Puente Grua

Customer: AGGREKO INTERNATIONAL PROJECTS
P.O. # : NHB-00052
Order # : 502262
Crane After Sale Manual

ZKKE CRANE SERVICE MANUAL
Date: April 25, 2013 Initials: TD & JC
Customer: User:
AGGREKO INTERNATIONAL PROJECTS AGGREKO INTERNATIONAL PROJECTS
CENTER SUR LOTE 9124 CENTER SUR LOTE 9124
CIUDAD DE PANAMA, TX. CIUDAD DE PANAMA, TX.
Job Number 502262 Serial Numbers

Capacity 15.00 TON From 13057 To 13058
Span 41' - 11.5" Control Sliding P/B - DSE-10R

Supply Voltage 460/3/60
Bridge Speed 160 VFC FPM Speed Control Infinitely Variable

Endtruck DFW-L-Z 250/4000
Qty 2 Motor ZBA 90B4 B020 Motor Voltage 220/50 Duty 100%
Rated HP 2.1 @ 50Hz Operational HP 3.6 @ 87Hz
Gearbox ADE40 Gear ratio 39.9:1
Trolley Speed 82 VFC FPM Speed Control Infinitely Variable

Trolley Type / Size EZDR / DRS 160
Qty 2 Motor ZBA 80A4 B007 Motor Voltage 220/50 Duty 100%
Rated HP .74 @ 50Hz Operational HP 1.2 @ 80Hz
Gearbox AMK20 Gear ratio 44.1:1
HOIST #1: DR10-16 6/1-13.3 Z-0.7-6

Lift 25 FT 5.120 IN
Lifting Speed 20 VFC FPM
Speed Control Infinitely Variable
Main Motor ZBR132C4
HP, Duty 21.8 60%
Pg. 1
AFTERSALES MANUAL CONTENTS
Job: 502262
SECTION I Mechanical & Electrical Drawings Sheet Demag ID

ZKKE CRANE INSTALLATION DRAWING 01/01 213 621 49
ZKKE & ZLKE INSTALLATION INSTRUCTIONS 01/01 313 012 85
ELECTRICAL DRAWING SET 01-31 384 029 85_01
TROLLEY POWER & CANBUS FESTOON CABLE 01 719 029 45_06
SLIDING P/B CANBUS FESTOON CABLE 01 730 004 45_05
P/B CABLE CAN-DSE (2TY) 01 719 070 45_04
BRIDGE MOTOR CABLE - VFC 1.5mm2 01 730 021 45_07
DR3-10 CRANE CABLE LAYOUT - ONE OR TWO TROLLEYS 01 730 025 45_03
DR PARAMETERS (one set per crane):
Crane # 1 Serial # 13057

502262 - DR-Bridge Idapsy 01-06
502262 - DR-Hoist Idapsy 01-10
502262 - Bridge Inverter Settings 01-09
502262 - Hoist Inverter Settings 01-10
502262 - ZBA80A4 Trolley Inverter 01-08
Crane # 2 Serial # 13058
502262 - DR-Bridge Idapsy 01-06
502262 - DR-Hoist Idapsy 01-10
502262 - Bridge Inverter Settings 01-09
502262 - Hoist Inverter Settings 01-10
502262 - ZBA80A4 Trolley Inverter 01-08
FUSE SHEET 01
CABLE SHEET 01
SECTION II Operating Instructions

OPERATING INSTRUCTIONS OVERHEAD TRAVEL CRANES WITH DR HOISTS 229 324 49
DOUBLE-RAIL TROLLEY, EZDR 5-10 OPERATING INSTRUCTIONS 214 961 44
OPERATING INSTRUCTIONS MOTORS ZNA ZBA ZBF 229 203 49
OFFSET GEARED MOTOR AU-AD-AG-AM 229 200 49
DFW-L-E & DFW-L-Z ENDTRUCKS WITH DRS 229 255 49
DEDRIVE COMPACT MASTER OPERATING INSTRUCTIONS MANUAL 214 716 44
DEDRIVE COMPACT -BRIEF OPERATING INSTRUCTIONS MANUAL 214 708 44
DSE-10 CONTROL PENDENT OPERATING INSTRUCTIONS MANUAL 214 795 44
MGS LOAD DETECTORS –DR_PRO WIRE ROPE HOISTS 211 038 44
SECTION III Component Parts List

RECOMMENDED SPARE PARTS LIST 02
SPARE PARTS LIST ROPE HOIST EZDR10 PRO 217 119 44
ZBA – ZBF – ZNA 80 & 90A PARTS LIST 229 242 49
ZBA – ZBF – ZNA 90B & 100 PARTS LIST 229 244 49
OFFSET GEARBOXES A20 229 211 49
OFFSET GEARBOXES A40 229 213 49
1
DFW-L-E ENDTRUCK 229 248 49
DRS 160 WHEEL BLOCK 229 920 49

TAGLINE KBK 25 930 107 49
SPARE PARTS LIST ROPE HOIST EZDR10 PRO 217 124 44
Job: 502262
SECTION IV Log Book

MANUFACTURER’S WARRANTY 900 069 49
REQUEST FOR WARRANTY / REWORK FORM 900 222 49
CRANE INSPECTION LOG 813 032 50
CRANE INSPECTION SHEETS 813 034 50
CRANE INSTALLATION CHECK OFF SHEETS Per Serial#
2
Section I - Mechanical & Electrical Drawings
DEMAG
Crane Installation Instructions
Standard single girder cranes with EKDR or EUDC trolleys
Standard double girder cranes with EZDR or EZDH trolleys
0509 900 503 49

22 PAGES PAGE 2
Demag Overhead Cranes IDENT NO.
Types: EKKE, EDKE, ZKKE 900 503 49
U.S.A. & CANADA Installation instructions ISSUED MAY, 2009
Installation Instructions
EKKE cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 2 - 8
EDKE cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 9 - 12
ZKKE cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 13 - 17
Please review the detail below which covers the typical items that will be provided
with the Demag crane. The trolley for single girder cranes and many of the double
girder trolleys will be crated. When the hoist/trolley is a type “DRPro” the crate
should include the trolley towing arm, runway power pickup arm, and clamp-on
trolley endstops when supplied, otherwise these items will be packaged sepa-
rately. The girder connection hardware which include; bolts, nuts, and washers are
generally found in a separate box.
EKKE CRANE
BRIDGE MOTOR WIRE

& SUPPORT BRACKET
RUNWAY POWER
PICK-UP ARM
PANEL
SUPPORTS
BRIDGE DRIVE
BRIDGE GIRDER
BRIDGE MOTOR WIRE FESTOON SUPPORTS

& SUPPORT BRACKET
TORQUE ARM
GIRDER CONNECTION
HARDWARE
GIRDER MOUNTING PLATES

( WELDED TO GIRDER ) SLIDING PUSHBUTTON
TROLLEY / HOIST FESTOON SYSTEM
FESTOON SYSTEM
BRIDGE ENDTRUCKS
Supercedes Classification No.

JANUARY 2009 Crane Product Department 714 IS 111
90050349d0509 Reproductions, including partial, only with permission of DEMAG Cranes & Components Corporation
22 PAGES PAGE 3
Toprunning Single Girder Cranes IDENT NO.
Type: EKKE 900 503 49
U.S.A. & CANADA Installation Instructions ISSUED MAY, 2009
1. Refer to the CRANE INSTALLATION DRAWING which indicates the “AS ORDERED” specifications including, crane
weight, trolley type, crane and trolley orientation, girder construction, etc... The CRANE INSTALLATION DRAWING
must be used in conjunction with these instructions.
2. Raise girder, position accordingly, (see Fig. 1, Pg 5,6) and place on stands with sufficient clearance to mount trolley to
underside of girder.
3. Prepare endtrucks: Prior to assembly, remove protective covering on endtruck and girder mounting plates. It is
important to insure that contact surfaces are dry and free of all contaminants.
IF THE CRANE CAN BE ASSEMBLED COMPLETE WITH THE ENDTRUCKS ON THE FLOOR AND LIFTED
ONTO THE RUNWAY, PROCEED TO STEP 4. IF THERE IS INSUFFICIENT CLEARANCE TO ORIENT
THE COMPLETE CRANE BRIDGE, RAISE THE INDIVIDUAL BRIDGE ENDTRUCKS, SECURE TO RUNWAY
COLUMNS, AND PROCEED TO STEP 5.
4. Insert girder mounting bolts in the left endtruck, mount to girder and tighten snugly. Insert girder mounting bolts in right
endtruck, mount to girder and tighten snugly. Always TAKE CARE TO INSURE ENDTRUCK CONNECTION WASH-
ERS ARE SEATED PROPERLY in both the endtruck and girder mounting plates. At this time DO NOT TORQUE
GIRDER MOUNTING BOLTS, this is done in step 13.
5. Mount the trolley on the girder by spreading the trolley wheel gauge sufficiently to clear the crane bridge beam. Check
clearance between the trolley travel wheel flanges and the girder flange. Maximum permissible clearance is 1/8" on
each side. Refer to applicable hoist/trolley operating instructions to secure load bar (see Fig. 2, Pg. 7) properly.
6. Mount the festoon track support brackets to the top of the girder per the spacing shown (see Fig. 1, Pg. 5,6). Refer to
COMPONENT PARTS & INSTALLATION INSTRUCTIONS FOR FESTOON SUPPORTS AND KBK 25 TAGLINE SYS-
TEM Document # 93010749. Mount the festoon track to the brackets with the trolley festoon system on the inside and
the sliding control festoon system on the outside (see fig. 1, Pg. 5,6). Start at the panel side and position the track
sections so that any track splices are no greater away from a support than 15% of the space between hanger
supports. Complete the span using the 16.4' track sections and cut the last piece to fit.
7. Mount the trolley towing arm. Locate trolley at closest end approach on runway power side of
the crane girder. Determine the vertical location of the towing arm and drill holes to mount arm to hoist. Slide trolley
conductor Master Carrier to the closest end approach. Slide the towing arm (if possible) through the Master Carrier.
PROCEED TO STEP 8. If the Master Carrier does not reach the trolley towing arm, a chain must be installed (see Fig.
2, Pg. 7). Slide the trolley towing arm so that it clears the inside of the festoon power cable and mount a towing chain.
Adjust the chain length and cut off excess as required. Open the last link of the chain and pass end through the hole
in the Master Carrier Plate and press shut.

22 PAGES PAGE 4
Type: EKKE 900 503 49
8. Route the portion of trolley festoon flat cables which extend beyond the Master Carrier, along the trolley towing arm,
and secure with tie wraps. Either connect cable with supplied plug connectors or feed the cable ends into hoist panel
enclosure. Strip wire ends and refer to applicable wiring diagram for hook up.
9. Plug pushbutton control fitting into P/B sliding receptacle (and secure strain relief chains - where applicable, (DST
style). Adjust cable clamps as required such that there is a slack loop at the top of the P/B control cable (DST style)
and that the tension is carried by the strain relief.
10. Snap the black round cable clamps to the top of the KBK sliding festoon track. Space clamps equally (approx. 30”)
along crane span. Mount bridge motor round cable to track clamps and route cable along festoon track supports and
crossover cable supports to bridge motors. either connect plug connectors to motors or feed cable into motor junction
boxes, strip ends and refer to applicable wiring diagram for hook up.
11. SECURE HOIST/TROLLEY SO LOAD CANNOT SHIFT, raise crane and lower onto runway. If endtrucks are mounted
to girder PROCEED TO STEP 13.
12. Insert the girder mounting bolts in the left endtruck and tighten snugly. Set up right endtruck, insert girder mounting
bolts, and tighten snugly. Always TAKE CARE TO INSURE ENDTRUCK CONNECTION WASHERS ARE SEATED
PROPERLY in both the endtruck and the girder mounting plates.
13. Torque the endtruck mounting bolts ONLY AFTER THE CRANE IS MOUNTED ON THE RUNWAY. Refer to fig. 3 and
pages 18 and 19 for information regarding the girder connection hardware. Torque values are also indicated on a torque
plate mounted to the endtruck. Note: Once bolts have been torqued, they shall NOT be re-used.
14. Mount runway collector bracket, note endtrucks with 2000mm wheelbase may need to be re-drilled (See Fig 3).
15. Route incoming power cable along runway collector bracket and secure with tie wraps. Refer to applicable wiring
diagram and to collector assembly manufacturer’s instructions for proper installation.
16. Apply capacity decal to the bottom block. Refer to instructions on pages 20 and 21.
17. PRIOR TO CRANE START UP - Make certain trolley endstops (clamp-on style) are mounted such that no interfer-
ences exist. Refer to specific hoist and crane operating instructions. Refer to product operating instructions regarding
gearbox venting. Gearbox sizes A10 thru A40 do not normally require venting, sizes A50 - A90 require venting. Vent
plugs are shipped loose, typically wire tied to the drive unit. Motor phasing must be checked and corrected if neces-
sary for proper operation. Phasing corrections are the responsibility of those performing the start up. For DR Pro
cranes refer to inverter ID-RUN information and other relevant documents.
ASSURE PROPER ASSEMBLY ACCORDING TO THESE

INSTRUCTIONS TO MAINTAIN YOUR WARRANTY

22 PAGES PAGE 5
Type: EKKE with DR HOIST 900 503 49

22 PAGES PAGE 6
Type: EKKE with DC hoist 900 503 49

22 PAGES PAGE 7
Type: EKKE 900 503 49

22 PAGES PAGE 8
Underrunning Single Girder Cranes IDENT NO.
Type: EDKE 900 503 49
2. Raise girder, position accordingly, (see Fig. 1, Pg. 10,11) and place on stands with sufficient clearance to mount trolley
to underside of girder.
3. Mount the trolley on the girder by spreading the trolley wheel gauge sufficiently to clear the crane bridge beam. Check
clearance between the trolley travel wheel flanges and the girder flange. Maximum permissible clearance is 1/8" on
each side. Refer to applicable hoist/trolley operating instructions to secure load bar (see Fig. 3, Pg. 12) properly.
4. Mount the festoon track support brackets to the top of the girder per the spacing shown (see Fig. 1, Pg. 10,11). Refer
to COMPONENT PARTS & INSTALLATION INSTRUCTIONS FOR FESTOON SUPPORTS AND KBK 25 TAGLINE
SYSTEM Document # 93010749. Mount the festoon track to the brackets with the trolley festoon system on the
inside and the sliding control festoon system on the outside (see fig. 1, Pg. 10,11). Start at the panel side and position
the track sections so that any track splices are no greater away from a support than 15% of the space between hanger
supports. Complete the span using the 16.4' track sections and cut the last piece to fit.
the crane girder. Determine the vertical location of the towing arm and drill holes to mount arm to hoist. Slide trolley
conductor Master Carrier to the closest end approach. Slide the towing arm (if possible) through the Master Carrier.
PROCEED TO STEP 8. If the Master Carrier does not reach the trolley towing arm, a chain must be installed (see Fig.
3, Pg. 12). Slide the trolley towing arm so that it clears the inside of the festoon power cable and mount a towing chain.
Adjust the chain length and cut off excess as required. Open the last link of the chain and pass end through the hole
in the Master Carrier Plate and press shut.
and secure with tie wraps. Either connnect cable with supplied plug connectors or feed the cable ends into hoist panel
enclosure. Strip wire ends and refer to applicable wiring diagram for hook up.
7. Plug pushbutton control fitting into P/B sliding receptacle and secure strain relief chains - where applicable, (DST
style). Adjust cable clamps as required such that there is a slack loop at the top of the P/B control cable (DST style)
and that the tension is carried by the strain relief.

22 PAGES PAGE 9
Type: EDKE 900 503 49
8. Snap the black round cable clamps to the top of the KBK sliding festoon track. Space clamps equally (approx. 30”)
along crane span. Mount bridge motor round cable to track clamps and route cable along festoon track supports and
secure to lower beam flange of the endtruck or cable support to bridge motors. Feed cable into motor junction boxes,
strip ends and refer to applicable wiring diagram for hook up.
9. Determine left and right endtrucks according to the crane installation drawing. Prior to assembly, insure that contact
surfaces are dry and free of all contaminants.
10. If possible slide each endtruck on the end of the runway beam. if this is not possible, spread endtrucks to clear runway
flange and raise into position. The endtruck wheel assemblies have been gauged at the factory to allow 1/8” clearance
between the edge of the runway flange and each wheel flange. KTD-DK style (see Fig. 2) - Remove the locking nut and
washers to spread the side plate wheel assemblies. Once the wheel assemblies are gauged and locking nut is
secured, the locking nuts shall NOT be re-used. KTD-DH style (see Fig. 2A) - Remove the snap ring securing the
outer washers on the load bars and spread the endtruck assembly sufficiently to clear the runway flange. Slide the
endtruck halves together, reinstall washers and snap ring, drive locking pins and torque as shown.
11. SECURE HOIST/TROLLEY SO LOAD CANNOT SHIFT and raise the girder assembly to meet the endtruck assem-
blies which are already mounted on the runway.
12. Insert the girder mounting bolts in the left endtruck and tighten snugly. Set up right endtruck, insert girder mounting
bolts, and tighten snugly. The endtrucks have been squared and drilled at the factory and shear bars are welded to
insure proper positioning. Refer to fig. 5 and pages 18 and 19 for information regarding the girder connection hardware.
Torque values are also indicated on a torque plate mounted to the endtruck. Note: Once bolts have been torqued, they
shall NOT be re-used.
13. Mount runway collector bracket. (see Fig. 4, Pg. 12)
14. Route incoming power cable along runway collector bracket and secure with tie wraps. Refer to applicable wiring
diagram and to collector assembly manufacturer’s instructions for proper installation.
16. PRIOR TO CRANE START UP - Make certain trolley endstops (clamp-on style) are mounted such that no interfer-
ences exist. Refer to specific hoist and crane operating instructions. Refer to product operating instructions regarding
gearbox venting. Gearbox sizes A10 thru A40 do not normally require venting, sizes A50 - A90 require venting. Vent
plugs are shipped loose, typically wire tied to the drive unit. Motor phasing must be checked and corrected if neces-
sary for proper operation. Phasing corrections are the responsibility of those performing the start up. For DR Pro
cranes refer to inverter ID-RUN information and other relevant documents.

