obliged by rele vant regulations such as DIN 685 part 5 to check the round section steel chain continuously in operatio...

Page 75: ...e chain over 11 links Measurements on 11 chain links may be taken in steps of 2 x 3 and 1 x 5 chain links The sum total of the 3 readings taken i e a1 a2 a3 must not exceed the specified limit a Other...

Page 76: ...st be suspended from the load hook when measuring the chain over 11 links 8 5 5 5 Chain set scope of supply The chain must be replaced when the permissible chain wear limit is reached to determine the...

Page 77: ...n steel to EN 818 7 part 5 3 1 Lubrication GP00H 30REN SO GFB grease Demag Corrud special chain Application e g galvanising electro plating facilities DC 1 2 250 4 2 x 12 2 DAT RDC TDK 0 38 13 8 22 10...

Page 78: ...nd remove service cover 1 2 Place bag 2 with the control cable on the chain hoist pull out mains cable union 3 with fitted mains cable 4 and place to one side if a travel drive is fitted remove the co...

Page 79: ...e area power supply insert DC Com 10 Fold cover 9 of the opening in the gearbox housing to the side 3 Remove chain guide 10 with the sprocket from the output shaft to do this slide the complete assemb...

Page 80: ...guide 4 Distance ring DC Com 1 2 3 off DC Com 5 1 off DC Com 10 2 off Tab 57 Apply Molykote or a similar lubricant to the splines of the output shaft before you install the chain sprocket Fitting the...

Page 81: ...sitioned between the hook assem bly and the limit stop In this case a geared limit switch is required for DC 10 units with 2 1 reeving Furher procedure after replacing the chain set If the chain has t...

Page 82: ...ervice and load conditions A dry film lubricant should be used in environments where abrasives occur em ery sand etc For non standard lubrication see Available hoist chains Page 77 CAUTION Premature w...

Page 83: ...o be replaced turn the nut on the bolt until at least two turns of the thread can be seen on the other side of the nut The bolted connection must only be tightened enough to allow the hook safety catc...

Page 84: ...cause loads to be dropped During assembly ensure that chain link sections 1 are positioned with their collar in bearing 2 Grease the bearing and bearing seat that retaining pin 3 is correctly fitted...

Page 85: ...ff springs 3 in new halves 4 of the bottom block 6 Install new guide half sections 1 and tighten bolts 5 to a torque of 5 5 Nm 7 Apply the load capacity plate 8 Perform a function check run against th...

Page 86: ...the course of the annual inspection Check for damage cracks and tears 2 Missing buffer plate Ensure that the component parts are installed in the right order when new buffers are installed see also Bu...

Page 87: ...ffer plate 3 Cut off spring Chain hoist range Load hook side Chain collector box side DC Pro 1 10 A B DC Com 1 10 with operating limit switch DC Pro 1 10 C D DC Com 1 10 without operating limit switch...

Page 88: ...mmedi ately For brake displacement up to 0 5 mm the brake can still be used until the next maintenance is due As of year of manufacture 04 2009 Fig 62 Since 04 2009 depending on the size of model brak...

Page 89: ...disc with a depth gauge or calliper gauge when the brake is actuated to do this press the brake disc against the springs until it stops Use both measured values to calculate the difference this diffe...

Page 90: ...ing Warning messages Page 98 When the slipping clutch function has been checked the limit stop must be fitted again to the section of chain which is not under load 8 5 9 2 Adjusting the slipping clutc...

Page 91: ...es lower than 20 C or higher than 45 C CAUTION Safe operation cannot be ensured Malfunctions of the slipping clutch may occur if oils are used that are not approved and safe operation can then no long...

Page 92: ...actor B using your other hand until the mechanism no longer holds it 3 Then unclip second locking tab A on the opposite side as described in step 1 above 4 Using your other hand remove contactor B by...

Page 93: ...The contactors are also socket mounted for sizes DC 1 to 5 manufactured as of 02 2011 and can be individually replaced 214 802 44 291113 93...

Page 94: ...eplacing the control cable Fig 69 DANGER Live components Danger to life and limb Work on the electric equipment may only be carried out by a qualified electrician or by trained personnel 94 214 802 44...

Page 95: ...nd remove the locking mechanism Remove the control cable Install the new control cable in reverse order It must be ensured that the groove on the connector holder lines up with the swivel lock in the...

Page 96: ...g the machine to an immediate standstill by actuating the emergency stop without delay if malfunctions occur that result in an immediate danger of personal injury damage and or an operating hazard 2 S...

Page 97: ...nection and fuse link check connection cable for interruption check mains connector in the service enclosure Check PE phase for correct connection 2 No lifting no lowering Emergency stop actuated Unlo...

