Electrical accessories

for Demag DC chain hoists

Technical data – Assembly – Application notes

This document must always be used together with our DC chain hoist operating instructions

040906 EN/PDF 203 656 44 714 IS 942

 Manufacturer Demag Cranes & Components GmbH
P.O. Box 67, D-58286 Wetter
Telephone +49 (0) 2335 92-0 · Telefax +49 (0) 2335 927676
www.demagcranes.com

Accompanying documents Technical data

Demag DC-Pro 1 to DC-Pro 20 chain hoists
Demag DCS-Pro 1 to DCS-Pro 5 chain hoists 203 525 44 714 IS 817
Demag DC-Com 1 to DC-Com 20 chain hoists 203 571 44 714 IS 817
CF5 Technical data – Assembly – Spare parts 203 568 44 714 IS 845
U11/U22/U34 Technical data – Assembly – Spare parts 203 569 44 714 IS 845
Clamp-fitted buffers 203 313 44 714 IS 888

Operating instructions - Assembly - Adjustment - Dimensions

DSE-C assembly instructions 214 785 44 720 IS 951
Demag DC-Pro 1 to DC-Pro 20 chain hoists 214 741 44 720 IS 817
Demag DCS-Pro 1 to DCS-Pro 5 chain hoists 214 827 44 720 IS 817
Demag DC-Com 1 to DC-Com 20 chain hoists 214 802 44 720 IS 817
E11/E22/E34 trolley operating instructions 214 810 44 720 IS 845

Test and inspection booklet 214 745 44 720 IS 817

Certificates 235 309 44

Contents 0 Foreword 3

1 Safety instructions 3

2 Installation diagrams 4

3 Electrical enclosures 10
3.1 3TK signal converter 10
3.2 KT3 signal converter 13
3.3 DT3 signal converter 16
3.4 DC Polu-Box 18
3.5 DC terminal box 20
3.6 3T3 terminal box 21
3.7 Manual crab terminal box 22
3.8 DC terminal box 2 23
3.9 Diode terminal box 26
3.10 KRBG crane bridge enclosure 28
3.11 KRBG2 crane bridge enclosure with DC Polu-Box 29

4 Accessories 30
20365644.indd/040906

4.1 Mounting arrangements 30

4.2 Mobile control system 31

2
 0 Foreword

The electrical equipment serves to convert signals between DC chain hoists with
Tri-State signal transmission and crane systems that are fitted with conventional
electrical contactor interfaces. Furthermore, the terminal boxes are described
which are required when differing conductor cross-sections are connected and for
parallel operation of chain hoists. The DC Polu-Box is used as a contactor control
arrangement for AC drives (for example for slewing cranes with a slewing drive).

The signal converter, terminal box and DC Polu-Box can be fitted to the DC chain
hoist motor. It may be necessary to fit them in a different position depending on
any other equipment (Harting connector in the power supply line, for example).

Depending on the application, crane bridge enclosures must be selected with

EU 11/22/34 trolleys and installations with AC motors for the travel drive.

All sub-assemblies are described in detail and provided with connection diagrams
for application examples in the relevant sections.

1 Safety instructions

This document must always be used together with our DC chain hoist operating
instructions.
20365644.indd/040906

We assume no liability for any damage to machinery or personal injury resulting

from failure to comply with the operating instructions and the safety information
contained in them.

3
 2 Installation diagrams

DK5 to DK20 with contactor control, mobile control pendant

42 - 115 V control voltage, see section 3.2 for description and wiring example
230 V control voltage, see section 3.3 for description and wiring example

Replacement of the travelling hoist

Old
Long-travel motor 1 Long-travel motor 2

Crane enclosure,
DK 5-20 Cross-travel also incl. transformer
motor and contactor

Line and signal

Line

New
Long-travel motor 1 Long-travel motor 2

 Crane enclosure,
DC E11, E22, E34 also incl. transformer
trolley and contactor

 Line and signal
 

Line

42691944.jpg

Old Item Designation Part no. Function

1 Connection cable 720 072 45 Line cable
20365644.indd/040906

New 2 Control cable 10-pole 1,5m 720 070 45 Travel unit cable
3 Control cable 10-pole 1,5m 772 062 45 Plug connection, to DC chain hoist -X31
4 Round cable YMHYK-J 4x1,5 504 931 44 to the trolley
KT3 box 772 077 45 42 - 115 V control voltage
5 Signal converter
4 DT3 box 772 066 45 230 V control voltage
 DK5 to DK20 with contactor control, mobile control pendant, pole-changing travelling hoist
42 - 115 V control voltage, see section 3.2, 3.4 for description and wiring example
230 V control voltage, see section 3.3, 3.4 for description and wiring example