22 PAGES PAGE 10
Type: EDKE with EKDR hoist 900 503 49

22 PAGES PAGE 11
Type: EDKE with EUDC hoist 900 503 49

22 PAGES PAGE 12
Type: EDKE 900 503 49

22 PAGES PAGE 13
Toprunning Double Girder Cranes IDENT NO.
Type: ZKKE 900 503 49
2. Raise girder, position accordingly, (see Fig. 1, Pg. 15 or Fig. 1A, Pg. 16) and place on blocks.
3. If the festoon track systems have been installed proceed to STEP 4. Refer to COMPONENT PARTS & INSTALLATION
INSTRUCTIONS FOR FESTOON SYSTEMS AND KBK 25 TAGLINE SYSTEM Document # 93010749. Mount the
festoon track to the brackets in the locations shown in figures 1 or 1A and 5. If the crane is supplied with the P/B
controller suspended from the trolley, the sliding festoon system is not provided. Start at the left side with the track
sections supplied with a complete festoon system. Complete the span using the 16.4' track sections and cut the last
piece to fit. Slide the trolley tagline flat cable carriers into the trolley festoon track starting with the Master carrier
(towing trolley) on the power side of the crane. Slide the P/B sliding tagline flat cable carriers into the sliding control
track starting with the Master carrier (supports the P/B controller) on the power side on the crane. Secure the open
ends of the track after all carriers are inserted with stop bolts.
4. Prepare endtrucks: Prior to assembly, remove protective covering on endtruck and girder mounting plates. It is
important to insure that contact surfaces are dry and free of all contaminants.
IF THE CRANE (4 WHEEL CRANE ONLY) CAN BE ASSEMBLED COMPLETE WITH THE ENDTRUCKS ON
THE FLOOR AND LIFTED ONTO THE RUNWAY, PROCEED TO STEP 5. IF THERE IS INSUFFICIENT CLEAR-
ANCE TO ORIENT THE COMPLETE CRANE BRIDGE, RAISE THE INDIVIDUAL BRIDGE ENDTRUCKS, SECURE
TO RUNWAY COLUMNS THEN RAISE THE INDIVIDUAL GIRDERS.
5. Insert girder mounting bolts in the left endtruck, mount to girder and tighten snugly. Insert girder mounting bolts in right
endtruck, mount to girder and tighten snugly. Always TAKE CARE TO INSURE ENDTRUCK CONNECTION WASH-
ERS ARE SEATED PROPERLY in both the endtruck and girder mounting plates. At this time (if assembly is being
completed on the floor) DO NOT TORQUE GIRDER MOUNTING BOLTS. Note: for 8 WHEEL CRANES do not link the
endtruck pairs together yet.
6. Raise crane (if assembly is being completed on the floor) and lower onto runway. Torque the endtruck mounting bolts
ONLY AFTER THE CRANE IS MOUNTED ON THE RUNWAY. Refer to fig. 2 and pages 18 and 19 for information
regarding the girder connection hardware. Torque values are also indicated on a torque plate mounted to the endtruck.
For 8 WHEEL CRANES torque the girder mounting bolts to each endtruck half (see fig. 2A and pages 18 and 19).
Once the girders are torqued, roll the girders together and mount MATCH-MARKED link plates. Insert all of the link
plate connector bolts and torque bolts. Note: Once bolts have been torqued, they shall NOT be re-used.

22 PAGES PAGE 14
Type: ZKKE 900 503 49
7. Set the trolley(s) onto the trolley rails on the girder. Refer to the Crane Installation Drawing for proper trolley(s)
orientation.
the crane girder. Slide trolley conductor Master Carrier to the closest end approach. Slide the towing arm (if possible)
through the Master Carrier. PROCEED TO STEP 9. If the Master Carrier does not reach the trolley towing arm, a
chain must be installed (see Fig. 5, Pg. 17). Slide the trolley towing arm so that it clears the inside of the festoon
power cable and mount a towing chain. Adjust the chain length and cut off excess as required. Open the last link of
the chain and pass end through the hole in the Master Carrier Plate and press shut.
9. If crane is not furnished with cab and walkway proceed to STEP 10. After crane is set on the runway bring cab in
position and insert cab mounting bolts. Bolt ladder to cab and walkway, (see Fig. 7 & 8, Pg. 17) note the position of
mounting hardware and tighten securely.
and secure with tie wraps. Feed the cable ends into hoist panel enclosure. Strip wire ends and refer to applicable
wiring diagram for hook up. Mount cable crossover (perforated angle or wire tray) to endtruck and route the opposite
end of the cables along the endtruck crossover, secure cables with wire ties and connect to the bridge enclosure. Use
plug connectors or strip cable ends & refer to applicable wiring diagram for hook up.
11. Plug pushbutton control fitting into P/B sliding receptacle (and secure strain relief chains - where applicable, DST
style). Adjust cable clamps as required such that there is a slack loop at the top of the P/B control cable (DST style
see Fig. 6, Pg. 17) and that the tension is carried by the strain relief chains.
12. Run bridge motor cables to motor junction boxes. Where applicable connect plug connectors to bridge motors or strip
cable ends & refer to applicable wiring diagram for hook up.
13. Mount runway collector bracket and route incoming power cable along runway collector bracket and secure with tie
wraps. Refer to applicable wiring diagram and to collector assembly manufacturer’s instructions for proper installation.
15. PRIOR TO CRANE START UP - Make certain trolley endstops (clamp-on style) are mounted. Refer
to specific hoist and crane operating instructions. Refer to product operating instructions regarding gearbox venting.
Gearbox sizes A10 thru A40 do not normally require venting, sizes A50 - A90 require venting. Vent plugs are shipped
loose, typically wire tied to the drive unit. Motor phasing must be checked and corrected if necessary for proper
operation. Phasing corrections are the responsibility of those performing the start up. For DR Pro cranes refer to
inverter ID-RUN information and other relevant documents.


22 PAGES PAGE 15
Type: ZKKE 900 503 49
(FIG. 2)

22 PAGES PAGE 16
Type: ZKKE 900 503 49
(FIG. 2A)

22 PAGES PAGE 17
Type: ZKKE 900 503 49

22 PAGES PAGE 18
High-tensile bolted connections IDENT NO.
Type: HV Galvanized 900 503 49
U.S.A. & CANADA For EKKE, EDKE & ZKKE cranes ISSUED MAY, 2009
Demag Cranes & Components has changed the type of girder connection bolts for standard and process cranes. Formerly
a black oiled design bolt, nut and washer set were used. The new design will be a galvanized bolt, nut and washer set with
MOS2 lubrication.
IMPORTANT:
1. THESE DESIGNS HAVE DIFFERENT TORQUE VALUES. THE GALVANIZED BOLT SETS HAVE SIGNIFICANTLY
LOWER TORQUE VALUES.
2. THE DIFFERENT DESIGNS MUST NOT BE EXCHANGED OR MIXED IN ANY WAY. ALL CONNECTION BOLTS
MUST BE OF ONE DESIGN, AND AS IN THE PAST, ONCE A BOLT SET IS TORQUED IT CANNOT BE RE-USED.
3. THE BOLTS SETS ARE LUBRICATED. LUBRICATION OF THE HIGH TENSILE BOLTED CONNECTION AT A LATER
DATE IS NOT PERMITTED.
4. PAINTING OF THE HOT-DIP GALVANISED HIGH-TENSILE BOLTED CONNECTION AT A LATER DATE IS NOT
PERMITTED.
5. VARIFY BOLT SIZE AND REFER TO THE TORQUE CHART BELOW FOR THE CORRECT TORQUE VALUE.
NEW DESIGN OLD DESIGN
TORQUE VALUES FOR HOT-DIP GALVANIZED HIGH TENSILE

BOLTED CONNECTIONS WITH NUTS LUBRICATED WITH MOS2
NEW DESIGN OLD DESIGN

Size
Nm LB FT Nm LB FT
M12 100 74
M16 250 184
STANDARD SIZE--> M20 450 332 590 410
M22 650 479
M24 800 590

22 PAGES PAGE 19
High-tensile bolted connections IDENT NO.
Type: HV Galvanized 900 503 49
TYPICAL ARRANGEMENT FOR VARIOUS GIRDER CONNECTIONS
DFW-L-E & Z DFW-L-Z & T

112, 125, 160 & 250, 315 &
200mm WHEELS 400mm WHEELS
DFW-L-T
ENDTRUCK
LINK PLATES
KTD-DK STYLE KTD-DH STYLE

80, 112, & 125, & 160mm
125mm WHEELS WHEELS

22 PAGES PAGE 20
Bottom Block Capacity Decals IDENT NO.
Type: DR hoists 900 503 49
T HE BOTTOM BLOCK ASSEMBLY FOR HOIST
MODEL DR IS SHIPPED UNREEVED WITHOUT
THE CAPACITY MARKINGS .
REFER TO THE CAPACITY DECAL ON THE
CRANE GIRDER TO DETERMINE THE CORRECT
CAPACITY DESIGNATION TO PLACE ON THE
BOTTOM BLOCK .
C RANE GIRDERS WITH THE CAPACITY
INDICATED AS :
“METRIC TON” USE LOWER CASE “t”

“TON” USE UPPER CASE “T”
“METRIC” TON (t) 2200 LBS / TON

“SHORT” TON (T) 2000 LBS / TON

22 PAGES PAGE 21
Bottom Block Capacity Decals IDENT NO.
Type: DR Hoists 900 503 49
SELECT APPROPRIATE DECAL: IN THIS EXAMPLE 5 METRIC TON (2200 LBS / TON), USE DECAL 5t
P EEL OFF D ECAL AND APPLY IN THE AREA SHOWN BELOW .

Sales and Service Centers in North America
California South Carolina
5435 Industrial Parkway • San Bernardino, California 92407 BTC 560, Suite 150, 454 S. Anderson • Rock Hill, SC 29730
Telephone: (909) 880-8800 • Fax: (909) 880-4469 Telephone: (803) 909-9000 • Fax: (803) 909-9001
Georgia Ohio
254 Lake Ruby Drive • Suwanee, Georgia 30024 29201 Aurora Road • Cleveland, Ohio 44139
Illinois Ontario
11261 Kiley Drive • Huntley, Illinois 60142 1155 North Service Road West • Oakville, Ontario L6M 3E3
Michigan Quebec
46545 Continental Drive • Chesterfield, Michigan 48047 3524 Rue Ashby • St-Laurent, Quebec H4R 2C1
Missouri Te x a s
Not liable for errors or omissions, Subject to change.
3375 Hwy 185 • Washington, Missouri 63090 16430 Aldine-Westfield Road • Houston, Texas 77032
Washington
704 - 228th Avenue NE • Sammamish, Washington 98074
Telephone: (425) 883-4668 • Fax: (425) 883-4828
DEMAG Cranes & Components

29201 Aurora Road
Cleveland, Ohio 44139
Printed in the U.S.A.
Telephone: (440) 248-2400

Fax: (440) 248-3874
www.demag-us.com
0509 US/EN 900 503 49

1 2 3 4 5 6 7 8
A
Demag Cranes & Components A
CRANES / PROCESS CRANES
: 44DIN4
Classification-No. : 141
: 082
Order Data Associated Documents

Code Point
Customer Demag Crane & Components

Norm
B Order No. 38402985 B

Item No. 001 Cover Sheet
Contents
Circuit Diagram
Installation Data Terminals diagrams
Type ZKKE Equipment Layout
List of Equipment
Observe legal Protection according to DIN 34
C SWL 16 t Cable List C

Span Interconnection Diagram
26.02.2009 13:51
D D
Operating Data
Operating Voltage 460 V 60 Hz
E Control Voltage 48 V 60 Hz E
CAD Drawing, no manual Changes
Type of Control Floor Control

RADIO CONTROL
SIA-Date
F Date 26.02.2009 Customer Demag Crane & Components Designation = Cover F

Drawn McQuerry ZKKE 16 t x 20 m Cover Sheet +
Check EZDR10-Pro 6/1 (16M ton) Order No. Dept. Format Lang. Ident No. SK DT Sheet 01
Issue Mod. Date Name Ch.Date Compiled f. Repl.from Repl.by 38402985 270 3 EN 38402985 N 00 1 Sh.
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
DT Designation Higher level assignmt. Place fitted Sheet No. Sheets
00 Cover Sheet =Cover 01 1
A 01 Contents =Contents 01 1 A
03 Legends =Legend 01 3
: 44DIN4
11 POWERFEED CRANE =10D11 +K1BG1 01 4

: 082
11 LONG TRAVEL UNIT =10D41 +K1BG1 01 5

11 CROSS TRAVEL UNIT =11D21 +K1K1G1 01 3
11 HOIST UNIT =11D31 +K1K1G1 01 5
11 FLOOR CONTROL =19N11 +K1BS1 01 1
Code Point
11 RADIO CONTROL =19N14 +K1B 01 1

20 Layout Terminals =TERM 1 4
Norm
30 Equipment Layout =Layout 01 5

B 43 List of Equipment =PartList 01 3 B
55 Cable List =CableList 01 1
60 Interconnection Diagram =Connection 01 2
C C
26.02.2009 13:51
D D
E E
SIA-Date
F Date 26.02.2009 Customer Demag Crane & Components Designation = Contents F

Drawn McQuerry ZKKE 16 t x 20 m Contents +
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
: 44DIN4
: 082
CORE IDENTIFICATION
DIN/VDE 0293-308
Code Point
CONTROL TRANSFORMER (IN A TRANSITION PERIOD THE MARKING OLD/NEW ARE EQUALLY GOOD)
Norm
B Mains voltage Connection PRIMARY OLD NEW OLD NEW OLD NEW B
380 V -20V / 400V BK BN BK BN BK1 BN
380 V +10% +20V / 400V BU BU BU BK BU BK
380 V -10% 0 / 340V PE PE BN GY BN GY
400 V 0 / 400V PE PE BK2 BU
400 V +10% -20V / 460V PE PE
400 V -10% +20V / 340V
415 V +20V / 400V
C 415 V +10% 0 / 460V C

415 V -10% -20V / 400V CONNECTION MARKINGS MOTORS
440 V -20V / 460V DIN EN 60034-8
26.02.2009 13:51
440 V +10% +20V / 460V

440 V -10% 0 / 400V (IN A TRANSITION PERIOD THE MARKING OLD/NEW ARE EQUALLY GOOD)
460 V 0 / 460V
460 V +10% 0 / 500V OLD NEW
460 V -10% +20V / 400V
D 480 V +20V / 460V 601 TB1 D
480 V +10% +20V / 500V THERMOSTATIC SWITCH
480 V -10% -20V / 460V 602 TB2
803 1S1
BRAKE RELEASE MONITORING
802 801 1S2 1S3
E 401 BD1 E
Brake
402 BD2
SIA-Date
F Date 26.02.2009 Customer Demag Crane & Components Designation = Legend F

Drawn McQuerry ZKKE 16 t x 20 m Legends +
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CONTROL CABLE FREQUENCY INVERTER DEDRIVE DIC

A A
TYPE 1 TYPE 2
: 44DIN4
: 082
GND 24V
GND 24V
0-10V
0-10V
Enable
Enable
Ready
Ready
Brake
Brake
+24V
+24V
FWD
FWD
REV
REV
CONNECTOR CONNECTOR
CONNECTION CONTROLLER BASIC MODULE CONTROLLER BASIC MODULE
Code Point
CONTROLLER BASIC MODULE X15 X15

Norm
B CROSS TRAVEL UNIT / LONG TRAVEL UNIT B
GN
GN
BN
OG
BU
BN
OG
BU
BK
RD
BK
RD
YE
YE
VI
VI
8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7
PLUG
THERMOSTATIC CONTACT THERMOSTATIC CONTACT SELECTION
MOTOR MOTOR PARAMETER SET
C FREQUENCY INVERTER C
X61 X61 X63
26.02.2009 13:51
D D
FREQUENCY INVERTER DEDRIVE
Selection parameterset
Selection parameterset
Thermal
Thermal
0-10V
0-10V
Ready
Ready
Brake
Brake
GND 24V
GND 24V
E X210B X210B E
Enable
Enable
+24V
+24V
FWD
FWD
REV
REV
X210A +10V 4mA X210A
+10V 4mA
GND 24V
GND 10V
GND 24V
GND 10V
S1 OUT
S1 OUT
S6 IND
S6 IND
MF01
MF01
MFI1
MFI1
GND 24V
GND 24V
S1 IND
S2 IND
S3 IND
S4 IND
S5 IND
S1 IND
S2 IND
S3 IND
S4 IND
S5 IND
+24V
+24V
PLUG PLUG
FREQUENCY INVERTER FREQUENCY INVERTER
SIA-Date

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
IEC vs. JIC SYMBOL CROSS-REFERENCE
A IEC JIC IEC JIC IEC JIC IEC JIC A
: 44DIN4
-Q011 L1 L2 L3 -Q011 L1 L2 L3 A2 A2 -S016.1? 2

: 082
3 Phase -K012 2 Cam-

Disconnect Coil -F011 Control Operated
T1 T2 T3 Switch T1 T2 T3 A1 A1 Fuse 1 L/S
Relay or 1 SGG 4
Contactor N.C. N.O. N.C. N.C. N.O.
(Held Open)
1 3 5 1 3 5 18 22 18 22
-F011 3 Phase
Code Point
-F011 TB2 TB2 SGG

Power Contacts -M012 Motor -S016.1? 2 3 5 7 Geared L/S
2 4 6 Fuses 2 4 6 15 21 15 21 or
2 4 6
Temperature
Norm
N.O. Contact N.O. Contact N.C. Contact Switch XCK-MR/F

SGG 4 1 4 6 8 Travel L/S 1 3 5
B -Q011 1 3 5
A2 A2
TB1 TB1 B
-Q011 1 3 5 -K013
3 Phase Coil B1 2
Circuit A1 A1 2
Breaker 2 4 6 -H013 Warning Resistor or
I> I> I> On Delay Horn Bank
2 4 6 Timer 1
1 Resistor Resistor Resistor
-K013 18 -K013 22 18 22
1 3 5 1 3 5 Contacts
3 Phase 15 21 15 21 -H013 2
-F047 Overload -F047 Delay Close/ Delay Open/ Delay Close/ Delay Open/ 2 Warning -V018 -V018.1 Diode
Relay Inst. Open Inst. Close Inst. Open Inst. Close 1 Bell or LED
2 4 6 2 4 6
A2 1 Diode LED Diode LED

C U1 V1 W1 PE T1 -K014 A2
Coil B1
Release
C
A1 A1 Contact X2 1 2 2
-M013? M 3 Phase, T2 M X2 Warning Cooling
3AC One Speed 3~ Off Delay Beacon R -E016.2 Fan
Motor Timer or
26.02.2009 13:51
T3 18-=Legend- 22 18 22 Pilot Light PE 1

-K014 X1 X1
Contacts 15 21
-=Legend- T1 15 21
1W 2W Inst. Close/ Inst. Open/ Inst. Close/ Inst. Open/ Installation Location
T2 Delay Open Delay Close Delay Open Delay Close Designation Designation
-M011 1V M
3AC
2V 3 Phase, M
3~
1U 2U Two Speed T3 Location Desigantion
PE Motor 14 22 14 22 (Doc.) K1 B G1
-SO17 -SO17
D T11 T12 T13 Manual
Pushbutton
DT Description
00 Cover Sheet
Installation No./Description Location
K1
Description
Crane 1
German
(Kran 1)
D
13 21 13 21
01 Contents
L1 H1 N.0. Contact N.C. Contact N.O. Contact N.C. Contact 03 Legend B Bridge (Brücke)
L1 L2 L3 PE1 3 Phase, 11 Crane 1 Schematic G1,G2,... Enclosure 1,2,... (Gehäuse)
Auto- U X1 10D11 - Powerfeed Crane K1BG1 K1,K2,... Terminal Box 1,2,... (Klemmenkasten)
Transformer General 10D41 - LongTravel Unit 1
N V 14 22 14 22 K1B, K1BG1 S1 Controller (Pendant) (Steuerung)
N X2 L2 Mushroom 11D21 - Cross Travel Unit 1 K1K1G1 FK1,2,... Flat Cable to Trolley 1 (Flachleitung)
H2 Head H-T #1 11D31 - Hoist Unit 1 K1K1G1
-SO18 13 -SO18 21 (Maintained)
U V W PE2 X3 Pushbutton 13 21 11D33 - Aux. Hoist K1K1G2 K1 Trolley 1 (Katze 1)
H3 W PE N.O. Contact N.C. Contact N.O. Contact N.C. Contact 12D21 - Cross Travel Unit 2 K1K2G1 G1,G2,... Enclosure 1,2,... (Gehäuse)
-T016 L3 H-T #2 12D31 - Hoist Unit 1 K1K2G1 K1,K2,... Terminal Box 1,2,... (Klemmenkasten)
12D33 - Aux. Hoist K1K2G2
E -S019 14 -SO19
22 ON 14 ON 22 12 Crane 2 Schematic K2 Trolley 2 (Katze 2) E
1U 1V 1W Manual 10D11 - Powerfeed Crane K2BG1 G1,G2,... Enclosure 1,2,... (Gehäuse)