Page 98: ...switches function correctly The slipping clutch acts as an emergency stop device if there is a malfunction Limit switch contact connection and operation must be in spected by an experienced technician...

Page 99: ...ystem Check error message by actuating and unlocking the emer gency stop Then actuate Lowering If necessary remove suspended load Defective electronic monitoring Replace hoist control system 6 E 6 Cha...

Page 100: ...ment has been concluded separated components must be recycled after proper removal Scrap any remaining metallic material Dispose of plastic elements for recycling Separate and dispose of any other com...

Page 101: ...2 Return sprocket assembly consisting of 1 return sprocket 1 pin 1 retaining ring 1 supporting washer 2 thrust wash ers 2 needle roller assemblies DC Com 1 2 717 808 45 DC Com 5 718 808 45 DC Com 10...

Page 102: ...214802ET indd 291113 102 12 Spare parts 12 1 Overview 1 1 reeving 2 1 reeving 42764247 eps...

Page 103: ...Nm DC Com 5 until 09 2008 2 71874133 1 Motor set 240V50Hz 220 V 240 V 50 Hz 9 5 Nm 2 71874233 1 Motor set 415V50Hz 380 V 415 V 50 Hz 9 5 Nm 2 71874433 1 Motor set 575V60Hz 500 V 525 V 50 Hz 575 V 60 H...

Page 104: ...214802ET indd 291113 104 12 3 Parts on the gearbox 42763847 eps...

Page 105: ...eeving As of year of manufacture 08 2008 3 71773433 1 Gearbox set DC Com 1 V8 2 3 71774033 1 Gearbox set DC Com 2 V6 1 5 3 71890433 1 Gearbox set DC Com 5 V4 5 1 1 3 71570533 1 Gearbox set DC COM 10 V...

Page 106: ...214802ET indd 291113 106 12 4 Chain drive 42764346 eps 1 1 reeving 2 1 reeving...

Page 107: ...7 4 Nm 12 71596133 1 Chain set DC10 2 1 H 8 DC 10 2 1 7 4 Nm 12 75263933 1 Chain set DC 10 5m 2 1 for GGS 1 12 75264033 1 Chain set DC 10 8m 2 1 for GGS 1 14 71588033 1 Limit switch set DC 10 3 Nm 15...

Page 108: ...Designation Material Standard 18 71778033 1 Hook fittings set DC Com 2 6 8 Nm 18 71878033 1 Hook fittings set DC Com 5 9 5 Nm 18 71578033 1 Hook fittings set DC Com10 25 Nm 21 71851633 1 Hook safety...

Page 109: ...ernal cut off springs standard Item Part no Qty Designation Material Standard 23 71598533 1 Bottom block set DC 2 1 24 71544233 1 Bottom block half set DC10 2 1 25 83865633 1 Hook safety catch set GR...

Page 110: ...1 See section 11 Item Part no Qty Designation Material Standard 28 Bottom block with cut off springs 1 29 83785233 1 Bottom block half set DK10 6 8 Nm 30 83865033 1 Load hook DC16 25 DK10 20 31 83865...

Page 111: ...Control set DC1 15 400V 380 V 415 V 50 Hz 380 V 400 V 60 Hz 3 Nm 50 77336033 1 Control set DC1 15 575V 500 V 525 V 50 Hz 575 V 60 Hz 3 Nm 50 77316033 1 Control set DC1 15 460V 440 V 480 V 60 Hz 3 Nm...

Page 112: ...53 71892033 1 Service cover set DC 5 5 5 Nm 53 71592033 1 Service cover set DC10 7 5 Nm 54 71881033 1 Control cable set 5m 11 Nm 54 71880933 1 Control cable set 8m 11 Nm 54 72003745 1 DC control cable...

Page 113: ...te 52 E Elapsed operating time counter 30 F Factor depending on the type of recording 66 I Infrared interface 29 L Load spectrum factor 66 N Number of operating hours 66 O Operating limit switches 29...

Page 114: ...achinery Electrical equipment of machines Part 32 Requirements for hoisting machines The relevant technical documentation according to Annex VII Part A of Directive 2006 42 EC has been compiled and wi...

Page 115: ...nery Electrical equipment of machines Part 32 Requirements for hoisting machines The safety objectives of Low Voltage Directive 2006 95 EC are achieved The product additionally complies with the follo...

Page 116: ...emag Cranes Components GmbH PO Box 67 58286 Wetter Germany Distributed by Ergonomic Partners Sales ErgonomicPartners com www ErgonomicPartners com Tel 314 884 8884 Reproduction in whole or in part onl...

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