Replacement of the hoist (travel drive is kept)

Old
Long-travel motor 1 Long-travel motor 2

DK 5-20 Crane enclosure,

Cross-travel also incl. transformer
motor and contactor

Line and signal

Line

New
Long-travel motor 1 Long-travel motor 2

Crane enclo-
  sure, also incl.
DC DC Polu-Box transformer and
contactor
 Cross-travel motor
 with trolley

Line and signal

 

Line

42692044.jpg
Old Item Designation Part no. Function
1 Connection cable 720 072 45 Line cable
New 2 Control cable 10-pole 1,5m 720 070 45 Travel unit cable
20365644.indd/040906

3 Control cable 10-pole 1,5m 772 062 45 Plug connection, to DC chain hoist -X31
4 Round cable YMHYK-J 4x1,5 504 931 44 to the trolley DC Polu-Box
KT3 box 772 077 45 42 - 115 V control voltage
5 Signal converter
DT3 box 772 066 45 230 V control voltage
6 Housing DC Polu-Box 720 080 45 5
 DK5 to DK20 with contactor control, control pendant on the chain hoist
42 - 230 V control voltage, see section 3.1 for description and wiring example

Replacement of the travelling hoist

Old
Long-travel motor 1 Long-travel motor 2

Crane enclosure,
DK 5-20 Cross-travel also incl. transformer
motor and contactor

Line and signal

Line

New
Long-travel motor 1 Long-travel motor 2

 Crane enclosure,
DC E11, E22, E34 also incl. transformer
trolley and contactor


Line and signal
 3TK
42-230 V

Line

DSE 8-C
height adjustable

42692144.jpg
20365644.indd/040906

Old Item Designation Part no. Function

1 Connection cable 720 072 45 Line cable
New 2 Control cable 10-pole 1,5m 720 070 45 Travel unit cable
3 Round cable YMHYK-J 12x1,5 504 945 44 to the E22 trolley -X11
6 4 Signal converter 3TK box 772 076 45 42 - 230 V control voltage
 DK5 to DK20 with contactor control, control pendant on the chain hoist, pole-changing travelling hoist
42 - 230 V control voltage, see section 3.1 for description and wiring example

Replacement of the hoist (travel drive is kept)

Old
Long-travel motor 1 Long-travel motor 2

Crane enclosure,
Cross-travel also incl. transformer
DK 5-20
motor and contactor

Line and signal

Line

New
Long-travel motor 1 Long-travel motor 2

Crane enclo-
 sure, also incl.

DC DC Polu-Box transformer and
contactor
 Cross-travel motor
 with trolley
Line and signal
 3TK
42-230 V

Line

DSE 8-C
height adjustable

42693744.jpg

Old Item Designation Part no. Function

20365644.indd/040906

1 Connection cable 720 072 45 Line cable

New 2 Control cable 10-pole 1,5m 720 070 45 Travel unit cable
3 Round cable YMHYK-J 12x1,5 504 945 44 to the trolley DC Polu-Box
4 Signal converter 3TK box 772 076 45 42 - 230 V control voltage
6 Housing DC Polu-Box 720 080 45 7
 2 chain hoists parallel

2 DC chain hoists parallel with monorail trolley

DC 1 DC 2

   

 Line and signal

 4-pole line
 DC terminal  DC terminal
box  box

Round cable for fixed cabling and Signal

wiring arrangement 

DST 3-C DP2



Item Designation Part no. Function

1 Control cable 10-pole 1,5m 772 073 45
2 Power cable 4-pole 1,5m 772 068 45 included in the terminal box
3 Terminal box DC 772 067 45
5 Mounting plate for strain relief 716 354 45
6 8G1,5 flat cable W07VVH6-H 504 226 44 Line and signal
7 8x1,5 round cable YMHYK-O2TY 792 578 44 to the control pendant
8 Control pendant on request

2 DC chain hoists parallel with travel drive

 
E11, E22, E34 E11, E22, E34
DC 1 DC 2
trolley trolley
 

   
DC terminal
Line and signal ○
11
 DC terminal
 box  box
4-pole line

Signal


DST 6-C DP2


42717644.jpg

Item Designation Part no. Function

1 Control cable 10-pole 1,5m 772 073 45
2 Power cable 4-pole 1,5m 772 068 45
3 Terminal box DC 772 067 45
4 Mounting set 716 540 45
5 Mounting plate for strain relief 716 354 45
6 13G1,5 flat cable MDF05VVH6H 895 171 44 Line and signal
20365644.indd/040906