L1 L11 Selector General 10D41 - LongTravel Unit 1
H1 X1 13 21 Switch OFF 13 OFF 21 K2B, K2BG1 K1,K2,... Terminal Box 1,2,... (Klemmenkasten)
N.O. Contact N.C. Contact N.O. Contact N.C. Contact 11D21 - Cross Travel Unit 1 K2K1G1
L2 H2 X2
L12 H-T #1 11D31 - Hoist Unit 1 K2K1G1 K2 Crane 2 (Kran 2)
PE 11D33 - Aux. Hoist K2K1G2 B Bridge 2 (Brücke)
H3 X3 (402) 12D21 - Cross Travel Unit 2 K2K2G1 K1 Trolley 1 on Crane 2 (Katze 1)
L3 L13 BD2 BD2 H-T #2 12D31 - Hoist Unit 1 K2K2G1 K2 Trolley 2 on Crane 2 (Katze 2)
-M012 Brake 12D33 - Aux. Hoist K2K2G2
3 Phase, Coil BR
SIA-Date
2U 2V 2W N Isolation- BD1 BD1

Transformer
-T019 D-Y (401)
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
INCOMMING CABLE FUSE CTRL. TRANSFORMER
ISOLATOR SUPPLY SUPPLY CONTROL TRANSFORMER
POWER SUPPLY CRAB MAIN CURRENT FREQUENCY INVERTER
CRAB 1 CONTROLLER LONG TRAVEL UNIT
A A
: 44DIN4
PE
L1
L2
L3
Code Point : 082
-W1 BN BK GY PE
Norm
B B
-Q011 L1 L2 L3
-X1 PE -X1 PE
* T1 T2 T3 PE
001 006 011
1 3 5 -OM017
-F011 DR
* 2 4 6
002 007 012
-X1 1 3 5
C C
26.02.2009 13:51
-X1 2 4 6
003 008 013 071 075

-K022 1 3 5
Kurzschlussfest -F017.1
1 3
2x2AT 2
D 2
004
4
009
6
014 072
4
076
D
PE PE
9 9
8 8
-X1 7 -X1 7
+20V
-20V
500V
460V
400V
340V
230V
022 025 028 -T017
0
1 3 5 PE -X1 PE
005 010 015 019 020 021 -F016 130VA 48V -5% 0
*
* 2 4 6
-XF011 023 026 029 073 077
Power AWG6 3 2 1 PE
E +K1B
-XM011 3 2 1 PE -Z016
L1 L2 L3 PE1
-F017.2
1 E
Kurzschlussfest
* NF 40A L1' L2' L3' PE2 1x3AT 2
-W2 BN BK GY PE 024 027 030 074
101L1 =11D31/04.1
101L2 =11D31/04.2
101L3 =11D31/04.2
1PE =11D31/04.2
106L1 =10D41/02.1
106L2 =10D41/02.1
106L3 =10D41/02.1
6PE =10D41/02.1
105L1 03.1
105L2 03.1
105L3 03.1
5PE 03.1
1L4 02.1
1L5 02.1
1PE1 03.1
SIA-Date
F Date 26.02.2009 Customer Demag Crane & Components Designation = 10D11 F

Drawn McQuerry ZKKE 16 t x 20 m POWERFEED CRANE + K1BG1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CONTROL RELAY CRANE SWITCH CONTACTOR
CRANE SWITCH
A A
1L4 01.7 04.1 1L4
: 44DIN4
Code Point : 082
Norm
085
-K021 13
B B
14
03.2 X66.3
081
-K022 21
22
C C
26.02.2009 13:51
082
03.2 X66.4
D D
083 03.2 X66_A1
-K021 A1
CA2-SK20E7 A2
084
03.2 X66_A2 086
-K022 A1
* A2
087
E 1L5 01.7 04.1 1L5 E
.2 1323 14
24 /01.1 1
3
2
4
/01.1 5 6
/01.1
13 14
.1 21 22
SIA-Date

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CAN-BUS 1 CAN-BUS 2 CAN-BUS 3
POWER SUPPLY CRAB CONTROL MOBILE Großanzeige
POWER SUPPLY CONTROL
MAIN CURRENT CRAB 1
A A
1PE1 01.8 1PE1
: 44DIN4
: 082
105L1 01.5 X66.4 02.2

105L2 01.5 X66.3 02.2
105L3 01.5 X66_A1 02.2
5PE X66_A2
Code Point
01.5 02.2
Norm
B B
PE
X73.1 X73.2 X73.3 X134 1 2 X66.1 X66.2 X66.3 X66.4 X27.1 X27.2
/04.1
-A031 PE PE =10D41/01.1
D-SUB 9 =10D41/02.1
Controller =10D41/03.2
=10D41/04.1
X44.5 X44.7 X44.2 X44.3

C -X2 PE
C
26.02.2009 13:51
X2 A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6 -XF036 X3/1 X3/4 X3/2 X3/3 X4/5

+K1B A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6
-XM031 X4/1 F2 F1 X4/3 125
CAN-Bus X4/6 X4/8 126 04.2 1L40
X4/2 X4/4 127 04.2 1L50
X4/7 X4/9 128
2x 250mA F
D A4 A1 A2 B3 B6 B2 2xCAN -XF037
12-pol. A4 A1 A2 B3 B6 B2 D
+K1B A4 A1 A2 B3 B6 B2
-XM036
CAN-Bus
-W6 WH GN S BN 1 2 -W11 BN WH GN 1 2 PE S
E E
CAN_H_3 =19N11/01.1
CAN_L_3 =19N11/01.1
CAN_Gnd_3 =19N11/01.1
1L43 =19N11/01.1
1L53 =19N11/01.1
1PE3 =19N11/01.1
CAN_L_1 =11D31/02.5
CAN_Gnd_1 =11D31/02.5
CAN_H_1 =11D31/02.5
1L41 =11D31/02.6
1L51 =11D31/02.7
SIA-Date

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
1L4 02.8 1L4
: 44DIN4
1L5 02.8 1 1L5

-X2 2
Code Point : 082
Norm
B B
161 162
X71.1 X71.2 X34.1 X34.2 X35.1 X35.2 X37.1 X37.2

-A031
C D-SUB 9
C
Uni-Out 1 Uni-Out 2
26.02.2009 13:51
X74.7 X74.2 X74.3 X74.5 X72.1 X72.2 X99.1 X99.2 X99.3 X99.4
1L50 03.8
1L40 03.8
D D
E E
SIA-Date

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
: 44DIN4
: 082
=10D11
-A031
Code Point
X101.1 X101.2 X101.3 X10.1 X10.2 X10.3 X10.4 X10.5 X10.6

Norm
1L1 3L2 5L3

B -A011 DR LS-10A B
2T1 4T2 6T3
02.1 107L1
02.1 107L2
02.1 107L3
C C
26.02.2009 13:51
D D
E E
SIA-Date

Drawn McQuerry ZKKE 16 t x 20 m LONG TRAVEL UNIT + K1BG1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
THERMOSTATIC SWITCH
THERMOSTATIC SWITCH
Brake Brake FREQUENCY INVERTER PARAMETER SWITCHING
LONG TRAVEL MOTOR 1 LONG TRAVEL MOTOR 2 LONG TRAVEL MOTOR 1 LONG TRAVEL MOTOR 2 BRAKING RESISTOR
A +K1B
-M026 TB1
+K1B
-M024 TB1 A
106L1
: 44DIN4
106L2 =10D11/01.6
=10D11/01.6
: 082
106L3 TB2 TB2

6PE =10D11/01.6 +K1B +K1B
=10D11/01.6 -XM026.1 9 10 -XM024.1 9 10
+K1B 9 10 +K1B 9 10
-XF026.1 -XF024.1
-W5 7 8 -W4 7 8
Code Point
+K1B +K1B
-XM026 D1 D2 -XM024 D1 D2
Norm
-XF026 D1 D2 -XF024 D1 D2
B X64 1 2 3 BLACK B
107L1 X62 1 2
107L2 01.3
107L3 01.3
01.3
X61 1 2 X63 1 2 3 X64 1 2 3 RED
3
X64 1 2 3 BLUE
8 5 3
X13.1 X13.2 X13.3 PE X201.1 X201.2 X201.3 X15 L1 L2 L3 PE X1 + - X210A X210B
C =10D11 C
-A031 -G024
X10.2 X10.3
X10.1
*
26.02.2009 13:51
X14.1 X14.2 X2 U V W PE X2 Rb1 Rb2
247 248
D D
.1
.2
.6
.6
.2
.2
.5
.6
-XF024 B2 C1 D1 D2 -XF026 B2 C1 D1 D2 -X3 1 1 2 2 3 3
-XF024 B2 C1 -XF026 B2 C1 7-pol.+ PE A1 A2 B1 C2 7-pol.+PE A1 A2 B1 C2
+K1B +K1B +K1B +K1B
-XM024 B2 C1 -XM026 B2 C1 -XM024 A1 A2 B1 C2 B2 C1 D1 D2 -XM026 A1 A2 B1 C2 B2 C1 D1 D2
7-pol.+PE 7-pol.+PE
.1
.2
.6
.6
.2
.2
.5
.6
251
261
249
259
253
255
257
263
-W4 5 6 -W5 5 6 -W4 1 2 3 PE S -W5 1 2 3 PE S 1 3 5 7 9 11 13 15
E -R027 E
+K1B .1 +K1B
.2
.6
.6
.2
.2
.5
.6
+K1B +K1B -XF024.1 1 2 4 5 6 7 8 9 10 -XF026.1 1 2 4 5 6 7 8 9PWR10 R34 4,8kW
-XF024.1 4 5 -XF026.1 4 5 HAN 10 E 3 PE HAN 10 E 3 PE
+K1B 4 5 +K1B 4 5 +K1B +K1B
-XM024.1 -XM026.1 -XM024.1 1U1 2V1 3
W1
PE
PE 4 5 6 7 8 9 10 -XM026.1 1U1 2V1 3
W1
PE
PE 4 5 6 7 8 9 10 2 4 6 8 10 12 14 16
+K1B +K1B
250
252
256
258
260
262
254
264
.1
+K1B +K1B
.2
.6
.6
.2
.2
.5
.6
-M024 BD1 -M026 BD1 -M024 M -M026 M
3AC 3AC
* *
BD2 BD2
.6 TB1 TB2 .5 TB1 TB2
SIA-Date
.1 BD1 BD2 .2 BD1 BD2

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
LIMIT SWITCH LIMIT SWITCH
LIMIT SWITCHING PRELIMINARY SWITCH-OFF
FORWARDS / REVERSE FORWARDS / REVERSE
A A
: 44DIN4
: 082
OPTIONAL : OPTIONAL :
Code Point
Norm
B B
+K1B +K1B
-S032 B21 B13 A21 A13 -S036 B21 B13 A21 A13
PE PE
XCK-MR/F B22 B14 A22 A14 XCK-MR/F B22 B14 A22 A14
-W16 1 2 3 4 PE -W17 1 2 3 4 PE
C C
26.02.2009 13:51
X16FI.1 X16FI.2 X16FI.3 X16FI.4 X16PC.1 X16PC.2 X16PC.3 X16PC.4 PE X48.1 X48.2 X48.3 X48.4 PE
=10D11
D -A031 L4 FORWARDS REVERSE L5 L4 FORWARDS REVERSE L5 L4 FORWARDS REVERSE L5
D
+K1B XCK-MR1618668002 (F) +K1B XCK-MR1618668002 (F)

A21
-S032
A22
180° 90° 0° -90°-180° A21
-S036
A22
180° 90° 0° -90°-180°
E 1
A13 A14
1
A13 A14 E
B21 B22 B21 B22

2 2
B13 B14 B13 B14
R1 G R2 R1 G R2
* *
SIA-Date

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
: 44DIN4
Code Point : 082
Norm
B B
C C
26.02.2009 13:51
X47.1 X47.2 X47.3 X47.4 X47.5 PE

D =10D11
-A031 L4 UniIn 1 UniIn 2 UniIn 3 L5 D
E E
SIA-Date

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X
: 44DIN4
: 082
JP11 FIXED SETTING

Code Point
Norm
X
B B
JP13 CONNECTION
GND - GNDext
C C
OFF
0
ON
SW301 X 2 Code304 CODING SWITCH 0 - F :

26.02.2009 13:51
X 1
RUN CORRECTION PARTIAL LOAD
Code303 0 CODING SWITCH 0 - F :

CORRECTION SLACK ROPE
D Code305 8 7
X X X X X X X X
6 5 4 3 2 1
OFF
ON
CORRECTION OVERLOAD D
END OF BUS CAN-BUS
OFF
ON
Code301 X CONTROL PARALLEL/CAN
X
8
CONTROL AT TESTING STAND
X
7
E TESTING OVERLOAD ON E
X
6
CRANE/CRAB
X
5
CRANE/CRAB BRAKE PERFORMANCE
X
4
Baud-Rate: 125 kBit
X
3
X
2
CAN-ID
SIA-Date
F Date 26.02.2009 Customer Demag Crane & Components Designation 1 = 10D41 F

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
THERMOSTATIC SWITCH THERMOSTATIC SWITCH
FREQUENCY INVERTER
SUPPLY CROSS TRAVEL UNIT CROSS TRAVEL UNIT PARAMETER SWITCHING
Brake Brake CROSS TRAVEL MOTOR 2 CROSS TRAVEL MOTOR 1 BRAKING RESISTOR
A +K1K1 TB1
A
=11D31/01.1 111L1
: 44DIN4
-M014 -W10 7
=11D31/01.1 111L2
: 082
=11D31/01.1 111L3 +K1K1 TB1

TB2 -M016
-W10 8
1 2
-X015 TB2
Code Point
1 2
-W9 7 -W9 8
Norm
BLUE
B B
X62 1 2 X64 1 2 3
X61 1 2 X63 1 2 3
301 303 305 3
1 3 5
-F011
* 2 4 6 8 5 3
302 304 306
X13.1 X13.2 X13.3 PE X201.1 X201.2 X201.3 X15 L1 L2 L3 PE X1 + - X210A X210B
C =11D31 C
-A011 -G014
X10.2 X10.3
X10.1
*
26.02.2009 13:51
X14.1 X14.2 X2 U V W PE X2 Rb1 Rb2
307 308
PE
D D
-W9 1 2 3 PE S 1
-W9 5 6 -R017
* 2
E E
-W10 5 6 -W10 1 2 3 PE S
+K1K1 BD1 +K1K1 BD1
-M014 -M016
U1 V1 W1 PE U1 V1 W1 PE
BD2 BD2 +K1K1 +K1K1
-M014 M PE -M016 M PE
3AC 3AC
* STAR CONNECTION * STAR CONNECTION
.5 TB1 TB2 .6 TB1 TB2
SIA-Date
.1 BD1 BD2 .2 BD1 BD2

Drawn McQuerry ZKKE 16 t x 20 m CROSS TRAVEL UNIT + K1K1G1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
LIMIT SWITCH LIMIT SWITCH
GENERAL FAST
RIGHT RIGHT
LEFT LEFT
A A
: 44DIN4
Code Point : 082
+K1K1 +K1K1
-S022 B21 A21 -S022 B11 A11
B11
A11
A21
Norm
XCK-MR54D1H29 B22 A22 B12 A12
B12
A12
A22
PE
B PE B
.6
.6
.3
.8
-W18 1 2 3 4 5 6 PE
C C
26.02.2009 13:51
X16.1 X16.2 X16.3 X16.4 PE X48.1 X48.2 X48.3 X48.4 PE

D =11D31
-A011 L4 RIGHT LEFT L5 L4 RIGHT LEFT L5 D
E +K1K1
-S022
XCK-MR54D1
180° 90° 0° -90°-180° E
A21 A22
1
A11 A12
B21 B22
2
B11 B12
R1 G R2
SIA-Date
*
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
: 44DIN4
Code Point : 082
Norm
B B
C C
26.02.2009 13:51
X47.1 X47.2 X47.3 X47.4 X47.5 PE

D =11D31
-A011 L4 UniIn 1 UniIn 2 UniIn 3 L5 D
E E
SIA-Date

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
POWER SUPPLY CRAB THERMOSTATIC SWITCH
CONTROLLER BASIC MODULE MAIN CURRENT HOIST MOTOR PULSE DEVICE
CONTROLLER-MODULE FI THERMOSTAT ( POLE CHANGING ) Brake HOIST MOTOR
MONITORING BRAKING RESISTOR VENTILATOR BRAKE RELEASE MONITORING ( POLE CHANGING )
A A
: 44DIN4
: 082
04.1 110L1
04.1 110L2
04.1 110L3
04.1 10PE
401 403 405
Code Point
Norm
+K1K1G2 1 3 5
-F011
B * 2 4 6 B
402 404 406
111L1
111L2 =11D21/01.3
111L3 =11D21/01.3
=11D21/01.3
X1 3 2 1 PE PE
X73.1 X73.2 X73.3 X44.7 X44.2 X44.3 X71.2 X71.1 X66.1 X66.2 X66.3 X66.4 X134 1 2 X27.1 X27.2 X72.1 X72.2
-A011 /02.1 PE
C PE D-SUB 9
D-SUB 9 =11D21/01.1
PE C
Controller BRAKE MODULE =11D21/02.2
=11D21/03.1
26.02.2009 13:51
X101.1 X101.2 X101.3 5 6 7 X74.7 X74.2 X74.3 X74.5 X10.1 X10.2 X10.3 X10.4 X10.5 X10.6 X52.1 X52.2 X52.3 X52.4 X52.5 X52.6
X4.1 X4.2 X4.3 X92.1 X92.2 X92.3
-A011.1 DR FI 2 1 4
X60.1 X60.2 X60.3 X60.4 X60.5 X60.6 X80.1 X80.2
D D
407 408 409 410 411 412 413 415

