Product presentation DR 3 - DR 5 - DR 10
1 DR Pro
1.0 DR Com
Contents
1
Mechanical equipment of DR 3, 5 and 10 rope hoists 4
1.1 Components of the EKDR monorail hoist
5
1.2 C design
6
6
1.2.1 Hoist unit side
1.2.2 Travel unit side
6
1.3
Hoist motor cylindrical rotor brake motor
7
7
1.3.1 Motor selection table
1.4
Hoist brake
8
8
1.4.1 Assignment of brake to the motor
1.5
Hoist gearbox
9
1.6
Rope guide
10
1.6.1 Coupling
10
1.6.2 Rope anchorage
10
1.6.3 Rope guide, standard and acid resistant
10
1.7
Rope retaining crosshead, top block
and bottom block
11
11
1.7.1 Rope retaining crosshead
1.7.2 Top block
11
1.7.3 Bottom block
11
1.8
Securing the EKDR on the girder flange
12
12
1.8.1 Thrust rocker
1.8.2 Counterweight plates
12
1.9
Travel wheels and travel drive
13
13
1.9.1 Integrated gearbox for cross travel unit
Notes
14
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
Notes
1.20
1.21
1.22
1.23
17
17
17
17
18
19
20
21
21
21
21
22
22
22
22
22
23
23
23
23
23
23
24
24
24
25
26
27
30
30
30
31
32
32
32
33
1.1
5
6
7
9
1
2
10
3
11
4
12
2
3
4
5
6
7
9
10
11
12
13
13
Thrust rocker
4/1 top block
Rope retaining crosshead with SGS or
optionally ZMS overload protection
Three-stage offset gearbox
Bottom block with protective cover and
2 handle recesses
C design
Compact design for optimum utilization of space
The design of the Demag DR rope hoist
provides outstanding approach dimensions for better utilization of the space
served by the crane. This means that either
a larger area can be served or new buildings can be designed smaller. This cuts
new construction and subsequent costs.
1.2
1.2.2
5
6
1.4
The low-vibration and low-noise ZBR cylindrical rotor motor is available as 12/2 or
4-pole motor with phase insulation, IP55
type of enclosure and optionally also with
IP65 type of enclosure.
1 Aluminium housing
2 Position of the integral pulse generator
(not visible in the figure) for detecting
the speed and direction of rotation.
The information is sent to the electronic
system for evaluation
3 Plastic fan cover
(must not be loaded
mechanically)
4 Optional: External pulse generator
5 Thermal contact, temperature class F
(The control switches off the motor at
excessive heat within a short time)
6 Brake system
(ventilated DC brake)
7 Plastic fan
3,2 t
ZBA 100B4
7,1 kW with FI
60 % CDF
5t
ZBA 132AL4
11 kW with FI
60 % CDF
ZBA 132B4
16 kW with FI
60 % CDF
ZBA 132C4
22,2 kW with FI
60 % CDF
Brake B140
Brake B140
10 t
Brake B050
Brake B140
V1
6 m/min
6 m/min
5 m/min
V2
9 m/min
9 m/min
9 m/min
V3
12 m/min
12 m/min
12 m/min
Friction plate
Carrier
Brake disk
with brake
linings
Wear
indicator
Adjusting nut
Distance spring
Collared pin
1.5
1.6
B140, 23 Nm
ZBR 132D 12/2
ZBR 132AL4
ZBA 132B4
ZBA 132C4
B050, 8,3 Nm
ZBR 100C 12/2
ZBR 100D 12/2
ZBA 100B4
1.7
3
4
5
3
1.8
The 2m+ classification only applies to the gearbox! The other components of the monorail hoist
are classified in 2m with 1600 full load hours!
1
2
3
4
5
6
1.9
Rope drum
Coupling elements
Insert
Aluminium bushing
Clip
Drive flange with involute splining
1.11
1.10
6
1.12
1.13
1
2
3
4
Insert
Aluminium bushing
Coupling elements
Clip
1.14
1
2
2
10
1.17
1.16
1.17
2
1.18
11
1.19
1
1.20
1.21
Counterweights
A compensating weight is necessary to increase the wheel load of the driven
wheel when the travelling hoist is used with small lower flange widths.
These plates are pushed onto the connecting rod, positioned at the end
of the rod and fixed into place using the existing retaining spacer sleeves,
washers and seeger rings. The retaining spacer sleeves also have to be fitted
to the second connecting rod.
The thrust rocker is maintained.