7 12x1,5 round cable YMHYK-O2TY 792 579 44 to the control pendant

8 Control pendant on request with selector switch and diodes
9 Connection cable 720 072 45 Line cable
10 Control cable 10-pole 1,5m 720 070 45 Travel unit cable
8 11 Terminal box on request
20365644.indd/040906

9
 3 Electrical enclosures

3.1 3TK signal converter

3TK → 3-state To Conventional

1 4

2 6

3 5

1 -X2 terminal strip, PE 42692344.jpg

2 -X6 terminal strip, control signals → travelling hoist
3 -X5 terminal strip, control signals → crane
4 -X1 terminal strip, main current from crane → travelling hoist
5 -X3 terminal strip, reference voltage
6 Transformer

Description Is used for converting “tri-state” signals into floating contacts. Includes the For-
ward, Reverse, Fast, Right, Left, Fast, Special signal_1, Special signal_2, Emer-
gency-stop (safety relay) contacts. Transformer for control voltage connection: 42
V, 48 V, 115 V, 230 V. Wiring via RJ45 sockets and cage clamp terminals.

Application Use: For replacing DK and existing contactor control, control pendant on DC.

Technical data Part no.: 772 076 45

Type: 3TK signal converter
Material: ABS H 95 G
Finish: RAL 7035
Enclosure (EN 60529): IP 66
Weight: 0,8 kg
Dimensions: 170 mm x 140 mm x 95 mm (WxHxD)
Mounting: 4 x M4
Ambient temperature: -40 to +60 °C
Chemical properties: Halogen-free
Flammability classification (UL 746 C 5): UL 94 HB

Scope of delivery Size of signal converter in the terminal box

Cable unions 2x M20 twist-type cable entry gland
2x M25 twist-type cable entry gland
1x flat M25 twist-type cable entry gland
20365644.indd/040906

2x M20 cable entry gland

10
 DK5 to DK20 Wiring example for 115 V control voltage, control pendant on the chain hoist,
with contactor control system replacement of the travelling hoist

Emergency stop
Control voltage

Back
Fast
Forwards

Reference
(115 V)

 

E11, E22, E34

trolley

42693144.jpg

Item Designation Part no. Function

3 Round cable YMHYK-J 12x1,5 504 945 44 to the E22 trolley -X11
4 Signal converter 3TK box 772 076 45 42 - 230 V control voltage
7 Cable By customer Flat cable from the crane enclosure
20365644.indd/040906

11
 DK5 to DK20 Wiring example for 42 - 230 V control voltage, control pendant on the chain hoist,
with contactor control system pole-changing travelling hoist, replacement of the hoist (travel drive is kept)

Emergency stop
Control voltage

Back
Fast
Forwards

Reference
(115 V)

 

Trolley with
DC-Polu

42693144.jpg

Item Designation Part no. Function

3 Round cable YMHYK-J 12x1,5 504 945 44 to the trolley DC Polu-Box
4 Signal converter 3TK box 772 076 45 42 - 230 V control voltage
7 Cable By customer Flat cable from the crane enclosure
20365644.indd/040906

12
 3.2 KT3 signal converter
KT3 → Conventional To 3-state

1
4

1 -X2 terminal strip, 42 / 48 V signals 42692444.jpg

2 -X4 terminal strip, main current from crane → travelling hoist
3 -X3 plug connection, to DC chain hoist -X31
4 -X1 terminal strip, 110 / 115 V signals

Description Is used for converting control pendant contacts into tri-state signals. Creates float-
ing Lift, Lower, Right (forwards), Left (reverse) tri-state signals. Permissible volt-
ages: 42, 48, 110 and 115 V. Wiring via RJ45 sockets and cage clamp terminals.

Application Use: For replacing DK and existing contactor control, travelling control pen-
dant.