FI1_1 05.1
FI1_2 05.1
FI1_3 05.1
FI1_4 05.1
CAN_H_FI1 04.5
CAN_L_FI1 04.5
CAN_Gnd_FI1 04.5
+K1K1G2 1 +K1K1G2 +K1K1G2
-B013 -XF041.2 3 4 -XF041.2 6 11
T +K1K1 +K1K1
-XM041.2 3 4 -XM041.2 6 11
40°C 2
KTS 011 414
416
E 417 E
+ - + - +K1K1
+K1K1G2 95 +K1K1G2 +K1K1G2 +K1K1 1S1 -M041 BD1
-F047 -E013 -E014 -M041
96 PF 2000 FM PF 2000 FMA 1S2 1S3 BD2
SIA-Date

Drawn McQuerry ZKKE 16 t x 20 m HOIST UNIT + K1K1G1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
INCOMMING CABLE
GEARED LIMIT SWITCH SIGNAL CAN-BUS
ZMS MGS
A A
=10D11/03.1 CAN_Gnd_1
=10D11/03.2 CAN_H_1
=10D11/03.1 CAN_L_1
: 44DIN4
=10D11/03.2 1L41
=10D11/03.3 1L51
: 082
-S021 1 -S021 3 5 7
-H024
1
3
5
7
Code Point
SGG 4 2 4 6 8 B/CP28 5-24V DC 2
.3 6
.3 8
.2 4
Norm
B B
+K1K1
-XM025 A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6
Control 12-pol.
X5.1 X5.2 X5.3 X5.4 X5.5 X5.6 X5.7 X5.8 X54.1 X54.2 X2 A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6
-A011
C OPTIONAL : OPTIONAL : C
DR ZMS Uni-Out 1 Uni-Out 2
26.02.2009 13:51
X53.1 X53.2 X35.1 X35.2 X34.1 X34.2 X37.1 X37.2 X99.1 X99.2 X99.3 X99.4
-A021
X7.4 X7.2 X7.1 X7.3 PE X8.4 X8.2 X8.1 X8.3 PE
-W20 WH YE
D D
+K1K1
-S023 11
-W21 WH BN GN YE S
MGS 12
E E
+K1K1 WH BN GN YE
-B021
ZMS
SIA-Date

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
X
: 44DIN4
=11D31
: 082
-D045 X
ON
OFF
END OF BUS CAN-BUS JP11 FIXED SETTING
Code Point
Norm
X
B B
JP13 CONNECTION
GND - GNDext
C C
OFF
?
ON
SW301 X 2 Code304 CODING SWITCH 0 - F : STRAIN GAUGE CARRIER LINK : VALUE 1

26.02.2009 13:51
X 1
RUN CORRECTION PARTIAL LOAD MGS: VALUE 7

CORRECTION SLACK ROPE
D Code305 8 7
X X X X X X X X
6 5 4 3 2 1
OFF
ON
Code302 A CODING SWITCH 0 - F :
CORRECTION OVERLOAD D
END OF BUS CAN-BUS
OFF
ON
Code301 X CONTROL PARALLEL/CAN
X
8
CONTROL AT TESTING STAND
X
7
E TESTING OVERLOAD ON E
X
6
CRANE/CRAB
X
5
CRANE/CRAB BRAKE PERFORMANCE
X
4
Baud-Rate: 125 kBit
X
3
X
2
CAN-ID
SIA-Date
F Date 26.02.2009 Customer Demag Crane & Components Designation 1 = 11D31 F

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
HOIST UNIT
FREQUENCY INVERTER CAN-BUS BRAKING RESISTOR
HOIST MOTOR
A A
01.4 CAN_Gnd_FI1
: 44DIN4
01.4 CAN_H_FI1
01.4 CAN_L_FI1
=10D11/01.1 101L1
=10D11/01.2 101L2
=10D11/01.2 101L3
=10D11/01.2 1PE
: 082
+K1K1
-XM041.1 3
Code Point
2 1 PE
+K1K1G2*
-XF041.1 3 2 1 PE
Norm
Power 4G16
B 441 443 445
+K1K1G2
PE B
+K1K1G2 1 3 5 -OM043
-F041
DR
* 2 4 6
110L1
110L2 01.2
110L3 01.2
10PE 01.2
01.2 442 444 446
U1 V1 W1
+K1K1G2
-L041
C *
PE C
U2 V2 W2
447 448 449 +K1K1G2
26.02.2009 13:51
L1 L2 L3 PE1 A -XF045
DE09S064T 7 2 3 5
+K1K1G2 +K1K1G2 7 2 3 5
-G041 -D045
CM-CAN D-SUB 9 /05.2
*
D U
450
V
451
W
452
PE2 Rb1 Rb2 PE D
453 454
+K1K1G2 1 3 5 455
97
95
-F047
* 2 4 6
/01.2 9896
/05.8
/05.8
/01.5
/01.6
/01.6
/01.6
+K1K1G2
-XF041.2 U V W PE 1 2 3 4 5 6 7 8 9 10 11 12 456 457
15-pol.+PE
+K1K1
-XM041.2 U V W PE 1 2 3 4 5 6 7 8 9 10 11 12 +K1K1G2
15-pol.+PE -R047.1
/05.8
/05.8
/01.5
/01.6
/01.6
/01.6
E U1 V1 W1 PE 1 2 E
+K1K1 *
-M041 M
3AC DELTA CONNECTION
* 458 +K1K1G2 459
-R047.2
/05.8 TB1 TB2 1 2
/01.6 BD1 BD2 *
/01.5 1S1 1S3
1S2
SIA-Date

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
HOIST UNIT
FREQUENCY INVERTER PULSE DEVICE
PARAMETER SWITCHING HOIST MOTOR
BRAKE RELEASE THERMOSTATIC SWITCH
A A
: 44DIN4
X64 1 2 3 RED +K1K1

: 082
-B055
VCC GND B Alarm A A N N B
AG 3 BNGN WHGN GY VI GN BN BK RD PK S
12 10 8 7 6 5 4 3 1 9
X64 1 2 3 BLUE +K1K1 12 10 8 7 6 5 4 3 1 9
-XF055
RC-12
Code Point
3 BLACK +K1K1
Norm
X64 1 2 -W64 BNGN WHGN GY BN

B B
FI1_1 01.1 -X5 3 3 +K1K1G2 525

-XF041.2 1
+K1K1
-XM041.2 1
521 +K1K1 TB1
-M041
X63 1 2 3
FI1_2 01.2 TB2

C 522 523 524 +K1K1
-XM041.2 2 C
+K1K1G2
-XF041.2 2
526
X210A 1 3 4 5 6 7 X210B 1
26.02.2009 13:51
+K1K1G2 +24V S1 IND S2 IND S3 IND S4 IND S5 IND S6 IND

-G041
GND GND S1 OUT MFO1 +10V MFI GND
X210A 2 X210B 2 3 4 5 6 7 X10 1 2 3

D D
FI1_3
FI1_4 01.2
01.2
E E
SIA-Date

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CONNECTOR
CONTROL MOBILE
CONTROLLER DSE
A A
: 44DIN4
1PE3 =10D11/03.7
: 082
1L53 =10D11/03.7
1L43 =10D11/03.6
CAN_H_3 =10D11/03.6
CAN_Gnd_3 =10D11/03.6
CAN_L_3 =10D11/03.6
Code Point
Norm
B +K1B
-XF012 A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6
B
CAN-Bus
-XM012 A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6
CAN DSE
-W12 BN WH GN 1 2 S
C BN WH GN 1 2 S C
DISPLAY
5 6 4 1 2 3
26.02.2009 13:51
-S012
DSE10-R VVV
D D
E E
F1 F2
SIA-Date
F Date 26.02.2009 Customer Demag Crane & Components Designation = 19N11 F

Drawn McQuerry ZKKE 16 t x 20 m FLOOR CONTROL + K1BS1
Check EZDR10-Pro 6/1 (16M ton) DSE Order No. Dept. Format Lang. Ident No. SK DT Sheet 01
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
RADIO CONTROL RECEIVER
RADIO CONTROL TRANSMITTER
A A
: 44DIN4
DISPLAY
: 082
-U014
Code Point
FST micron 6
Norm
B B
C C
26.02.2009 13:51
-XM011 A1 A2 A3 A4 A5 A6 B1 B2 B3 B4 B5 B6
CAN-Bus
-W52 BN WH GN GY PK S
D D
ST3.4 ST3.8 ST3.3 L N PE 4 5 6
-U011 7 K1 8 16 K5 15 24 K9 23 32 K13 31 42 K17 43
CAN H
CAN GND
Output
Input
PE
CAN L
Emergency Stop
9 K2 10 18 K6 17 26 K10 25 33 K14 34
39
12 K3 11 20 K7 19 28 K11 27 35 K15 36
40
14 K4 13 22 K8 21 30 K12 29 37 K16 38
E FSE 516 41 E
SIA-Date
F Date 26.02.2009 Customer Demag Crane & Components Designation = 19N14 F

Drawn McQuerry ZKKE 16 t x 20 m RADIO CONTROL + K1B
Check EZDR10-Pro 6/1 (16M ton) FST 516 micron 6 Order No. Dept. Format Lang. Ident No. SK DT Sheet 01
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
: 44DIN4
: 082
BRAKING RESISTOR LONG TRAVEL UNIT

BACK SIDE ENCLOSURE
Code Point
Norm
B B
=10D41 =10D41 =10D11
-XF024 -XF026 -XF037
AMP
AMBUS 3A CA2
STR 130VA 2x2AT SK20E7 X101
=10D11 -F017.2
Controller
*
*
230-500/48V
*
*
* *
* *
Basic
* *
100
*
DR-LS 10A
*
=10D11
*
*
=10D11
*
-K021140
=10D11 =10D11 =10D11
-F017.1
=10D11
=10D11
-Q011 -K022 -T017 -F016 X73
-XF036
NF 40A *
=10D11 =10D41
305
X48 X16FI
-A031 -A011
X41
X27
X66 X47
304
C =10D41 =10D11
303
302
JP11
X10 C
-G024 -Z016 X2
Code 301
X134 X16PC X34
Code
X35 X201 X13 X37
TERMINALS
SW
301 JP13 X15 X99 X2
26.02.2009 13:51
X72 X71
X74
X44
=10D11
*
*
*
*
*
-F011
*
375
*
*
*
*
*
=10D11
-XF011
=10D11
-OM017 962 x 343
D D
E E
SIA-Date
F Date 26.02.2009 Customer Demag Crane & Components Designation = Layout F

Drawn McQuerry ZKKE 16 t x 20 m Equipment Layout + K1BG1
Check EZDR10-Pro 6/1 (16M ton) CASING CRANE BRIDGE Order No. Dept. Format Lang. Ident No. SK DT Sheet 01
Issue Mod. Date Name Ch.Date Compiled f. Repl.from Repl.by M 1:4 38402985 270 3 EN 38402985 N 30 5 Sh.
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
GENERAL OVERVIEW ELECTRICAL CASING DR
: 44DIN4
: 082
BRAKING RESISTOR
CROSS TRAVEL UNIT
Code Point
Norm
B B
C =11D21 C
-F011
26.02.2009 13:51
GEARED LIMIT SWITCH

HOIST UNIT
D D
FUSE FREQUENCY INVERTER

CROSS TRAVEL UNIT CROSS TRAVEL UNIT
E E
SIA-Date

Drawn McQuerry ZKKE 16 t x 20 m Equipment Layout + K1K1G1
Check EZDR10-Pro 6/1 (16M ton) ENCLOSURE DR Order No. Dept. Format Lang. Ident No. SK DT Sheet 02
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A
OPTIONAL : A
: 44DIN4
: 082
DR-ZMS X101
Controller
Code Point
Norm
B Basic DR-FI B
=11D31 X1
-A021 X73
=11D31 =11D31
305
X48 -A011 -A011.1 100dB
C
X16 C
X41
X66 X27
=11D31
26.02.2009 13:51
304 X47
303
302
X52 JP11 -H024
D X10 D
Code 301
X134
Code
X34 X5 X35 X201 X13

SW X37
301 X53 JP13 X15 X99 X2
E
X72 X71 E
X74
X44
SIA-Date

Check EZDR10-Pro 6/1 (16M ton) CASING COVER DR Order No. Dept. Format Lang. Ident No. SK DT Sheet 03
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A =11D31
-XF041.1 A
: 44DIN4
PF 2000 FMA
: 082
24V DC
=11D31
-E014
Code Point
=11D31
-L041
Norm
B B
=11D31
-F041 =11D31
C KTS011 -G041 C
CM-CAN
=11D31
26.02.2009 13:51
-B013 =11D31
*
*
-D045
=11D31
*
*
*
*
*
-XF045
100
=11D31
-F011
D D
TERMINALS
=11D31
*
*
*
*
-XF041.2
*
*
*
200
=11D31
-F047
=11D31 400 x 600 x 300

E -OM043 E
PF 2000 FM
24V DC
=11D31
-E013
SIA-Date
IN CASING BOTTOM
Check EZDR10-Pro 6/1 (16M ton) ENCLOSURE FREQUENCY INVERTER Order No. Dept. Format Lang. Ident No. SK DT Sheet 04
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
: 44DIN4
: 082
Display
Code Point
Norm
B B
1 2
C 3 4 C
26.02.2009 13:51
5 6
D D
7 8
1 1+2 2
E E
SIA-Date

Drawn McQuerry ZKKE 16 t x 20 m Equipment Layout + K1B
Check EZDR10-Pro 6/1 (16M ton) RADIO CONTROL TRANSMITTER Order No. Dept. Format Lang. Ident No. SK DT Sheet 05
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
2x =10D11
: 44DIN4
+K1B
-W1
*
: 082
BRAKING RESISTOR LONG TRAVEL UNIT

=10D41
Code Point
+K1BG1
-R027
Norm
Gehäuse Kranbrücke
B +K1BG1 B
*
*
=10D11 -XF011 X2 =10D11 -XF037 =10D41 -XF024 =10D41 -XF026 X16 X48 X47 =10D11 -XF036
+K1BG1 +K1BG1 +K1BG1 +K1BG1 +K1BG1
=10D11 -XM011 =10D11 -XM031 =10D41 -XM024 =10D41 -XM026 =10D11 -XM036
+K1B +K1B +K1B +K1B +K1B
HYSLY-JZ 5x1
HYSLY-JZ 5x1
=10D41 =10D41
3xAWG16+(2x2xAWG24)C
+K1B +K1B
PUR 4x +2x(2x )C
PUR 4x +2x(2x )C
=10D11 =10D11 =10D41 =10D41 -W16 -W17 =10D11

C +K1BFK1
-W2
+K1BFK1
-W6
+K1B
-W4
+K1B
-W5
+K1B
-W11
C
*
26.02.2009 13:51
LONG TRAVEL PRELIMINARY SWITCH-OFF

LONG TRAVEL LIMIT SWITCHING
=10D41 =10D41
VP_1 02.2
VP_3 02.3
+K1B +K1B
=10D41 -XF024.1 =10D41 -XF026.1 -S032 -S036 =19N11 -XF012
+K1B +K1B +K1B
=10D41 -XM024.1 =10D41 -XM026.1 =19N11 -XM012
D CRAB 1 +K1B +K1B +K1BS1 D
LONG TRAVEL MOTOR 1
LONG TRAVEL MOTOR 2

=10D41 =10D41
+K1B +K1B
YMHY-02TY(2x2x0,25C)+2x0,75
-M024 -M026
=19N14 -XM011 =19N11
+K1B +K1BS1
-W12
Superflex PUR 3x2x0,25
E =19N14
+K1B E
RADIO CONTROL TRANSMITTER
-W52
=19N14
+K1B
-U014 =19N11
CONTROLLER
+K1BS1
-S012
=19N14
RADIO CONTROL
+K1B
SIA-Date
-U011
F Date 26.02.2009 Customer Demag Crane & Components Designation = Connection F

Drawn McQuerry ZKKE 16 t x 20 m Interconnection Diagram +
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
: 44DIN4
OPTIONAL :
Code Point : 082
SUPERFLEX-N PUR 7x0,5 CRAB LIMIT SWITCH 2-STAGE

=11D21
Norm
01.1 VP_1
01.2 VP_3
+K1K1
-S022
B B
=10D11 =10D11
+K1BFK1 +K1BFK1
-W2 -W6
*
=11D21
+K1K1
-W18
C C
=11D31 -XM041.1 =11D31 =11D31 -XM025
+K1K1 +K1K1
FILTER FAN
+K1K1G2
CROSS TRAVEL UNIT BRAKING RESISTOR

=11D31 -XF041.1 -E014
26.02.2009 13:51
CROSS TRAVEL UNIT CONVERTER

+K1K1G2 X2 X16 X48 X47
Gehäuse Frequenzumrichter Katze 1 Gehäuse Katze 1
BRAKING RESISTOR
BRAKING RESISTOR
=11D31 =11D31 =11D21 =11D21

+K1K1G2 +K1K1G2 +K1K1G2 +K1K1G1 +K1K1G1 +K1K1G1
-R047.1 -R047.2 *
*
*
*
OPTIONAL : OPTIONAL : -G014 -R017
=11D31 -XF041.2 =11D31 X7 X8 X53 X14
FILTER FAN
+K1K1G2 +K1K1G2
=11D31 -XM041.2 -E013
D +K1K1 D
RC-12 2x0,5+10x0,14
=11D31 =11D31
HOIST MOTOR
+K1K1 +K1K1
PUR 4x +2x(2x )C
PUR 4x +2x(2x )C
-M041
LIYCY(TP)2x2x0,25
-W64 =11D31 =11D31 =11D21 =11D21
LIYY 4x0,25
+K1K1 +K1K1 +K1K1 +K1K1
-W21 -W20 -W9 -W10
E =11D31 -XF055 E
STRAIN GAUGE CARRIER LINK 1

+K1K1
CROSS TRAVEL MOTOR 1
CROSS TRAVEL MOTOR 2

=11D31 =11D31 =11D31 =11D21 =11D21
PULSE DEVICE
+K1K1 +K1K1 +K1K1 +K1K1 +K1K1

-B055 -B021 -S023 -M016 -M014
MGS
SIA-Date
F Date 26.02.2009 Customer Demag Crane & Components Designation = Connection F

Drawn McQuerry ZKKE 16 t x 20 m Interconnection Diagram +
1 2 3 4 5 6 7 8
Order no. 502262 EZDR 16T 1O... IDAPSY 1/8
IDAPSY AfterSalesBusiness
Service Software DR/DC Name:

Parameter-Listing
Telephone:
Telefax:
Demag DR RopeHoist
Serial no. 87000568-2 EMail:
Date: 05.09.2013
General data
Order no.: 502262 EZDR 16T 1OF2
Customer no.:
Customer: AGGREKO INTERNATIONAL PROJECT PANAMA
PACIFICO- PANAMERICAN C
Street: CENTDR SUR LOTE 9124
Post code:
Town/city: PANAMA PANAMA
Date of Delivery: 9/5/13
Owner (final customer): AGGREKO INTERNATERIONAL PROJECT

PANAMA PACIFICO PANAMERICAN
Customer number owner:
Street: CENTER SUR LOTE 9124
Post code:
Contact:
Telephone:
Delivery date owner: 9/5/13
Date of installation:
Basic data - Order datas
Order number: 261449

Customer number: 926230
Serial number: 87000568
Year of manufacture: 2012
Serial no. 87000568-2 Data set 06.09.2013 08:40:33