12
Guide rollers
Non-driven travel wheel
4-pole ZBA 71B4 cross-travel motor,
0,37 kW, 1400 rpm, 100 % CDF with
brake
Directly driven travel wheel
1.22
1 2
1.23
Travel drive:
fully integrated gearbox
oil-lubricated
no intermediate stage
directly driven travel wheel without
flange
guide rollers
4-pole ZBA motor with
frequency inverter
Cross travel speed 1,5 30 m/min
13
Notes
14
Notes
15
Notes
16
1
2
3
4
5
6
Enclosure cover
PCB
Cabling via encoded plugs
Trolley inverter
Braking resistor
Geared limit switch with 4 contacts
1.25
1.10.3
17
X7 ZMS1
Direction relay
Lifting/lowering
(no-load switching)
Speed relay
for pole-changing
hoist motor
1.11
X15 FI card
DIL switches
X9 Hoist 2-pole
18
X54 Horn
Circuit breaker
K1 Contactor
1.27
X1 400 V
PE
X2 CAN bus
X48 Cross 2
Fast-to-slow
X49 UniInput
(not ass.)
19
K2 pole-changing relay
K1 contactor
1.28
At rest
K1 contactor is OFF
K1 contactor OFF
K3 direction relay
K2 pole-changing relay
~~
1.13.1
20
1U 1V 1W 2U 2V 2W
In the case of a power failure, the intelligent contactor control (ISS) additionally ensures that K1 always drops first.
Contactor K1 is an AC contactor. However, the print relays are DC relays with a
large amount of accumulated magnetic
residual energy and a small moved mass.
In addition, a buffer voltage from a buffer
capacitor prevents the relays from dropping for a defined period of time.
1.29
1.32
1.30
4
5
6
7
1.31
1 Battery capacity
2 Crane number
3 Radio link
4 Maintenance symbol
5 Overload warning
6 Load display for ZMS application
7 Bar display for load
8 Trolley selection
Other symbols
Initialisation
Error with number
Warning with number
1.33
21
Parallel transmission
Groups of bits are transmitted on parallel channels
Wireless transmission
via radio
Data
Additional inputs
Hoist and trolley
FI trolley
Trolley
motor
HW1 or HW2
Bus
Hoist
motor
No-load switching
Power
Assignment of the
parallel inputs see
annex
Parallel
wiring
Crane
motor
Conventional crane
electrical equipment
Power
22
1.34
1
2
1.35
3
4
1
3 4
1.36
2
1
2
3
4
5
1.37
1
1.38
Parallel Out
Parallel In
1 Cicuit breaker
2 Terminal strip
3 Transformer
1.39
2 1
23
1.40
1.43
1.42
External
heat sinks and
braking resistors
24
1.44
Hoist inverter
The EKDR hoist inverter is accommodated
in a separate enclosure with possible connection to the hoist motor. The Dedrive
Compact is used as hoist inverter. The
functions that underline the particular suitability of the inverters as hoist inverters do
not only include the outstanding control
characteristics, but also the ProHub or performance optimisation and load spectrum
recorder functions. This makes it possible
to operate the motor in field-weakening mode with a partial load. Integrated
torque calculation enables the motor to be
operated safely close to the output limit
with a partial load, without subjecting the
motor to overload. This function is mainly
used for hoist drives and makes it possible
to reduce handling cycle times.
1.45
Distributor box
1
2
3
2
2
3
1.46
1.46
25
1.47
Standard wiring
1.47
1.47
1.47
1.47
26
Notes
27
Notes
28
Notes
29
1
1
2
3
4
1.48
Derailment protection
Top block
DRS Wheel block system
Thrust rocker
30
1.49
1
1.50
31
DR Pro
DR Com
Features
Reeving
4/1
2m+ (1900 h)
1 Am (800 h)
3,2 / 4 / 5 / 6,3 / 8 / 10 t
FEM group
Load capacity
Hoist speed
Pole-changing:
DR3 / DR5: v0: 4,5/0,8 m/min
DR10: v0: 4/0,7 m/min
5 - 30 m/min
5 - 20 m/min
6 / 10 m
6 / 10 m
-10 C - +45 C
-10 C - +45 C
Type of enclosure
IP55
IP55
Control pendant
Cross-travel speed
Lifting height
Temperature range
Type of control
Safety function
32
Pole-changing:
DR3 / DR5: v1: 6/1 m/min
v2: 9/1,5 m/min
Frequency-controlled:
DR3 / DR5: v3: -12,5 m/min
DR10: v2: -9 m/min
v3: -12,5 m/min
1
2
3
4
5
1.51
10
11
9
4
4
3
8
6
7
5
33