Technical data Part no.: 772 077 45

Type: KT3 signal converter
Material: ABS H 95 G
Finish: RAL 7035
Enclosure (EN 60529): IP 66
Weight: 0,8 kg
Dimensions: 170 mm x 140 mm x 95 mm (WxHxD)
Mounting: 4 x M4
Ambient temperature: -40 to +60 °C
Chemical properties: Halogen-free
Flammability classification (UL 746 C 5): UL 94 HB

Scope of delivery Size of signal converter in the terminal box

Cable unions 2x M20 twist-type cable entry gland
2x M25 twist-type cable entry gland
1x flat M25 twist-type cable entry gland
20365644.indd/040906

3x M20 cable entry gland

1x M25 cable entry gland

13
 DK5 to DK20 Wiring example for 42 / 48 V control voltage, mobile control pendant,
with contactor control system replacement of the travelling hoist

42 / 48 V signals

110 / 115 V signals

Lifting
Lowering
Fast
Right
Left
Fast

Reference (42-48 V)

   
42693244.jpg

Item Designation Part no. Function

3 Control cable 10p 1,5 772 062 45 Plug connection, to DC chain hoist -X31
4 Round cable YMHYK-J 4x1,5 504 931 44 to the E22 trolley -X11
5 Signal converter KT3 box 772 077 45
6 Control cable Flat cable from the crane enclosure
By customer
7 Main power line Flat cable from the crane enclosure

DK5 to DK20 Wiring example for 110 / 115 V control voltage, mobile control pendant,
with contactor control system replacement of the travelling hoist
42 / 48 V signals

110 / 115 V signals


Reference (42-115 V)

Fast
Left
Right
Fast
Lowering
Lifting

   
42693344.jpg

Item Designation Part no. Function

3 Control cable 10p 1,5 772 062 45 Plug connection, to DC chain hoist -X31
4 Round cable YMHYK-J 4x1,5 504 931 44 to the E22 trolley -X11
5 Signal converter KT3 box 772 077 45
6 Control cable Flat cable from the crane enclosure
By customer
7 Main power line Flat cable from the crane enclosure
20365644.indd/040906

14
 DK5 to DK20 Wiring example for 42 / 48 V control voltage, mobile control pendant,
with contactor control system pole-changing travelling hoist, replacement of the hoist (travel drive is kept)

42 / 48 V signals

110 / 115 V signals

Lifting
Lowering
Fast
Right
Left
Fast

Reference (42-115 V)

   

42693544.jpg

Item Designation Part no. Function

3 Control cable 10p 1,5 772 062 45 Plug connection, to DC chain hoist -X31
4 Round cable YMHYK-J 4x1,5 504 931 44 to the trolley DC Polu-Box
5 Signal converter KT3 box 772 077 45
6 Control cable Flat cable from the crane enclosure
By customer
7 Main power line Flat cable from the crane enclosure

DK5 to DK20 Wiring example for 110 / 115 V control voltage, mobile control pendant,
with contactor control system pole-changing travelling hoist, replacement of the hoist (travel drive is kept)
42 / 48 V signals

110 / 115 V signals

 Reference (42-115 V)

Fast
Left
Right
Fast
Lowering
Lifting

   

42693644.jpg

Item Designation Part no. Function

3 Control cable 10p 1,5 772 062 45 Plug connection, to DC chain hoist -X31
20365644.indd/040906

4 Round cable YMHYK-J 4x1,5 504 931 44 to the trolley DC Polu-Box

5 Signal converter KT3 box 772 077 45
6 Control cable Flat cable from the crane enclosure
By customer
7 Main power line Flat cable from the crane enclosure
15
 3.3 DT3 signal converter
DT3 → Direct To 3-state

1
4

1 -X2 terminal strip, 230 V signals 42692544.jpg

2 -X4 terminal strip, main current from crane → travelling hoist
3 -X3 plug connection, to DC chain hoist -X31
4 -X1 terminal strip, 400 V signals

Description Is used for converting control pendant contacts into tri-state signals. Creates float-
ing Lift, Lower, Right (forwards), Left (reverse) tri-state signals. Permissible volt-
age: 230 V. Wiring via RJ45 socket and cage clamp terminals.

Application Use: For replacing DK and existing contactor control.