Basic data - Basic parameters

Control type crane: 2
Control signal source: 0
Trolley-/Bridge-electric: 1
Universal output UNI-OUT 1/2:
Hardware-version: 800
Software version: 5.11
PCB serial number: 50205532
Limit switch
---------- Limit switch - Crane ----------

Crane limit switch: 3
SGDM/BER
Min. time acc. V1: 0 [ms]
BER trip time: 500 [ms]

BER time: 1000 [ms]
Crane/trolley/hoist FI
Type of bridge control: 2
Add. control type crane: 0
Setpoint value 2-stage(crane): 0

Bridge inverter type: 1
Vmin/V1 - crane FI: 5 [m/min]

Vmax/V2 - crane FI: 52 [m/min]
Pre.lim. Crane: 5 [m/min]
Ana.setpoint-kneepoint 1: 0 [%]
Brake appl. for V=x: 1 [m/min]

Brake application funct. ON/OFF: 0
Gearbox-ratio (crane axis): 0.01

Wheel-diameter (crane): 0.1 [mm]
By-pass control
--- Bypass Control 1 Yes/No/Typ ---

Bypass control Yes/No/Type: 0

Type of Bypass control 1: 0
Bypass control middle: 0
Bypass control deact.: 0
--- Bypass Control 2 - add on ---

By-pass control add-on Crane: 0
Typ of signal source 2 (crane): 0
Add. enable signal (crane): 0
Selection of the signal source: 0
-- Area-dependent V reduction --
V reduction: 0
V-red - Tripping axis: 0
V-red - affected axis: 0
V-red - Select. of the signal source: 0
-- Conditional load reduction --

Load reduction: 0
Type of Conditional load reduction: 0
Signal source of control signal: 0
Parallel, synchronised operation
Position of crane: 0
---- Crane tandem mode ----

Crane tandem mode: 0
Crane tandem - mode: 0
Crane tandem - interlock: 0
Parallel inputs
Parallel control: 60
Type emmergency control:
ID CAN
Node-ID 1.signal source crane: 1
Node-ID 2.signal source: 0
Node-ID 1st trolley: 1

Node-ID 2nd trolley: 0
Node-ID other crane: 0
Own Node-ID: 0
Baud rate: 0

terminating resistor:

Operating Data
Hour counter: 8:00:26
Operating hours(crane): 0:11:58
K1 switch.op. Crane: 0
Switch.op.crane brake: 62
Max.switch.op.crane brake: 1500
Crane travel path: 438

Output functions
Universal output UNI-OUT 1: 0

Transfer -output OUT1: 0

DPC output function: 0
ext Output OUT Crane: 0

ext Output OUT 1: 0
ext Output OUT 2: 0
CAN coupling module: 0
-- Axis-specific release hoist --

Param.crane speed 54/55: 30
Travel motion signal: 0 [msec]
Special funktions
Status analysis: 0
- Approach supp./dest.pos.control -
Dearination positioning crane: 0
Function selection: 0
Selection F key: 0
--- Specific hoist movement enable ---

Spec. crane move.enable: 15
Affect from hoist: 15
Affect: 0
Enable active: 0
Safe enable: 0
Enable can be switched off: 0
Safety functions
Block control pendant: 0

Safety stage crane: 0
-- Deact.safety & operating funct. --

Deact.safety & operating funct.: 0
Deactivation by: 0
Select.F key/key-operated switch: 0

DIP-Code 305: 11111110
Process Data
I/O status port A: 11100000
I/O status port B: 11000101
I/O status port E: 10010101
I/O status port H: 11001010
I/O status port J: 11000001
I/O status port K: 00000010
I/O status port M: 11000011
I/O status port P: 00000000
I/O status port S: 10001011
I/O status port T: 00000100
Own Node-ID: 0
Baud rate: 0
Control on test bench: 0

Statistics
Limit value exceeded:

No.of EmergencyStop: 2
CAN-Error RX: 0
CAN-Error TX: 0

Parameter-Listing
Telephone:
Telefax:
Demag DR RopeHoist
Date: 05.09.2013
General data
Order no.: 502262 EZDR 16T 1OF2
Customer no.:
Customer: AGGREKO INTERNATIONAL PROJECT PANAMA
PACIFICO- PANAMERICAN C
Street: CENTDR SUR LOTE 9124
Post code:
Owner (final customer): AGGREKO INTERNATERIONAL PROJECT

PANAMA PACIFICO PANAMERICAN
Post code:
Contact:
Telephone:


Model code:
EZDRPRO 10 16 6/1 13,3Z 6 480 11 60 25
Solo trolley: 0
Control type trolley: 0
Full load hours: 2300

Gearbox transmission ratio: 61

Drum diameter: 274 mm

Rope diameter: 13 [mm]
Reeving: 6/1
Reeving factor: 6
Lifting height: 13.3 [m]
Hoist speed V1: 0.3 [m/min]
Hoist speed V2: 6 [m/min]
Limited load <50t:

Nominal load hoist<50t:
Limit switch
---------- Limit switch - Hoist ----------

Hoist limit switch: 1
Switch-off type: 1
Hoist limit switch type: 0
Lifting limit switch Z brake: 0
--------- Limit switch - Trolley ---------

Trolley limit switch: 0
Load parameters - Load (< 50t) up to V3.97
Nominal load hoist<50t: 10000 [kg]

Limited load <50t: 16000 [kg]
ZMS nom.load(<50t): 625 [kg]

Dead load(<50t): 0 [kg]
Permanent dead load ZMS1: 0 [t]
Load diff. Monitoring(<50t): 0 [kg]
Fall load 4/2-2(<50t): 1 [kg]
Load parameters - Load (<=>50t) from V3.98
Nominal load hoist HCH: 0 [t]

Limited load hoist HCH: 0 [t]

ZMS nominal load: 0 [t]

Dead load: 0 [t]
Load diff. Monitoring: 0 [t]
Fall load 4/2-2: 0 [t]
Heavy load 2 trolley-com.: 0
Load detection
with/without overload: 1
without/with/no. of ZMS: 0
Load display with other trolley: 1
Load display unit: 0
Partial load switching point: 7

Creep lifting time: 0 [sec]
ZMS Load detector

B/A lever transmission ratio: 1.5625
ZMS nom.load(<50t):
Tare function (radio): 0
Dead load:
Hysteresis slack rope case: 15 [%]

Slack rope correction value: 1
Max. load correction value: a

Hysteresis overload case: 20 [%]
Nom.load crane(2troll.op.): 0
Load diff. Monitoring(<50t):

Load diff. hysteresis: 18 [%]
Fall load 4/2-2(<50t):

Slip load detection
Line voltage: 480 [V]
Line frequency: 60 [Hz]
Hoist nom.speed V1: 1 [U/min]


Drive calc.factor V1: 0.9

Slip-Voltage-Factor: a
SGDM/BER
--- Hoist ---
Inching debounce time: 2 [s]

Min. time dec. V1: 0 [ms]
Braking time, decel.: 100 [ms]

time for mech.brake: 50 [ms]
--- Trolley ---

Attention !!!!
Only trolley with pol-changing motor !
Min. time acc. V1 trolley: 0 [s]

Min. time dec. V1: 0 [s]
Braking time, decel.: 0 [s]
time for mech.brake: 8 [s]
Type of hoist/trlley control: 2
Control type hoist: 2
Hoist inverter type: 1

Setpoint value 2-stage(hoist): 0
Prohub function: 0.1
Vmin/V1 - hoist FI: 0.3 [m/min]
Vmax/V2 - hoist FI: 6 [m/min]
Pre.lim. Hoist: 0.6 [m/min]
Setpoint value 2-stage(trolley): 0
Vmin/V1-trolley FI: 7 [m/min]
Vmax/V2-trolley FI: 25 [m/min]
Pre.lim. Trolley: 8 [m/min]
Ana.setpoint-kneepoint 1 [%]: 0
Ana.setpoint-kneepoint 2 [&]: 0
Gearbox-ratio (trolley axis): 44.1

Wheel-diameter (trolley): 160 [mm]

Brake
Wear limit/run-on: 4500
Hoist motor brake type: 0
--- Catching brake (2nd brake) ----

Release time: 0.5 [s]
Application delay: 1 [s]
By-pass control


By-pass control add-on Trolley: 0
Typ signal source 2 (trolley): 0
Add. enable signal (trolley): 0
V reduction: 0

Conditional load reduction: 0
Max. load (load red.: 0 [kg]

Parallel/synchron.lifting op.: 0
Parallel/synchron.op.hoist in: 0 [%]
Limit value synchron.op.diff.: 200
Parallel operation trolley: 0

Position of trolley: 0
Parallel/synchron.op.trolley in: 0 [%]


Parallel inputs
ID CAN
Node-ID load display: 0
Node-ID of hoist FI: 1

Node ID 2nd signal source trolley: 0
Node-ID crane: 1
Node-ID other trolley: 0

Own Node-ID: 0
Baud rate: 0

Operating Data
Operating hours(hoist): 0:06:40
Operating hours(trolley): 0:00:00
Load spectrum: 99.9913

Warning Rem. serv. Time: 0 [%]
K1 switch.op. Hoist: 39
Switch.op.hoist brake: 37
Max.switch.op.hoist brake: 0
Switch.op.trolley brake: 4
Max.switch.op.trolley brake: 0
Holding brake switching op.: 0
Trolley travel path: 0
Measured braking dist.: 0 [Ink]

Slip correction factor: 0

Output functions


ext.Output OUT Trolley: 0

ext.Output OUT 1: 0
ext.Output OUT 1: 0

CAN (USA) coupling module: 0

Load threshold UNIOUT40/41: 0 [%]
Param.hoist speed 56/57: 0
Param.cross speed 54/55: 0
Special funktions
Load spectrum active: 1
Status analysis: 0
Type of Load Display: 1
Dearination positioning trolley: 0
Selection F key: 0

Spec.hoist move.enable: 0
Affect from tgrolley/crane: 0
Affect: 0
Enable active: 0
Safe enable: 0
Spec.trolley move.enable: 0
Affect: 0
Enable active: 0
Safe enable: 0


Safety functions
Safety stage crab: 0
-- Deactivating slack rope cut-out --

Signal source of slack rope cut-off: 0
Selection of the source: 0
Slack rope cut-off activ: 0

Deactivation by: 0
DIP-Code 305: 00000000
Process Data
Own Node-ID: 0
Baud rate: 0
Overload test enable: 0
Actual values
Act.speed hoist mot.: 0 [U/min]

Curr. load meas.(slip): 0 [kg]
Curr.load meas. ZMS1: 0 [kg]

Curr.load meas.ZMS1(V3.98): 0
Tare value other hoist: 0

Tare value own hoist: 0
------ Analog values ZMS ------

ZMS1 ana.meas.value: 0 [mV]
Meas.val. +12 V monitor.: 0 [mV]
Meas.val. -12 V monitor.: 0 [mV]
Manufacturer data - ZMS Single board
ZMS1 factor: 0 [mV]

ZMS2 factor: 0 [mV]
ZMS1 offset: 0 [mV]
ZMS2 offset: 0 [mV]
Dev.at zero load ZMS1: 0 [mV]

Voltage mon. -12 V: 1700

Voltage mon. +12 V: 1900

Manufacturer data - ZMS Modular board
ZMS1 factor (mod): 0 [mV]

ZMS1 offset (mod): 0 [mV]
ZMS2 offset (mod: 0 [mV]

Voltage mon. -12 V (mod): 0

Voltage mon. +12 V (mod): 0

Hardware-vers.ZMS-mod: 0
ZMS-mod serial no.: 0

Statistics

Max. slip: 0
Max. rotation: 0
Brake: 0
Rope-drum brake: 0
Overload: 0
CAN-Error RX: 0
CAN-Error TX: 0

Dedrive Compact frequency inverter: 520 422 911 ; 13061337
Inverter Data
000 Serial Number = 520 422 911 ; 13061337
001 Optional Modules = - ; -
012 Inverter Software Version = 4.2.4/050-7a
027 Set Password = 0
028 Control Level = 3
029 User Name = 73024645_00_135018_CRANE (!)
030 Configuration = 410 - FOR speed without encoder
033 Language = 1 - English (!)
034 Program = 0 (!)
Motor Data
Rated Motor Parameters
370 Rated voltage [*] = 220.0 V (!)
371 Rated current [1] = 10.2 A (!)
[2] = 13.0 A (!)
[3] = 23.2 A (!)
[4] = 17.5 A (!)
372 Rated speed [1] = 1400 U/min (!)
[2] = 1430 U/min (!)
[3] = 1400 U/min (!)
[4] = 1415 U/min (!)
373 No. of Pole Pairs [*] = 2
374 Rated Cosinus Phi [1] = 0.74 (!)
[2] = 0.76 (!)
[3] = 0.81
[4] = 0.80 (!)
375 Rated frequency [*] = 50.00 Hz
376 Rated Mech. Power [1] = 2.2 kW (!)
[2] = 3.0 kW (!)
[3] = 6.0 kW (!)
[4] = 4.4 kW (!)
812 Cyclic duration factor [*] = 100 - 100 % CDF
Additional motor data

368 Rated voltage correction factor [*] = 100.00 %
377 Stator resistance [1] = 530 mOhm
[2] = 947 mOhm (!)
[3] = 530 mOhm
[4] = 530 mOhm
378 Leakage factor [1] = 7.0 %
[2] = 8.0 % (!)
[3] = 7.0 %
[4] = 7.0 %
713 Magnetising Current 50% Flux [1] = 31.00 %
[2] = 29.90 % (!)
[3] = 31.00 %
[4] = 31.00 %
[2] = 80.00 % (!)
[3] = 65.00 %
[4] = 65.00 %
[2] = 150.00 % (!)
[3] = 145.00 %
[4] = 145.00 %
716 Idle current [1] = 3.1 A (!)
[2] = 7.0 A (!)
[3] = 7.0 A (!)
[4] = 5.3 A (!)
718 Rotor time constant correction f [1] = 100.00 %
[2] = 98.71 % (!)
[3] = 100.00 %
[4] = 100.00 %
745 Stator+Rotor Resistance [1] = 795 mOhm
[2] = 1077 mOhm (!)
[3] = 795 mOhm
[4] = 795 mOhm
Encoder 1
490 Operation Mode Encoder 1 = 0 - off
491 Division Marks Encoder 1 = 1024
SETUP
796 Motor parameter identification = 0 - Clear Status
797 Status of motor parameter identi = Ok
System Data
389 Factor Actual Value System [*] = 1.000
Operational Behaviour
Starting Behaviour
623 Starting current [1] = 10.2 A (!)
[2] = 13.0 A (!)
[3] = 23.2 A (!)
(!) = Default value; [*] = values for all data sets are the same; [x] = value for data set x
05.09.2013 Page 1
[4] = 17.5 A (!)
Stopping Behaviour
630 Operation Mode [*] = 11 - R.->0, Off; R.->0, Off
Auto-Start
651 Operation Mode = 0 - off
Search Run
645 Operation Mode [*] = 0 - off
Positioning
458 Operation Mode [*] = 0 - Off
Reference positioning
459 Signal source = 2 - S2IND, falling edge
460 Positioning distance [*] = 0.000 U
461 Signal correction [*] = 0.00 ms
462 Load correction [*] = 0
463 Activity after positioning [*] = 0 - End positioning
464 Time to wait [*] = 0 ms
470 Rotations = 0.000 U
Brake-Control
820 Start delay [*] = 0 ms
821 DC pre-magnetisation time [*] = 0 ms
822 DC post-magnetisation time [*] = 0.0 s
824 Brake release dalay [*] = 0 ms
825 Brake application time [*] = 200 ms (!)
Brake release monitoring

826 Operation mode = 0 - Off
828 Brake release time = 400 ms
894 Brake application time = 200 ms
899 Error response time = 100 ms
Load spectrum calculation

829 Factor = 1.00
830 Operation Mode = 0 - Off
831 Theoretical duration of service = 0.0 h
832 Lifting correction factor = 100 %
833 Lowering correction factor = 100 %
834 Duration of service specificatio = 0.0 h
835 Actual duration of service = 0.0 h
836 Remaining service life = 0.00 %
837 Relative torque = 0.00 %
838 Ramp Factor = 1.00
839 Frequency at rated hoist speed = 0.00 Hz
Limit Switch Functions

871 Setpoint val. limit 1+ [*] = 2.00 Hz
872 Setpoint val. limit 1- [*] = 2.00 Hz
875 Limit switch monitoring freq. + [*] = 2.00 Hz
876 Limit switch monitoring freq. - [*] = 2.00 Hz
External error / Quick stop

535 Operation Mode = 0 - Disabled
Error/Warning Behaviour
405 Warning Limit Short Term Ixt = 80 %
406 Warning Limit Long Term Ixt = 80 %
407 Warning Limit Heat Sink Temp. = -5 deg.C
408 Warning Limit Inside Temp. = -5 deg.C
409 Controller-Status Message = 1 - Warning Status
415 IDC Compensation Limit = 0.0 V
417 Frequency Switch-off Limit [*] = 200.00 Hz (!)
429 Max. frequency deviation = 10.00 Hz
468 Frequency monitoring = 2 - Maximum Leading
570 Motor-PTC Operation Mode = 2 - Therm.-Cont.: Error Switch-Off (!)
576 Phase Supervision [*] = 10 - Mains: Error Switch-Off
578 Allowed No. of Auto-Acknowl. = 0
579 Restart Delay = 20 ms
Reference Values
Frequency Limits
418 Minimum frequency [1] = 0.00 Hz (!)
[2] = 5.00 Hz (!)
[3] = 0.00 Hz (!)
[4] = 0.00 Hz (!)
419 Maximum frequency [*] = 100.00 Hz (!)
719 Slip limit [*] = 250 % (!)
Reference Frequency Channel
05.09.2013 Page 2
475 Drive control [*] = 1 - Analog MFI1A (!)
SOST-Parameters
480 SOST step 1 [*] = 5.00 Hz
481 SOST step 2 [*] = 50.00 Hz
482 SOST step 3 [*] = 5.00 Hz
483 SOST step 4 [*] = 5.00 Hz
489 JOG-Frequency = 5.00 Hz
Blocking Frequencies
447 1st Blocking Frequency [*] = 0.00 Hz
448 2nd Blocking Frequency [*] = 0.00 Hz
449 Frequency Hysteresis [*] = 0.00 Hz
Frequency Ramps
420 Acceleration [*] = 20.00 Hz/s (!)
421 Deceleration [*] = 20.00 Hz/s (!)
422 Acceleration Anticlockwise [*] = -0.01 Hz/s
423 Deceleration Anticlockwise [*] = -0.01 Hz/s
424 Emergency Stop Clockwise [*] = 30.00 Hz/s
425 Emergency Stop Anticlockwise [*] = 30.00 Hz/s
426 Maximum Leading [*] = 5.00 Hz
430 Ramp Rise Time Clockwise [*] = 0 ms
431 Ramp Fall Time Clockwise [*] = 0 ms
432 Ramp Rise Time Anticlockwise [*] = 0 ms
433 Ramp Fall Time Anticlockwise [*] = 0 ms
434 Ramp Setpoint [*] = 3 - Internal + Line Setpoint
Percentage-Value Limits
518 Minimum Reference Percentage [*] = 0.00 %
519 Maximum Reference Percentage [*] = 100.00 %
Keypad Motor Potentiometer