Technical data Part no.: 772 066 45

Type: DT3 signal converter
Material: ABS H 95 G
Finish: RAL 7035
Enclosure (EN 60529): IP 66
Weight: 0,8 kg
Dimensions: 170 mm x 140 mm x 95 mm (WxHxD)
Mounting: 4 x M4
Ambient temperature: -40 to +60 °C
Chemical properties: Halogen-free
Flammability classification (UL 746 C 5): UL 94 HB

Size of signal converter in the terminal box

Scope of delivery Cable unions 2x M20 twist-type cable entry gland
2x M25 twist-type cable entry gland
1x flat M25 twist-type cable entry gland
20365644.indd/040906

3x M20 cable entry gland

1x M25 cable entry gland

16
 DK5 to DK20 Wiring example for 230 V control voltage, mobile control pendant,
with contactor control system replacement of the travelling hoist

230 V signals

400 V signals
Lifting
Lowering
Fast
Right
Left
Fast

Reference (230 V)

   
42693244.jpg

Item Designation Part no. Function

3 Control cable 10p 1,5 772 062 45 Plug connection, to DC chain hoist -X31
4 Round cable YMHYK-J 4x1,5 504 931 44 to the E22 trolley -X11
5 Signal converter DT3 box 772 066 45
6 Control cable Flat cable from the crane enclosure
By customer
7 Main power line Flat cable from the crane enclosure

DK5 to DK20 Wiring example for 230 V control voltage, mobile control pendant,
with contactor control system pole-changing travelling hoist, replacement of the hoist (travel drive is kept)


230 V signals

400 V signals

Lifting
Lowering
Fast
Right
Left
Fast

Reference (230 V)

   

42693544.jpg

Item Designation Part no. Function

3 Control cable 10p 1,5 772 062 45 Plug connection, to DC chain hoist -X31
20365644.indd/040906

4 Round cable YMHYK-J 4x1,5 504 931 44 to the trolley DC Polu-Box

5 Signal converter DT3 box 772 066 45
6 Control cable Flat cable from the crane enclosure
By customer
7 Main power line Flat cable from the crane enclosure
17
 3.4 DC Polu-Box

3 6

7
1

2
9

4
8

10

42692644.jpg

1 -X1 plug-in connection 6 -X9 terminal strip

2 -X10 terminal strip 7 -X7 plug-in connection
3 -X3 terminal strip 8 -X12 plug-in connection
4 Transformer 9 -X6 plug-in connection
5 -X4 terminal strip 10 -X8 plug-in connection

Description Intelligent contactor control for DC systems with Tri-state control signals. Connec-
tion for power distribution, limit and fast-to-slow switches, pole-changing motor and
control signals to the chain hoist via RJ45 plug connection. The power supply can
be adjusted by ± 10% between 230 V and 575 V.

Application Use: Travel applications with squirrel-cage rotor motors, e.g. DRF 200
(Max. connection rating 1,5 kW; max. rated current 3,0 A).

Technical data Part no.: 720 080 45

Type: DC Polu-Box
Material: ABS H 95 G
Finish: RAL 7035
Enclosure (EN 60529): IP 66
Weight: 0,8 kg
Dimensions: 170 mm x 140 mm x 95 mm (WxHxD)
Mounting: 4 x M4
Ambient temperature: -40 to +60 °C
Chemical properties: Halogen-free
Flammability classification (UL 746 C 5): UL 94 HB

Scope of delivery Size of DC Polu-Box

20365644.indd/040906

18
 Terminal No. Signal Terminal No. Signal
1 L3 1 Reference (24 V~)
2 L3 2 24 V~
3 L2 Control penadant input 3 Var. switches
-X7 signals via single con-
Power supply connec- 4 L2 ductors 4 Emergency stop
-X1
tion and routing 5 L1 5 Forwards
6 L1 6 Back
7 PE 1 Reference (24 V~)
8 PE Control pendant signals 2 Emergency stop
-X8
1 PE to the crane 3 Forwards
2 U1/U2 4 Back
3 V1 1 Fast-to-slow RIGHT -
-X3 Motor connection 4 W1 2 Fast-to-slow RIGHT +
5 V2 3 Lim. sw. RIGHT -
6 W2 4 Lim. sw. RIGHT +
-X9 Limit switch connection
7 Brake 5 Fast-to-slow LEFT -
1 Sensor + 6 Fast-to-slow LEFT +
-X4 Thermo contact
2 Sensor - 7 Lim. sw. LEFT -
-X5 Earth connection PE Flat pin 8 Lim. sw. LEFT +
1 Special 1 1 575V
2 Forwards 2 460V
Input voltage range
3 Back -X10 3 400V ±15%
setting
4 Emergency stop 4 230V

Input Control pendant 5 Var. switches 5 Reference

-X6
signals via RJ45 6 Hoist (24 V~) 1 Special 1
-X12 Special functions
7 Reference (24 V~) 2 Special 2
8 Right
9 Left
10 Special 2

The terminals marked in grey are fitted with wire bridges when they leave the fac-
tory.