473 Ramp Keypad-Motorpoti = 2.00 Hz/s
SOSP function
474 SOSP-Function = 0 - Not Latching
Repetition Frequency Input

497 Divider = 1024
Additional setpoint value

841 Additional setpoint value source [*] = 9 - Zero
842 Max. additional frequency negati [*] = 0.00 Hz
843 Max. additional frequency positi [*] = 0.00 Hz
844 Acceleration additional setpoint [*] = 25.00 Hz/s
845 Deceleration additional setpoint [*] = 25.00 Hz/s
846 Additional setpoint value bus op [*] = 0.00 Hz
847 Additional fixed frequency 1 [*] = 0.00 Hz
Control Inputs/Outputs
Multi-function Input MFI1
450 Tolerance Band [*] = 2.00 %
452 Operation Mode = 1 - Voltage Input
453 Error/Warning Behaviour = 0 - Off
454 Point X1 [*] = 2.00 %
455 Point Y1 [*] = 0.00 %
456 Point X2 [*] = 96.00 % (!)
457 Point Y2 [*] = 100.00 %
870 Characteristic type [*] = 1 - linear
Multi-function Output MFO1

550 Operation Mode MFO1 = 1 - Digital
551 Voltage 100% = 10.0 V
552 Voltage 0% = 0.0 V
553 Operation Mode analog MFO1A = 7 - Abs. Actual Frequency
554 Operation Mode digital MFO1D = 41 - Release brake (!)
555 Operation Mode Repetition Freq. = 1 - Actual Frequency
556 Division Marks = 1024
Digital Outputs
510 Setting Frequency [*] = 3.00 Hz
530 Op. Mode Digital Output 1 S1OUT = 1 - Ready
532 Op. Mode Digital Output 3 S3OUT = 0 - off (!)
536 Create Warning Mask = 0 - No Change (!)
537 Actual Warning Mask = A0000FFFF Ixt IxtSt IxtLt Tc Ti Lim LK PTC
540 Op. Mode Comparator 1 = 1 - Absolute Current
541 Comparator 1 On above = 100.00 %
542 Comparator 1 Off below = 50.00 %
05.09.2013 Page 3
Digital Inputs
062 (SOSP) Acceleration = 7 - Off (!)
066 (SOST) Step 2 = 7 - Off (!)
067 (SOST) Step 3/4 = 7 - Off
068 SW-Step 1+ = 71 - S2IND
069 SW-Step 1- = 72 - S3IND
070 Data Set Change-Over 1 = 73 - S4IND (!)
083 Timer 1 = 7 - Off
084 Timer 2 = 7 - Off
103 Error Acknowledgment = 270 - S1IND inverted
183 External error / Quick stop = 7 - Off
204 Motor thermal contact = 75 - S6IND (!)
800 Additional fixed frequency selec = 7 - Off
802 Additional setpoint value releas = 6 - On
803 Fast to slow limit switch limita = 6 - On
806 Operating limit switch + = 6 - On
807 Operating limit switch - = 6 - On
827 Brake feedback = 7 - Off
Timer and Logic Functions

Timers
790 Operation Mode Timer 1 = 3 - AND-Connect., Rising Edge, Sec.
791 Time 1 Timer 1 = 0.00 s/m/h
792 Time 2 Timer 1 = 0.00 s/m/h
794 Time 1 Timer 2 = 0.00 s/m/h
795 Time 2 Timer 2 = 0.00 s/m/h
Logic Function 1
199 Input 1 = 7 - Off
200 Input 2 = 7 - Off
Logic Function 2
202 Input 1 = 7 - Off
203 Input 2 = 7 - Off
Logic Function 3
206 Input 1 = 7 - Off
207 Input 2 = 7 - Off
Logic Function 4
504 Input 1 = 7 - Off
505 Input 2 = 7 - Off
Logic Function 5
818 Input 1 = 7 - Off
819 Input 2 = 7 - Off
Logic Function 6
858 Input 1 = 7 - Off
859 Input 2 = 7 - Off
Logic Function 7
878 Input 1 = 7 - Off
879 Input 2 = 7 - Off
Logic Function 8
883 Input 1 = 7 - Off
884 Input 2 = 7 - Off
Logic Function 9
886 Input 1 = 7 - Off
887 Input 2 = 7 - Off
Logic Function 10
892 Input 1 = 7 - Off
893 Input 2 = 7 - Off
Control Functions
05.09.2013 Page 4
Intelligent Current Limits

574 Power Limit [*] = 80.00 %
575 Limitation Time [*] = 15 min
Voltage Controller
671 Mains Failure Threshold = -100.0 V
672 Reference Mains Support Value = -40.0 V
674 Acceleration on Mains Resumption [*] = 0.00 Hz/s
675 Shutdown Threshold [*] = 0.00 Hz
676 Reference Shutdown Value = 730.0 V
677 Amplification [*] = 2.00
678 Integral Time [*] = 23 ms
680 Reference DC-Link Limitation = 760.0 V
681 Max. Frequency Rise = 10.00 Hz
683 Gen. Ref. Current Limit [*] = 25.0 A
Current Controller
700 Amplification [1] = 0.13
[2] = 0.16 (!)
[3] = 0.13
[4] = 0.13
701 Integral Time [1] = 10.00 ms
[2] = 1.75 ms (!)
[3] = 10.00 ms
[4] = 10.00 ms
702 Factor P, Ta=125us [1] = 4.00
[2] = 3.92 (!)
[3] = 4.00
[4] = 4.00
703 Factor P, Ta=250us [1] = 2.00
[2] = 1.90 (!)
[3] = 2.00
[4] = 2.00
704 Factor P, Ta=500us [*] = 1.00
705 Factor P, Ta=1000us [1] = 0.50
[2] = 0.15 (!)
[3] = 0.50
[4] = 0.50
706 Factor Tn, Ta=125us [1] = 1.00
[2] = 0.85 (!)
[3] = 1.00
[4] = 1.00
707 Factor Tn, Ta=250us [*] = 1.00
708 Factor Tn, Ta=500us [*] = 1.00
709 Factor Tn, Ta=1000us [1] = 1.00
[2] = 2.85 (!)
[3] = 1.00
[4] = 1.00
Speed Controller
720 Operation Mode [*] = 1 - Limits for Motor/Generator Op.
721 Amplification [*] = 5.00 (!)
722 Integral time [*] = 268 ms
723 Amplification f > f um [*] = 5.00
724 Integral time f > f um [*] = 536 ms
728 Motor current limit [*] = 50.0 A
729 Generative current limit [*] = -0.1 A
730 Motor torque limitation [*] = 200.00 % (!)
731 Generative torque limitation [*] = 200.00 % (!)
732 P share motor torque limitation [*] = 650.00 %
733 P share generative torque limita [*] = 650.00 %
734 Isq Limit Source Motor Operation [*] = 110 - Fixed Limit
735 Isq Limit Source Generator Op. [*] = 110 - Fixed Limit
736 Torque Limit Source Motor Op. [*] = 110 - Fixed Limit
737 Torque Limit Source Gen. Op. [*] = 110 - Fixed Limit
738 switch-over frequency f um [*] = 100.00 Hz (!)
739 Power Limit Motor Operation [*] = 44.00 kW
740 Power Limit Generator Operation [*] = 44.00 kW
748 Backlash Damping [*] = 0 %
766 Source Actual Speed [*] = 2 - Speed Sensor 2
Acceleration Pre-Control
726 Minimum Acceleration [*] = 1.0 Hz/s
727 Mech. Time Constant [*] = 10 ms
Field Controller
717 Flow correction factor [*] = 100.00 %
[2] = 62.1 ms (!)
[3] = 100.0 ms
[4] = 100.0 ms
743 Ref. Isd Upper Limit [1] = 10.2 A (!)
05.09.2013 Page 5
[2] = 13.0 A (!)

[3] = 23.2 A (!)
[4] = 17.5 A (!)
744 Ref. Isd Lower Limit [*] = 0.0 A
Modulation Controller
750 Reference Modulation [*] = 98.00 %
752 Integral Time [*] = 10.0 ms
753 Operation Mode [*] = 1 - V-Absolute Value Control
755 Reference Imr Lower Limit [*] = 0.3 A
756 Control Deviation Limitation [*] = 10.00 %
Special Functions
Pulse Width Modulation
399 Voltage Drop Compensation [1] = 2012070402300 (!)
[2] = 09020.0.0.083 (!)
[3] = 2012070402300 (!)
[4] = 2012070402300 (!)
400 Modulation frequency = 4 - kHz
401 Min. Modulation frequency = 4 - kHz (!)
402 Switching Compensation = 50 %
580 Reduction Limit Ti/Tc = -4 deg.C
Fan
039 Switch-On Temperature = 20 deg.C
Brake Chopper
095 Brake Chopper Release = 6 - On (!)
506 Trigger Threshold = 780.0 V
Motor Chopper
507 Trigger Threshold [*] = 800.0 V
508 Current Limit [1] = 25.0 A
[2] = 26.0 A (!)
[3] = 25.0 A
[4] = 25.0 A
Motor Protective Switch

572 Frequency Limit [*] = 0 %
Bus Controller
412 Local/Remote [*] = 0 - Control via Contacts
Temperature Adjustment
466 Temperature Coefficient [*] = 39.00 %/100
467 Adjusting Temperature [*] = 35.0 deg.C
Tandem
040 Source Reference Frequency = 46 - KeyPad-Gate Output
137 Source Reference Line Value = 5 - Fixed Frequency in RAM
Software Configuration
099 Remote Control Word = 740 - Remote Control Word
808 Memoryaddress Offset-Value 1 = 71 - S2IND (!)
895 Memoryaddress Offset-Value 3 = 11431 (!)
Actual Values
Actual Freq. Inv. Values
222 Link voltage = 676.4 V
223 Output voltage ratio = 0 %
228 Internal Reference Frequency = 0.00 Hz
244 Working Hours Counter = 0 h
245 Operation Hours Counter = 2 h
249 Active Data Set = 2
250 Digital Inputs = 40 . . . ! . ! . . . . . . . . . .
251 Analog Input MFI1A = 0.21 %
252 Repetition Frequency Input = 0.00 Hz
254 Digital Outputs = 0 . . . . . . . . . . . . . . . .
255 Heat Sink Temperature = 28.8 deg.C
256 Interior temperature = 33.4 deg.C
257 Analog Output MFO1A = 0.0 V
259 Current error = F0000 No Fault
269 Warnings = A0000 No Warning
271 Interior temperature 24 h = 30.2 deg.C
272 Duty factor = 0.0 %
275 Controller Status = C0000 No controller active
278 Frequency MFO1F = 0.00 Hz
862 Maximum Interior temperature = 36.0 deg.C
863 Maximum Interior temperature 24h = 35.0 deg.C
864 Time of Maximum Interior tempera = 0 h
05.09.2013 Page 6
Actual Machine Values

210 Stator Frequency = 0.00 Hz
211 Motor Current = 0.0 A
212 Motor Voltage = 0.0 V
213 Active Power = 0.0 kW
215 Flow current share Isd = 0.0 A
216 Torque current share Isq = 0.0 A
217 Encoder 1 Frequency = 0.00 Hz
218 Encoder 1 Speed = 0 1/min
221 Slip frequency = 0.00 Hz
224 Torque = 0.0 Nm
225 Rotor Flux = 0.0 %
226 Winding Temperature = 0.0 deg.C
227 Current rotor time constant = 108.1 ms
235 Flux-Forming Voltage = 0.0 V
236 Torque-Forming Voltage = 0.0 V
240 Actual Speed = 0 1/min
241 Actual Frequency = 0.00 Hz
Actual System Values

242 Actual Value System = 0.000
Actual Value Memory

231 Peak Value Long Term Ixt = 0.00 %
232 Peak Value Short Term Ixt = 0.00 %
237 Reset memory = 0 - No Reset
287 Peak Value Vdc = 750.1 V
288 Average Value Vdc = 670.4 V
289 Peak Value Heat Sink Temp. = 35.5 deg.C
290 Average Value Heat Sink Temp. = 30.2 deg.C
291 Peak Value Inside Temperature = 36.1 deg.C
292 Average Value Inside Temperature = 33.9 deg.C
293 Peak Value Irms = 13.3 A
294 Average Value Irms = 8.7 A
295 Peak Value Active Power pos. = 2.0 kW
296 Peak Value Active Power neg. = -0.1 kW
297 Average Value Active Power = 0.7 kW
301 Energy, positive = 0 kWh
302 Energy, negativ = 0 kWh
Error Protocol
Error List
310 Last Error = 00000:00 ; F0000 No Fault
311 Last Error but one = 00000:00 ; F0000 No Fault
312 Error 3 = 00000:00 ; F0000 No Fault
313 Error 4 = 00000:00 ; F0000 No Fault
314 Error 5 = 00000:00 ; F0000 No Fault
315 Error 6 = 00000:00 ; F0000 No Fault
316 Error 7 = 00000:00 ; F0000 No Fault
317 Error 8 = 00000:00 ; F0000 No Fault
318 Error 9 = 00000:00 ; F0000 No Fault
319 Error 10 = 00000:00 ; F0000 No Fault
320 Error 11 = 00000:00 ; F0000 No Fault
321 Error 12 = 00000:00 ; F0000 No Fault
322 Error 13 = 00000:00 ; F0000 No Fault
323 Error 14 = 00000:00 ; F0000 No Fault
324 Error 15 = 00000:00 ; F0000 No Fault
325 Error 16 = 00000:00 ; F0000 No Fault
362 No. of Errors = 0
363 No. of self acknowledged Errors = 0
Error Environment
330 Link voltage [*] = 0.0 V
331 Output Voltage [*] = 0.0 V
332 Stator frequency [*] = 0.00 Hz
333 Encoder 1 Frequency [*] = 0.00 Hz
335 Phase Current Ia [*] = 0.0 A
336 Phase Current Ib [*] = 0.0 A
337 Phase Current Ic [*] = 0.0 A
338 R.m.s Current [*] = 0.0 A
339 Flow current share Isd [*] = 0.0 A
340 Torque current share Isq [*] = 0.0 A
341 Rotor Magnetizing Current [*] = 0.0 A
342 Torque [*] = 0.0 Nm
343 Analog Input MFI1A [*] = 0.00 %
346 Analog Output MFO1A [*] = 0.0 V
349 Repetition Frequency Output [*] = 0.00 Hz
350 Status of Digital Inputs [*] = 0
351 Status of Digital Outputs [*] = 0
352 Time since Release [*] = 00000:00:00.000
353 Heat Sink Temperature [*] = 0.0 deg.C
354 Housing temperature [*] = 0.0 deg.C
355 Controller Status [*] = C0000 No controller active
356 Warning Status [*] = A0000 No Warning
357 Int Value 1 [*] = 0
05.09.2013 Page 7
358 Int Value 2 [*] = 0

359 Long Value 1 [*] = 0
360 Long Value 2 [*] = 0
361 Checksum [*] = OK
05.09.2013 Page 8
Inverter Data
000 Serial Number = 520 426 010 ; 13041506
001 Optional Modules = CM-CAN ; -
029 User Name = 73023545_0_135011_HOIST100B_132C (!)
030 Configuration = 210 - FOR speed with encoder (!)
034 Program = 0 (!)
Motor Data
370 Rated voltage [*] = 220.0 V (!)
371 Rated current [1] = 12.5 A (!)
[2] = 14.9 A (!)
[3] = 26.5 A (!)
[4] = 34.0 A (!)
372 Rated speed [1] = 1400 U/min (!)
[2] = 1440 U/min (!)
[3] = 1435 U/min (!)
[4] = 1440 U/min (!)
[2] = 0.83 (!)
[3] = 0.85 (!)
[4] = 0.84 (!)
[2] = 4.0 kW (!)
[3] = 7.5 kW (!)
[4] = 9.5 kW (!)

[2] = 7.0 %
[3] = 7.0 %
[4] = 5.8 % (!)
[2] = 31.00 %
[3] = 31.00 %
[4] = 43.42 % (!)
[2] = 65.00 %
[3] = 65.00 %
[4] = 63.05 % (!)
[2] = 145.00 %
[3] = 145.00 %
[4] = 122.38 % (!)
716 Idle current [1] = 12.0 A
[2] = 12.0 A
[3] = 12.0 A
[4] = 15.2 A (!)
[2] = 100.00 %
[3] = 100.00 %
[4] = 70.29 % (!)
[2] = 345 mOhm
[3] = 345 mOhm
[4] = 233 mOhm (!)
Encoder 1
490 Operation Mode Encoder 1 = 4 - Quadruple Evaluation (!)
815 Filter time constant encoder 1 = 0 - Off
SETUP
System Data
Starting Behaviour
780 Maximum flux build-up time [*] = 1000 ms
781 Current during Flux-Formation [1] = 40.0 A
[2] = 40.0 A
[3] = 40.0 A
[4] = 34.0 A (!)
Stopping Behaviour
05.09.2013 Page 1
Auto-Start
Search Run
Positioning
Axle positioning
037 Start Positioning of Axle = 7 - Off
469 Reference orientation [*] = 0.0 Grad
471 Positioning Frequency [*] = 50.00 Hz
472 Max positional error [*] = 3.0 Grad
479 time constant positioning contr. [*] = 20.00 ms
Brake-Control
821 DC pre-magnetisation time [*] = 200 ms (!)
825 Brake application time [*] = 100 ms


829 Factor = 1.00
830 Operation Mode = 1 - On (!)
831 Theoretical duration of service = 1900.0 h (!)
832 Lifting correction factor = 85 % (!)
833 Lowering correction factor = 50 % (!)
838 Ramp Factor = 0.30 (!)


468 Frequency monitoring = 1 - Max. frequency deviation
Reference Values
Frequency Limits
418 Minimum frequency [*] = 0.00 Hz (!)
719 Slip limit [*] = 330 %
05.09.2013 Page 2

475 Drive control [*] = 10 - SOST
SOST-Parameters
480 SOST step 1 [*] = 5.00 Hz
481 SOST step 2 [*] = 50.00 Hz
482 SOST step 3 [*] = 5.00 Hz
483 SOST step 4 [*] = 5.00 Hz
Frequency Ramps
424 Emergency Stop Clockwise [*] = 100.00 Hz/s (!)
425 Emergency Stop Anticlockwise [*] = 100.00 Hz/s (!)
434 Ramp Setpoint [*] = 2 - Line Setpoint (!)

SOSP function

497 Divider = 1024
ProHub-function
849 Hoist rating factor [*] = 1.00
850 Operation Mode [*] = 1 - On (!)
851 Field weakening enable = 6 - On (!)
852 Field weakening start [*] = 166 % (!)
853 Lifting correction value [*] = 15 % (!)
854 Lowering correction value [*] = 10 %
855 Start of measurement [*] = 80.00 Hz (!)
856 Field weakening factor [*] = 0.50
860 Current measuring value = 100.00 %
861 Valid max. frequency = 83.00 Hz

841 Additional setpoint value source [*] = 480 - Bus operation P.846 (!)
842 Max. additional frequency negati [*] = -100.00 Hz (!)
843 Max. additional frequency positi [*] = 100.00 Hz (!)
844 Acceleration additional setpoint [*] = 300.00 Hz/s (!)
845 Deceleration additional setpoint [*] = 300.00 Hz/s (!)
454 Point X1 [*] = 2.00 %
455 Point Y1 [*] = 0.00 %
456 Point X2 [*] = 98.00 %
457 Point Y2 [*] = 100.00 %

551 Voltage 100% = 10.0 V
552 Voltage 0% = 0.0 V
554 Operation Mode digital MFO1D = 3 - Error
05.09.2013 Page 3
Digital Outputs
532 Op. Mode Digital Output 3 S3OUT = 41 - Release brake
540 Op. Mode Comparator 1 = 107 - Actual Frequency (+/-) (!)
541 Comparator 1 On above = 0.00 % (!)
542 Comparator 1 Off below = 0.00 % (!)
549 Max. Control Deviation = 5.00 %
Digital Inputs
066 (SOST) Step 2 = 7 - Off (!)
067 (SOST) Step 3/4 = 7 - Off
068 SW-Step 1+ = 171 - Output Comparator 1 (!)
069 SW-Step 1- = 172 - Negated Output Comparator 1 (!)
083 Timer 1 = 7 - Off
084 Timer 2 = 7 - Off

Timers
791 Time 1 Timer 1 = 0.00 s/m/h
792 Time 2 Timer 1 = 0.00 s/m/h
794 Time 1 Timer 2 = 0.00 s/m/h
795 Time 2 Timer 2 = 0.00 s/m/h
Logic Function 1
199 Input 1 = 7 - Off
200 Input 2 = 7 - Off
Logic Function 2
202 Input 1 = 7 - Off
203 Input 2 = 7 - Off
Logic Function 3
206 Input 1 = 7 - Off
207 Input 2 = 7 - Off
Logic Function 4
504 Input 1 = 7 - Off
505 Input 2 = 7 - Off
Logic Function 5
818 Input 1 = 7 - Off
819 Input 2 = 7 - Off
Logic Function 6
858 Input 1 = 7 - Off
859 Input 2 = 7 - Off
Logic Function 7
878 Input 1 = 7 - Off
879 Input 2 = 7 - Off
Logic Function 8
883 Input 1 = 7 - Off
05.09.2013 Page 4
884 Input 2 = 7 - Off
Logic Function 9
886 Input 1 = 7 - Off
887 Input 2 = 7 - Off
Logic Function 10
892 Input 1 = 7 - Off
893 Input 2 = 7 - Off
Control Functions
574 Power Limit [*] = 80.00 %
Voltage Controller
Current Controller
[2] = 0.13
[3] = 0.13
[4] = 0.11 (!)
[2] = 10.00 ms
[3] = 10.00 ms
[4] = 4.50 ms (!)
702 Factor P, Ta=125us [1] = 4.00
[2] = 4.00
[3] = 4.00
[4] = 4.44 (!)
703 Factor P, Ta=250us [1] = 2.00
[2] = 2.00
[3] = 2.00
[4] = 1.68 (!)
704 Factor P, Ta=500us [*] = 1.00
705 Factor P, Ta=1000us [1] = 0.50
[2] = 0.50
[3] = 0.50
[4] = 0.22 (!)
706 Factor Tn, Ta=125us [1] = 1.00
[2] = 1.00
[3] = 1.00
[4] = 0.66 (!)
707 Factor Tn, Ta=250us [1] = 1.00
[2] = 1.00
[3] = 1.00
[4] = 0.72 (!)
708 Factor Tn, Ta=500us [*] = 1.00
709 Factor Tn, Ta=1000us [1] = 1.00
[2] = 1.00
[3] = 1.00
[4] = 1.11 (!)
Speed Controller
722 Integral time [*] = 100 ms (!)
723 Amplification f > f um [*] = 10.00 (!)
724 Integral time f > f um [*] = 300 ms (!)
730 Motor torque limitation [*] = 650.00 %
731 Generative torque limitation [*] = 650.00 %
05.09.2013 Page 5

766 Source Actual Speed [*] = 1 - Speed Sensor 1 (!)
Field Controller
[2] = 100.0 ms
[3] = 100.0 ms
[4] = 130.2 ms (!)
743 Ref. Isd Upper Limit [1] = 37.0 A
[2] = 37.0 A
[3] = 37.0 A
[4] = 34.0 A (!)
813 KB de-magnetisation time [*] = 0 ms
Special Functions
401 Min. Modulation frequency = 2 - kHz
Fan
Brake Chopper
Motor Chopper
[2] = 40.0 A
[3] = 40.0 A
[4] = 64.0 A (!)

CAN-Bus
385 CAN Baud Rate = 5 - 125 kBit/s
387 CAN Node Number = 49
388 CAN Error Behaviour = 1 - Error
Fieldbus-Monitoring
880 Toggle-Bit-Error Behaviour = 1 - Error (!)
881 Toggle-Bit-Time = 700 ms (!)
Bus Controller
392 state-transition 5 = 2 - Ramp
410 Control Word = 256 (!)
411 Status Word = 320
412 Local/Remote [*] = 1 - Control via Statemachine (!)
465 Operation Mode [*] = 4 - Temp. Meas. at Start (!)
467 Adjusting Temperature [*] = 20.0 deg.C (!)
Encoder Monitoring
760 Operation Mode [*] = 2 - Error
761 Timeout: Signal fault [*] = 150 ms
762 Timeout: Channel fault [*] = 150 ms
763 Timeout: Direction fault [*] = 500 ms
Tandem
05.09.2013 Page 6
Actual Values
250 Digital Inputs = 36 . . ! . . ! . . . . . . . . . .
254 Digital Outputs = 0 . . . . . . . . . . . . . . . .
282 Reference Bus Frequency = 0.00 Hz
283 Reference Ramp Frequency = 0.00 Hz

224 Torque = 0.0 Nm

Actual Value Memory

Error Protocol
Error List
310 Last Error = 00001:19 ; F2100 Feldbus-Toggle-Bit-OFF
311 Last Error but one = 00001:10 ; F2100 Feldbus-Toggle-Bit-OFF
312 Error 3 = 00000:55 ; F2100 Feldbus-Toggle-Bit-OFF
315 Error 6 = 00000:04 ; F1102 Max. frequency deviation
316 Error 7 = 00000:04 ; F0400 Motor Temperature
318 Error 9 = 00000:00 ; F0000 No Fault
319 Error 10 = 00000:00 ; F0000 No Fault
320 Error 11 = 00000:00 ; F0000 No Fault
05.09.2013 Page 7
321 Error 12 = 00000:00 ; F0000 No Fault

322 Error 13 = 00000:00 ; F0000 No Fault
323 Error 14 = 00000:00 ; F0000 No Fault
324 Error 15 = 00000:00 ; F0000 No Fault
325 Error 16 = 00000:00 ; F0000 No Fault
Error Environment
330 Link voltage [1] = 452.4 V
[2] = 545.9 V
[3] = 565.7 V
[4] = 567.2 V
338 R.m.s Current [*] = 0.0 A
342 Torque [*] = 0.0 Nm
343 Analog Input MFI1A [1] = -0.01 %
[2] = 0.00 %
[3] = 0.01 %
[4] = 0.00 %
353 Heat Sink Temperature [1] = 23.6 deg.C
[2] = 21.7 deg.C
[3] = 31.6 deg.C
[4] = 23.6 deg.C
354 Housing temperature [1] = 27.1 deg.C
[2] = 27.0 deg.C
[3] = 38.2 deg.C
[4] = 27.3 deg.C
356 Warning Status [1] = AC000 UDC Toggle-Bit
[2] = A8000 Toggle-Bit
357 Int Value 1 [*] = 2825
358 Int Value 2 [*] = 0
359 Long Value 1 [*] = 0
360 Long Value 2 [*] = 0
05.09.2013 Page 8
Order no. 502262 EZDR 16T 2 o... IDAPSY 1/8
Parameter-Listing
Telephone:
Telefax:
Demag DR RopeHoist
Date: 10.09.2013
General data
Order no.: 502262 EZDR 16T 2 of 2
Customer no.:
Customer: AGGREKO INTERNATIONAL PROJECTS PANAMA
PACIFICO-PANAMERICAN
Post code:
Owner (final customer): AGGREKO INTERNATIONAL PROJECTS PANAMA

PACIFICO-PANAMERICAN C
Post code:
Contact:
Telephone:



Limit switch
---------- Limit switch - Crane ----------

Crane limit switch: 3
SGDM/BER
BER trip time: 500 [ms]

BER time: 1000 [ms]
Type of bridge control: 2
Add. control type crane: 0
Setpoint value 2-stage(crane): 0

Bridge inverter type: 1
Vmin/V1 - crane FI: 5 [m/min]

Vmax/V2 - crane FI: 52 [m/min]
Pre.lim. Crane: 5 [m/min]

Gearbox-ratio (crane axis): 0.01

Wheel-diameter (crane): 0.1 [mm]
By-pass control



By-pass control add-on Crane: 0
Typ of signal source 2 (crane): 0
Add. enable signal (crane): 0
V reduction: 0

Load reduction: 0
Position of crane: 0

Parallel inputs
ID CAN
Node-ID 1.signal source crane: 1
Node-ID 1st trolley: 1

Node-ID 2nd trolley: 0
Own Node-ID: 0
Baud rate: 0


Operating Data
Operating hours(crane): 0:04:49
Switch.op.crane brake: 30
Max.switch.op.crane brake: 1500
Crane travel path: 178

Output functions


ext Output OUT Crane: 0

ext Output OUT 1: 0
ext Output OUT 2: 0

Param.crane speed 54/55: 30
Special funktions
Status analysis: 0
Dearination positioning crane: 0
Selection F key: 0

Spec. crane move.enable: 15
Affect: 0
Enable active: 0
Safe enable: 0
Safety functions

Safety stage crane: 0

Deactivation by: 0

DIP-Code 305: 11111110
Process Data
Own Node-ID: 0
Baud rate: 0

Statistics

CAN-Error RX: 0
CAN-Error TX: 0


Parameter-Listing
Telephone:
Telefax:
Demag DR RopeHoist
Date: 10.09.2013
General data
Order no.: 502262 EZDR 16T 2 of 2
Customer no.:
Customer: AGGREKO INTERNATIONAL PROJECTS PANAMA
PACIFICO-PANAMERICAN
Post code:
Owner (final customer): AGGREKO INTERNATIONAL PROJECTS PANAMA

PACIFICO-PANAMERICAN C
Post code:
Contact:
Telephone:


Model code:
EZDRPRO 10 16 6/1 13,3Z 6 480 11 60 25
Solo trolley: 0
Full load hours: 2300

Gearbox transmission ratio: 61

Drum diameter: 274 mm

Rope diameter: 13 [mm]
Reeving: 6/1
Reeving factor: 6
Lifting height: 13.3 [m]
Hoist speed V1: 0.3 [m/min]
Hoist speed V2: 6 [m/min]
Limited load <50t:

Nominal load hoist<50t:
Limit switch
---------- Limit switch - Hoist ----------

Hoist limit switch: 1
Switch-off type: 1
Hoist limit switch type: 0
Lifting limit switch Z brake: 0
--------- Limit switch - Trolley ---------

Trolley limit switch: 0
Load parameters - Load (< 50t) up to V3.97
Nominal load hoist<50t: 10000 [kg]

Limited load <50t: 16000 [kg]
ZMS nom.load(<50t): 625 [kg]

Dead load(<50t): 0 [kg]
Load diff. Monitoring(<50t): 0 [kg]
Fall load 4/2-2(<50t): 1 [kg]
Load parameters - Load (<=>50t) from V3.98
Nominal load hoist HCH: 0 [t]

Limited load hoist HCH: 0 [t]

ZMS nominal load: 0 [t]

Dead load: 0 [t]
Load diff. Monitoring: 0 [t]
Fall load 4/2-2: 0 [t]
Heavy load 2 trolley-com.: 0
Load detection
with/without overload: 1
without/with/no. of ZMS: 0
Load display with other trolley: 1
Load display unit: 0

Creep lifting time: 0 [sec]
ZMS Load detector

B/A lever transmission ratio: 1.5625
ZMS nom.load(<50t):
Tare function (radio): 0
Dead load:
Hysteresis slack rope case: 15 [%]


Hysteresis overload case: 20 [%]
Nom.load crane(2troll.op.): 0
Load diff. Monitoring(<50t):

Load diff. hysteresis: 18 [%]
Fall load 4/2-2(<50t):

Slip load detection
Line voltage: 480 [V]
Line frequency: 60 [Hz]



SGDM/BER
--- Hoist ---
Inching debounce time: 2 [s]

Min. time dec. V1: 0 [ms]
Braking time, decel.: 100 [ms]

time for mech.brake: 50 [ms]
--- Trolley ---

Attention !!!!
Only trolley with pol-changing motor !
Min. time acc. V1 trolley: 0 [s]

Min. time dec. V1: 0 [s]
Braking time, decel.: 0 [s]
time for mech.brake: 8 [s]
Type of hoist/trlley control: 2
Control type hoist: 2
Hoist inverter type: 1

Setpoint value 2-stage(hoist): 0
Prohub function: 0.1
Vmin/V1 - hoist FI: 0.3 [m/min]
Vmax/V2 - hoist FI: 6 [m/min]
Pre.lim. Hoist: 0.6 [m/min]
Setpoint value 2-stage(trolley): 0
Vmin/V1-trolley FI: 7 [m/min]
Vmax/V2-trolley FI: 27 [m/min]
Pre.lim. Trolley: 8 [m/min]
Ana.setpoint-kneepoint 1 [%]: 0
Ana.setpoint-kneepoint 2 [&]: 0
Gearbox-ratio (trolley axis): 44.1

Wheel-diameter (trolley): 160 [mm]

Brake
Wear limit/run-on: 4500
Hoist motor brake type: 0
--- Catching brake (2nd brake) ----

Release time: 0.5 [s]
Application delay: 1 [s]
By-pass control


By-pass control add-on Trolley: 0
Typ signal source 2 (trolley): 0
Add. enable signal (trolley): 0
V reduction: 0

Conditional load reduction: 0
Max. load (load red.: 0 [kg]

Parallel/synchron.lifting op.: 0
Parallel/synchron.op.hoist in: 0 [%]
Limit value synchron.op.diff.: 200
Parallel operation trolley: 0

Position of trolley: 0
Parallel/synchron.op.trolley in: 0 [%]


Parallel inputs
ID CAN
Node-ID load display: 0
Node-ID of hoist FI: 1

Node ID 2nd signal source trolley: 0
Node-ID crane: 1
Node-ID other trolley: 0

Own Node-ID: 0
Baud rate: 0

Operating Data
Operating hours(hoist): 0:06:41
Operating hours(trolley): 0:02:02
Load spectrum: 99.9739

Warning Rem. serv. Time: 0 [%]
Switch.op.hoist brake: 41
Max.switch.op.hoist brake: 0
Switch.op.trolley brake: 23
Max.switch.op.trolley brake: 0
Holding brake switching op.: 0
Trolley travel path: 70
Measured braking dist.: 0 [Ink]

Slip correction factor: 0

Output functions


ext.Output OUT Trolley: 0

ext.Output OUT 1: 0
ext.Output OUT 1: 0

CAN (USA) coupling module: 0

Load threshold UNIOUT40/41: 0 [%]
Param.hoist speed 56/57: 0
Param.cross speed 54/55: 0
Special funktions
Load spectrum active: 1
Status analysis: 0
Type of Load Display: 1
Dearination positioning trolley: 0
Selection F key: 0

Spec.hoist move.enable: 0
Affect from tgrolley/crane: 0
Affect: 0
Enable active: 0
Safe enable: 0
Spec.trolley move.enable: 0
Affect: 0
Enable active: 0
Safe enable: 0


Safety functions
Safety stage crab: 0
-- Deactivating slack rope cut-out --

Signal source of slack rope cut-off: 0
Selection of the source: 0
Slack rope cut-off activ: 0

Deactivation by: 0
DIP-Code 305: 00000000
Process Data
Own Node-ID: 0
Baud rate: 0
Overload test enable: 0
Actual values
Act.speed hoist mot.: 0 [U/min]

Curr. load meas.(slip): 0 [kg]

Tare value other hoist: 0

Tare value own hoist: 0

Manufacturer data - ZMS Single board
ZMS1 factor: 0 [mV]

ZMS2 factor: 0 [mV]
ZMS1 offset: 0 [mV]
ZMS2 offset: 0 [mV]

Voltage mon. -12 V: 1700

Voltage mon. +12 V: 1900

Manufacturer data - ZMS Modular board

ZMS1 offset (mod): 0 [mV]
ZMS2 offset (mod: 0 [mV]

Voltage mon. -12 V (mod): 0

Voltage mon. +12 V (mod): 0

Hardware-vers.ZMS-mod: 0
ZMS-mod serial no.: 0

Statistics

Max. slip: 0
Max. rotation: 0
Brake: 0
Rope-drum brake: 0
Overload: 0
CAN-Error RX: 0
CAN-Error TX: 0

Inverter Data
000 Serial Number = 520 422 911 ; 13061268
029 User Name = 73024645_00_135018_CRANE (!)
034 Program = 0 (!)
Motor Data
370 Rated voltage [*] = 220.0 V (!)
371 Rated current [1] = 10.2 A (!)
[2] = 13.0 A (!)
[3] = 23.2 A (!)
[4] = 17.5 A (!)
372 Rated speed [1] = 1400 U/min (!)
[2] = 1430 U/min (!)
[3] = 1400 U/min (!)
[4] = 1415 U/min (!)
[2] = 0.76 (!)
[3] = 0.81
[4] = 0.80 (!)
[2] = 3.0 kW (!)
[3] = 6.0 kW (!)
[4] = 4.4 kW (!)

368 Rated voltage correction factor [*] = 100.00 %
[2] = 2231 mOhm (!)
[3] = 530 mOhm
[4] = 530 mOhm
378 Leakage factor [*] = 7.0 %
[2] = 30.76 % (!)
[3] = 31.00 %
[4] = 31.00 %
[2] = 80.00 % (!)
[3] = 65.00 %
[4] = 65.00 %
[2] = 150.33 % (!)
[3] = 145.00 %
[4] = 145.00 %
716 Idle current [1] = 3.1 A (!)
[2] = 3.9 A (!)
[3] = 7.0 A (!)
[4] = 5.3 A (!)
[2] = 94.92 % (!)
[3] = 100.00 %
[4] = 100.00 %
[2] = 1060 mOhm (!)
[3] = 795 mOhm
[4] = 795 mOhm
Encoder 1
SETUP
796 Motor parameter identification = 12 - Complete Setup, DS2 (!)
System Data
Starting Behaviour
[2] = 13.0 A (!)
[3] = 23.2 A (!)
[4] = 17.5 A (!)
624 Frequency Limit [1] = 4.60 Hz (!)
[2] = 4.54 Hz (!)
10.09.2013 Page 1
[3] = 4.60 Hz (!)