The wire bridge for the input voltage range -X10 muss must be assigned to the
available voltage, e.g. for 400V the bridge must be fitted from X10.5 to X10.3.

If the Polu-Box is used on a solo travelling hoist, a bridge must be fitted betwen
X7.2 and X7.3.
20365644.indd/040906

19
 3.5 DC terminal box

1 Terminal strip 42692744.jpg

Description Terminal strip with cage clamp terminals for power and control signals.

Application Use: e.g. connecting larger conductor cross-sections with smaller conductor
cross-sections (flat cable to RJ45 cable).
Power distribution, signal distribution

Technical data Part no.: 772 067 45

Type: DC terminal box
Material: ABS H 95 G
Finish: RAL 7035
Enclosure (EN 60529): IP 66
Weight: 0,8 kg
Dimensions: 170 mm x 140 mm x 95 mm (WxHxD)
Mounting: 4 x M4
Ambient temperature: -40 to +60 °C
Chemical properties: Halogen-free
Flammability classification (UL 746 C 5): UL 94 HB

Scope of delivery Terminal strip in the terminal box

Cable unions 2x M20 twist-type cable entry gland
2x M25 twist-type cable entry gland
1x flat M25 twist-type cable entry gland
20365644.indd/040906

2x M20 cable entry gland

2x M25 cable entry gland

20
 3.6 3T3 terminal box

1 Terminal strip 42692844.jpg

Description Terminal strip with cage clamp terminals for power and control signals.

Application Use: e.g. connecting larger conductor cross-sections with smaller conductor
cross-sections (flat cable to RJ45 cable).
Power distribution

Technical data Part no.: 772 074 45

Type: 3T3 terminal box
Material: ABS H 95 G
Finish: RAL 7035
Enclosure (EN 60529): IP 66
Weight: 0,8 kg
Dimensions: 170 mm x 140 mm x 95 mm (WxHxD)
Mounting: 4 x M4
Ambient temperature: -40 to +60 °C
Chemical properties: Halogen-free
Flammability classification (UL 746 C 5): UL 94 HB

Scope of delivery Terminal strip in the terminal box

Control cable 10-pole 1,5 m
Cable unions 2x M20 twist-type cable entry gland
3x M25 twist-type cable entry gland
20365644.indd/040906

1x flat M25 twist-type cable entry gland

2x M20 cable entry gland
2x M25 cable entry gland

21
 3.7 Manual crab
terminal box

1 Terminal strip 42692944.jpg

Description Terminal strip with cage clamp terminals for power and control signals.

Application Use: e.g. connecting larger conductor cross-sections with smaller conductor
cross-sections (2 x busbar line connection or flat cable to RJ45 cable).

Technical data Part no.: 772 075 45

Type: Manual crab terminal box
Material: ABS H 95 G
Finish: RAL 7035
Enclosure (EN 60529): IP 66
Weight: 0,8 kg
Dimensions: 170 mm x 140 mm x 95 mm (WxHxD)
Mounting: 4 x M4
Ambient temperature: -40 to +60 °C
Chemical properties: Halogen-free
Flammability classification (UL 746 C 5): UL 94 HB

Scope of delivery Terminal strip in the terminal box

Power cable 4-pole 1,5 m
Control cable 10-pole 1,5 m
Cable unions 2x M20 twist-type cable entry gland
3x M25 twist-type cable entry gland
20365644.indd/040906

1x flat M25 twist-type cable entry gland

2x M20 cable entry gland
2x M25 cable entry gland

22
 3.8 DC terminal box 2

1 Terminal strip 42693044.jpg

Description Terminal strip with cage clamp terminals for power and control signals.

Application Use: Control pendant signals shared to two parallel chain hoists.

Technical data Part no.: 772 080 45

Type: DC terminal box 2
Material: ABS H 95 G
Finish: RAL 7035
Enclosure (EN 60529): IP 66
Weight: 0,8 kg
Dimensions: 170 mm x 140 mm x 95 mm (WxHxD)
Mounting: 4 x M4
Ambient temperature: -40 to +60 °C
Chemical properties: Halogen-free
Flammability classification (UL 746 C 5): UL 94 HB

Scope of delivery Terminal strip in the terminal box

Power cable 4-pole 1,5 m
Control cable 10-pole 1,5 m
Cable unions 2x M20 twist-type cable entry gland
3x M25 twist-type cable entry gland
1x flat M25 twist-type cable entry gland
20365644.indd/040906

2x M20 cable entry gland

2x M25 cable entry gland

23
 2 DC chain hoists parallel with monorail trolley

Chain hoist 2 Chain hoist 1

Line
Emergency
stop 1

Lowering 2
Lowering 1

Lifting 2
Lifting 1

V2

V2
V2

V2

42717745.jpg

2 DC chain hoists parallel with travel drive

Chain hoist 2 Chain hoist 1

E11, E22, E11, E22,

E34 crab E34 crab

Line
Emergency
stop 1
Selector
switch

20365644.indd/040906
Lowering 2
Lowering 1

Lifting 2
Lifting 1

Right 1

Right 2
Left 1

Left 2
V2

V2

V2

V2
V2

V2

V2

V2

24 42717744.jpg
 Brief description of If 2 chain hoists are operated in parallel, hoist unit parameters 1 and 4 must be set
DC parameter programming to “y”.
(Issue 08/01/2004)

Starting parameter setting mode

• Actuate “Emergency stop”;
• Press and hold down the “Lifting V2” key;
• Release “Emergency stop”;
• Wait for approx. 10 seconds until a “P” is shown in the display;
• Release the “Lifting V2” key before the display goes out after approx. 2 sec-
onds;
• If the display has gone out, press and hold down the “Lifting V2” key again;
• Wait until an “o” for “OK” is displayed.

Setting the parameters

Meaning of the keys:
“Lifting V2” - Yes or On
“Lowering V2” - No or Off
“Emergency stop” - End parameter programming (changes are saved)

When parameter programming mode has been activated, the figures “0” – “9” are
each displayed successively for 4 seconds. Each figure represents a parameter.
The parameter is switched on with the “Lifting v2” key and switched off with the
“Lowering V2” key. The selected action is acknowledged with “Y” for “Yes or On”
or with an “N” for “No or Off”. In no key is actuated, the parameter remains un-
changed. If the parameter has sub-parameters, an “O” for “Open” is displayed. The
parameters are displayed with the characters “A”, “b”, “C”, “d”, “E” and “F”. Selec-
tion is also made with the “Lifting V2” or “Lowering V2” keys.
When the last parameter has been reached or when the “Emergency stop” key has
been actuated, the unit switches back to normal operation. All changes are first
saved.

Meaning of the parameters

1 - 3-phase electronic braking
No → 2-phase electronic braking (standard)
Yes → 3-phase electronic braking
4 - Time-controlled start-up (from software version 1.10)
No → Speed-dependent start-up (standard)
Yes → Time-controlled start-up
20365644.indd/040906

25
 3.9 Diode terminal box

1 2

1 Terminal strip 42711044.jpg

2 Diodes

Description Terminal strip with cage clamp terminals for power and control signals.

Application Use: Converting parallel contacts into tri-state signals.

Technical data Part no.: 772 065 45

Type: DC terminal box 2
Material: ABS H 95 G
Finish: RAL 7035
Enclosure (EN 60529): IP 66
Weight: 0,8 kg
Dimensions: 170 mm x 140 mm x 95 mm (WxHxD)
Mounting: 4 x M4
Ambient temperature: -40 to +60 °C
Chemical properties: Halogen-free
Flammability classification (UL 746 C 5): UL 94 HB

Scope of delivery Terminal strip in the terminal box

Power cable 4-pole 1,5 m
Control cable 10-pole 1,5 m
Cable unions 2x M20 twist-type cable entry gland
3x M25 twist-type cable entry gland
1x flat M25 twist-type cable entry gland
20365644.indd/040906

2x M20 cable entry gland

2x M25 cable entry gland

26
 Terminal box with diode for hoist Wiring example
and trolley

By customer

Emergency stop

Lowering
Lifting

Right
Fast

Fast
Left
Supply cable

 

Emergency stop
Lowering
24 V AC
Lifting

Right
Left


1) Wire bridge
 
2) May consist of one cable
to the DC

42711144.jpg

Item Designation Part no. Function

3 Control cable 10p 1,5 772 073 45 to the DC chain hoist -X31
4 Power cable 4x1,5 772 068 45 to the E22 trolley -X11
5 Signal converter DC/diode 772 065 45
6 Control cable By customer Flat cable from the control system
20365644.indd/040906

27
 3.10 KRBG crane bridge
enclosure

1 2 3

1 -X1 terminal strip

2 Crane switch contactor
3 Control transformer 42717444.jpg

Description Is used to provide power supply for crane installations with DC systems (tri-state
signals) with crane switch contactor. Connection for power and signal distribution
to DC travel drives.

Application Use: Crane applications, e.g. KBK crane, pillar-mounted slewing jibs with DC
travel drives.

Technical data Part no.: 772 078 45

Standard voltage: 380 - 415 V / 50 Hz
Finish: RAL 5009
Weight: 4,1 kg
Dimensions: 232 mm x 212 mm x 137 mm (WxHxD)
Circuit diagram: 631 005 46

Scope of delivery - Housing, terminal strip

- 24 V control transformer
- Crane switch contactor

-X1 terminal strip Line connection and routing

No. Signal No. Signal
L1 L3 4 Enable
L2 L2 5 Forwards
L3 L3 6 Back
PE PE 7 Var. switches
1 L1 8 Emergency stop
2 L2 9 Reference (24 V~)
20365644.indd/040906

3 L3 10 Right
PE PE 11 Left
12 Lifting
13 Lowering

28
 3.11 KRBG2 crane bridge
enclosure with DC
Polu-Box
1

1 -X1 terminal strip 3 Crane switch contactor

2 DC Polu-Box 4 Control transformer 42717544.jpg

Description Is used to provide power supply for crane installations with contactor control for DC
systems with tri-state control signals, crane switch contactor.
Connection for power distribution, limit and fast-to-slow switches, pole-changing
motor and control signals to the chain hoist via RJ45 plug connection.

Application Use: Crane applications, e.g. KBK crane, pillar-mounted slewing jibs with
squirrel-cage rotor motors.

Technical data Part no.: 772 178 45

Standard voltage: 380 - 415 V / 50 Hz
Finish: RAL 5009
Weight: 8,2 kg
Dimensions: 400 mm x 300 mm x 155 mm (WxHxD)
Circuit diagram: 631 056 46

Scope of delivery - Housing, terminal strip, plug-and-socket connections

- 24 V control transformer
- Crane switch contactor
- DC Polu-Box control (part no.: 720 080 45)

-X1 terminal strip Line connection and routing

No. Signal No. Signal
L1 L3 4 Enable
L2 L2 5 Forwards
L3 L3 6 Back
PE PE 7 Var. switches
1 L1 8 Emergency stop
2 L2 9 Reference (24 V~)
20365644.indd/040906

3 L3 10 Right
PE PE 11 Left
12 Lifting
13 Lowering
14 Reference (24 V~) 29
 4 Accessories

4.1 Mounting arrangements

42717844.jpg

42718044.jpg
Size Motor l2 l3 h5
DC 1/2 ZNK 71 B 8/2 170 50
DC 5 ZNK 80 A 8/2 175
20365644.indd/040906

ZNK 100 A 8/2 183

DC 10
ZNK 100 B 8/2 149 60
60
Designation Part no. Weight ZNK 100 B 8/2
DC 16
[kg] 177
ZNK 100 C 8/2
30 Phönix mounting plate 716 354 45 0,5 42717944.jpg DC 25
 4.2 Mobile control system

1
1
5 2
2
3
3

1 Connector enclosure
2 Plug adapter
3 Cable collector
4 Control pendant
5 Flat cable

42711244.jpg 42360744.jpg

Plug connection pin assignments Component parts

Con- Item Designation Comprising Part no.
Pin Signal
ductor Socket housing
A1 Forwards 1
Mounting frame
A2 Emergency stop 2 1 Connector enclosure cpl. 720 187 45
VC-AMS8 pin insert
A3 Lifting 3
Flat union
A4 Left 4
Bayonet connector
A5 Special 1 (F1/F2) 5
VC-MP-1-R-M25 bush enclosure
A6 Back 6 2 Plug adapter cpl. 720 087 45
VC-TR1/2M bush frame
A7 - -
VC-TFS8 socket insert
A8 Lowering 7
3 Cable collector 720 065 45
B1 Special 2 (horn) 8
4 DSE-C control pendant
B2 - -
5 11-pole flat cable + PE 720 139 45
B3 PE PE
B4 Control voltage (24 V, STS) 9
B5 Right 10
B6 - -
B7 - -
B8 Reference control voltage 11
20365644.indd/040906

31
 Printed in Germany PDF 040906

Demag Cranes & Components GmbH

P.O. Box 67 · D-58286 Wetter
Telephone +49 (0) 233592-0 · Telefax +49 (0) 2335 927676
www.demagcranes.com

Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Subject to change. No liability accepted for errors or omissions.