[4] = 4.60 Hz (!)
781 Current during Flux-Formation [1] = 10.2 A (!)
[2] = 13.0 A (!)
[3] = 23.2 A (!)
[4] = 17.5 A (!)
Stopping Behaviour
Auto-Start
Search Run
Positioning
Brake-Control


829 Factor = 1.00


Reference Values
Frequency Limits
418 Minimum frequency [1] = 0.00 Hz (!)
[2] = 5.00 Hz (!)
10.09.2013 Page 2
[3] = 0.00 Hz (!)

[4] = 0.00 Hz (!)

SOST-Parameters
480 SOST step 1 [*] = 5.00 Hz
481 SOST step 2 [*] = 50.00 Hz
482 SOST step 3 [*] = 5.00 Hz
483 SOST step 4 [*] = 5.00 Hz
Frequency Ramps
424 Emergency Stop Clockwise [*] = 30.00 Hz/s
425 Emergency Stop Anticlockwise [*] = 30.00 Hz/s

SOSP function

497 Divider = 1024

454 Point X1 [*] = 2.00 %
455 Point Y1 [*] = 0.00 %
456 Point X2 [*] = 96.00 % (!)
457 Point Y2 [*] = 100.00 %

551 Voltage 100% = 10.0 V
552 Voltage 0% = 0.0 V
Digital Outputs
10.09.2013 Page 3

Digital Inputs
066 (SOST) Step 2 = 7 - Off (!)
067 (SOST) Step 3/4 = 7 - Off
068 SW-Step 1+ = 71 - S2IND
069 SW-Step 1- = 72 - S3IND
083 Timer 1 = 7 - Off
084 Timer 2 = 7 - Off

Timers
791 Time 1 Timer 1 = 0.00 s/m/h
792 Time 2 Timer 1 = 0.00 s/m/h
794 Time 1 Timer 2 = 0.00 s/m/h
795 Time 2 Timer 2 = 0.00 s/m/h
Logic Function 1
199 Input 1 = 7 - Off
200 Input 2 = 7 - Off
Logic Function 2
202 Input 1 = 7 - Off
203 Input 2 = 7 - Off
Logic Function 3
206 Input 1 = 7 - Off
207 Input 2 = 7 - Off
Logic Function 4
504 Input 1 = 7 - Off
505 Input 2 = 7 - Off
Logic Function 5
818 Input 1 = 7 - Off
819 Input 2 = 7 - Off
Logic Function 6
858 Input 1 = 7 - Off
859 Input 2 = 7 - Off
Logic Function 7
878 Input 1 = 7 - Off
879 Input 2 = 7 - Off
Logic Function 8
883 Input 1 = 7 - Off
884 Input 2 = 7 - Off
Logic Function 9
886 Input 1 = 7 - Off
887 Input 2 = 7 - Off
Logic Function 10
10.09.2013 Page 4
892 Input 1 = 7 - Off

893 Input 2 = 7 - Off
Control Functions
574 Power Limit [*] = 80.00 %
Voltage Controller
Current Controller
[2] = 0.16 (!)
[3] = 0.13
[4] = 0.13
[2] = 2.00 ms (!)
[3] = 10.00 ms
[4] = 10.00 ms
702 Factor P, Ta=125us [1] = 4.00
[2] = 4.40 (!)
[3] = 4.00
[4] = 4.00
703 Factor P, Ta=250us [1] = 2.00
[2] = 1.96 (!)
[3] = 2.00
[4] = 2.00
704 Factor P, Ta=500us [*] = 1.00
705 Factor P, Ta=1000us [1] = 0.50
[2] = 0.15 (!)
[3] = 0.50
[4] = 0.50
706 Factor Tn, Ta=125us [1] = 1.00
[2] = 0.75 (!)
[3] = 1.00
[4] = 1.00
707 Factor Tn, Ta=250us [*] = 1.00
708 Factor Tn, Ta=500us [*] = 1.00
709 Factor Tn, Ta=1000us [1] = 1.00
[2] = 2.50 (!)
[3] = 1.00
[4] = 1.00
Speed Controller
Field Controller
10.09.2013 Page 5

[2] = 67.3 ms (!)
[3] = 100.0 ms
[4] = 100.0 ms
[2] = 13.0 A (!)
[3] = 23.2 A (!)
[4] = 17.5 A (!)
Special Functions
[2] = 0000000000000 (!)
[3] = 2012070402300 (!)
[4] = 2012070402300 (!)
Fan
Brake Chopper
Motor Chopper
[2] = 26.0 A (!)
[3] = 25.0 A
[4] = 25.0 A

Bus Controller
Tandem
Actual Values
250 Digital Inputs = 40 . . . ! . ! . . . . . . . . . .
254 Digital Outputs = 0 . . . . . . . . . . . . . . . .
10.09.2013 Page 6


224 Torque = 0.0 Nm

Actual Value Memory

Error Protocol
Error List
310 Last Error = 00004:21 ; F0701 Undervoltage
311 Last Error but one = 00004:19 ; F0701 Undervoltage
312 Error 3 = 00000:00 ; F0000 No Fault
313 Error 4 = 00000:00 ; F0000 No Fault
314 Error 5 = 00000:00 ; F0000 No Fault
315 Error 6 = 00000:00 ; F0000 No Fault
316 Error 7 = 00000:00 ; F0000 No Fault
317 Error 8 = 00000:00 ; F0000 No Fault
318 Error 9 = 00000:00 ; F0000 No Fault
319 Error 10 = 00000:00 ; F0000 No Fault
320 Error 11 = 00000:00 ; F0000 No Fault
321 Error 12 = 00000:00 ; F0000 No Fault
322 Error 13 = 00000:00 ; F0000 No Fault
323 Error 14 = 00000:00 ; F0000 No Fault
324 Error 15 = 00000:00 ; F0000 No Fault
325 Error 16 = 00000:00 ; F0000 No Fault
Error Environment
[2] = 477.9 V
[3] = 0.0 V
[4] = 0.0 V
331 Output Voltage [1] = 28.9 V
[2] = 31.0 V
[3] = 0.0 V
[4] = 0.0 V
335 Phase Current Ia [1] = -1.6 A
[2] = 5.8 A
[3] = 0.0 A
[4] = 0.0 A
336 Phase Current Ib [1] = 0.7 A
[2] = -2.9 A
[3] = 0.0 A
[4] = 0.0 A
10.09.2013 Page 7
337 Phase Current Ic [1] = 0.7 A

[2] = -3.1 A
[3] = 0.0 A
[4] = 0.0 A
338 R.m.s Current [1] = 1.6 A
[2] = 5.8 A
[3] = 0.0 A
[4] = 0.0 A
339 Flow current share Isd [1] = -1.6 A
[2] = 5.8 A
[3] = 0.0 A
[4] = 0.0 A
340 Torque current share Isq [1] = 0.0 A
[2] = 0.1 A
[3] = 0.0 A
[4] = 0.0 A
342 Torque [*] = 0.0 Nm
343 Analog Input MFI1A [1] = 0.22 %
[2] = 0.27 %
[3] = 0.00 %
[4] = 0.00 %
350 Status of Digital Inputs [1] = 41
[2] = 41
[3] = 0
[4] = 0
351 Status of Digital Outputs [1] = 0
[2] = 1
[3] = 0
[4] = 0
[2] = 29.7 deg.C
[3] = 0.0 deg.C
[4] = 0.0 deg.C
[2] = 34.3 deg.C
[3] = 0.0 deg.C
[4] = 0.0 deg.C
356 Warning Status [1] = A4000 UDC
[2] = A0000 No Warning
357 Int Value 1 [1] = 2825
[2] = 2825
[3] = 0
[4] = 0
358 Int Value 2 [*] = 0
359 Long Value 1 [*] = 0
360 Long Value 2 [*] = 0
10.09.2013 Page 8
Inverter Data
000 Serial Number = 520 426 010 ; 13041507
001 Optional Modules = CM-CAN ; -
029 User Name = 73023545_0_135011_HOIST100B_132C (!)
030 Configuration = 210 - FOR speed with encoder (!)
034 Program = 0 (!)
Motor Data
370 Rated voltage [*] = 220.0 V (!)
371 Rated current [1] = 12.5 A (!)
[2] = 14.9 A (!)
[3] = 26.5 A (!)
[4] = 34.0 A (!)
372 Rated speed [1] = 1400 U/min (!)
[2] = 1440 U/min (!)
[3] = 1435 U/min (!)
[4] = 1440 U/min (!)
[2] = 0.83 (!)
[3] = 0.85 (!)
[4] = 0.84 (!)
[2] = 4.0 kW (!)
[3] = 7.5 kW (!)
[4] = 9.5 kW (!)

[2] = 7.0 %
[3] = 7.0 %
[4] = 5.7 % (!)
[2] = 31.00 %
[3] = 31.00 %
[4] = 41.43 % (!)
[2] = 65.00 %
[3] = 65.00 %
[4] = 60.16 % (!)
[2] = 145.00 %
[3] = 145.00 %
[4] = 112.90 % (!)
716 Idle current [1] = 12.0 A
[2] = 12.0 A
[3] = 12.0 A
[4] = 15.6 A (!)
[2] = 100.00 %
[3] = 100.00 %
[4] = 73.86 % (!)
[2] = 345 mOhm
[3] = 345 mOhm
[4] = 235 mOhm (!)
Encoder 1
490 Operation Mode Encoder 1 = 4 - Quadruple Evaluation (!)
815 Filter time constant encoder 1 = 0 - Off
SETUP
System Data
Starting Behaviour
781 Current during Flux-Formation [1] = 40.0 A
[2] = 40.0 A
[3] = 40.0 A
[4] = 34.0 A (!)
Stopping Behaviour
10.09.2013 Page 1
Auto-Start
Search Run
Positioning
Axle positioning
037 Start Positioning of Axle = 7 - Off
469 Reference orientation [*] = 0.0 Grad
471 Positioning Frequency [*] = 50.00 Hz
472 Max positional error [*] = 3.0 Grad
479 time constant positioning contr. [*] = 20.00 ms
Brake-Control
821 DC pre-magnetisation time [*] = 200 ms (!)
825 Brake application time [*] = 100 ms


829 Factor = 1.00
830 Operation Mode = 1 - On (!)
831 Theoretical duration of service = 1900.0 h (!)
832 Lifting correction factor = 85 % (!)
833 Lowering correction factor = 50 % (!)
838 Ramp Factor = 0.30 (!)


468 Frequency monitoring = 1 - Max. frequency deviation
Reference Values
Frequency Limits
418 Minimum frequency [*] = 0.00 Hz (!)
719 Slip limit [*] = 330 %
10.09.2013 Page 2

475 Drive control [*] = 10 - SOST
SOST-Parameters
480 SOST step 1 [*] = 5.00 Hz
481 SOST step 2 [*] = 50.00 Hz
482 SOST step 3 [*] = 5.00 Hz
483 SOST step 4 [*] = 5.00 Hz
Frequency Ramps
434 Ramp Setpoint [*] = 2 - Line Setpoint (!)

SOSP function

497 Divider = 1024
ProHub-function
849 Hoist rating factor [*] = 1.00
851 Field weakening enable = 6 - On (!)
852 Field weakening start [*] = 166 % (!)
853 Lifting correction value [*] = 15 % (!)
854 Lowering correction value [*] = 10 %
855 Start of measurement [*] = 80.00 Hz (!)
856 Field weakening factor [*] = 0.50
860 Current measuring value = 100.00 %
861 Valid max. frequency = 83.00 Hz

841 Additional setpoint value source [*] = 480 - Bus operation P.846 (!)
842 Max. additional frequency negati [*] = -100.00 Hz (!)
843 Max. additional frequency positi [*] = 100.00 Hz (!)
844 Acceleration additional setpoint [*] = 300.00 Hz/s (!)
845 Deceleration additional setpoint [*] = 300.00 Hz/s (!)
454 Point X1 [*] = 2.00 %
455 Point Y1 [*] = 0.00 %
456 Point X2 [*] = 98.00 %
457 Point Y2 [*] = 100.00 %

551 Voltage 100% = 10.0 V
552 Voltage 0% = 0.0 V
554 Operation Mode digital MFO1D = 3 - Error
10.09.2013 Page 3
Digital Outputs
532 Op. Mode Digital Output 3 S3OUT = 41 - Release brake
540 Op. Mode Comparator 1 = 107 - Actual Frequency (+/-) (!)
541 Comparator 1 On above = 0.00 % (!)
542 Comparator 1 Off below = 0.00 % (!)
Digital Inputs
066 (SOST) Step 2 = 7 - Off (!)
067 (SOST) Step 3/4 = 7 - Off
068 SW-Step 1+ = 171 - Output Comparator 1 (!)
069 SW-Step 1- = 172 - Negated Output Comparator 1 (!)
083 Timer 1 = 7 - Off
084 Timer 2 = 7 - Off

Timers
791 Time 1 Timer 1 = 0.00 s/m/h
792 Time 2 Timer 1 = 0.00 s/m/h
794 Time 1 Timer 2 = 0.00 s/m/h
795 Time 2 Timer 2 = 0.00 s/m/h
Logic Function 1
199 Input 1 = 7 - Off
200 Input 2 = 7 - Off
Logic Function 2
202 Input 1 = 7 - Off
203 Input 2 = 7 - Off
Logic Function 3
206 Input 1 = 7 - Off
207 Input 2 = 7 - Off
Logic Function 4
504 Input 1 = 7 - Off
505 Input 2 = 7 - Off
Logic Function 5
818 Input 1 = 7 - Off
819 Input 2 = 7 - Off
Logic Function 6
858 Input 1 = 7 - Off
859 Input 2 = 7 - Off
Logic Function 7
878 Input 1 = 7 - Off
879 Input 2 = 7 - Off
Logic Function 8
883 Input 1 = 7 - Off
10.09.2013 Page 4
884 Input 2 = 7 - Off
Logic Function 9
886 Input 1 = 7 - Off
887 Input 2 = 7 - Off
Logic Function 10
892 Input 1 = 7 - Off
893 Input 2 = 7 - Off
Control Functions
574 Power Limit [*] = 80.00 %
Voltage Controller
Current Controller
[2] = 0.13
[3] = 0.13
[4] = 0.10 (!)
[2] = 10.00 ms
[3] = 10.00 ms
[4] = 4.50 ms (!)
702 Factor P, Ta=125us [1] = 4.00
[2] = 4.00
[3] = 4.00
[4] = 4.24 (!)
703 Factor P, Ta=250us [1] = 2.00
[2] = 2.00
[3] = 2.00
[4] = 2.08 (!)
704 Factor P, Ta=500us [*] = 1.00
705 Factor P, Ta=1000us [1] = 0.50
[2] = 0.50
[3] = 0.50
[4] = 0.23 (!)
706 Factor Tn, Ta=125us [1] = 1.00
[2] = 1.00
[3] = 1.00
[4] = 0.55 (!)
707 Factor Tn, Ta=250us [1] = 1.00
[2] = 1.00
[3] = 1.00
[4] = 0.72 (!)
708 Factor Tn, Ta=500us [*] = 1.00
709 Factor Tn, Ta=1000us [1] = 1.00
[2] = 1.00
[3] = 1.00
[4] = 1.11 (!)
Speed Controller
722 Integral time [*] = 100 ms (!)
723 Amplification f > f um [*] = 10.00 (!)
724 Integral time f > f um [*] = 300 ms (!)
730 Motor torque limitation [*] = 650.00 %
731 Generative torque limitation [*] = 650.00 %
10.09.2013 Page 5

766 Source Actual Speed [*] = 1 - Speed Sensor 1 (!)
Field Controller
[2] = 100.0 ms
[3] = 100.0 ms
[4] = 119.9 ms (!)
743 Ref. Isd Upper Limit [1] = 37.0 A
[2] = 37.0 A
[3] = 37.0 A
[4] = 34.0 A (!)
813 KB de-magnetisation time [*] = 0 ms
Special Functions
401 Min. Modulation frequency = 2 - kHz
Fan
Brake Chopper
Motor Chopper
[2] = 40.0 A
[3] = 40.0 A
[4] = 64.0 A (!)

CAN-Bus
385 CAN Baud Rate = 5 - 125 kBit/s
387 CAN Node Number = 49
388 CAN Error Behaviour = 1 - Error
Fieldbus-Monitoring
880 Toggle-Bit-Error Behaviour = 1 - Error (!)
881 Toggle-Bit-Time = 700 ms (!)
Bus Controller
392 state-transition 5 = 2 - Ramp
410 Control Word = 256 (!)
411 Status Word = 64
412 Local/Remote [*] = 1 - Control via Statemachine (!)
465 Operation Mode [*] = 4 - Temp. Meas. at Start (!)
467 Adjusting Temperature [*] = 20.0 deg.C (!)
Encoder Monitoring
760 Operation Mode [*] = 2 - Error
761 Timeout: Signal fault [*] = 150 ms
762 Timeout: Channel fault [*] = 150 ms
763 Timeout: Direction fault [*] = 500 ms
Tandem
10.09.2013 Page 6
Actual Values
250 Digital Inputs = 36 . . ! . . ! . . . . . . . . . .
254 Digital Outputs = 0 . . . . . . . . . . . . . . . .
282 Reference Bus Frequency = 0.00 Hz
283 Reference Ramp Frequency = 0.00 Hz

224 Torque = 0.0 Nm

Actual Value Memory

Error Protocol
Error List
310 Last Error = 00006:23 ; F2100 Feldbus-Toggle-Bit-OFF
311 Last Error but one = 00006:19 ; F2100 Feldbus-Toggle-Bit-OFF
318 Error 9 = 00000:04 ; F1102 Max. frequency deviation
319 Error 10 = 00000:03 ; F0400 Motor Temperature
10.09.2013 Page 7
321 Error 12 = 00000:00 ; F0000 No Fault

322 Error 13 = 00000:00 ; F0000 No Fault
323 Error 14 = 00000:00 ; F0000 No Fault
324 Error 15 = 00000:00 ; F0000 No Fault
325 Error 16 = 00000:00 ; F0000 No Fault
Error Environment
[2] = 653.4 V
[3] = 655.1 V
[4] = 279.3 V
338 R.m.s Current [*] = 0.0 A
342 Torque [*] = 0.0 Nm
343 Analog Input MFI1A [1] = 0.00 %
[2] = 0.01 %
[3] = 0.01 %
[4] = 0.00 %
[2] = 26.6 deg.C
[3] = 26.3 deg.C
[4] = 24.7 deg.C
[2] = 34.3 deg.C
[3] = 33.5 deg.C
[4] = 32.2 deg.C
356 Warning Status [1] = A8000 Toggle-Bit
[4] = AC000 UDC Toggle-Bit
357 Int Value 1 [*] = 2825
358 Int Value 2 [*] = 0
359 Long Value 1 [*] = 0
360 Long Value 2 [*] = 0
10.09.2013 Page 8
Inverter Data
000 Serial Number = 520 414 913 ; 13041684
029 User Name = 73024545_00_135017_CRAB (!)
034 Program = 0 (!)
Motor Data
370 Rated voltage [*] = 220.0 V (!)
371 Rated current [1] = 3.0 A (!)
[2] = 5.4 A (!)
[3] = 6.0 A (!)
[4] = 5.1 A (!)
372 Rated speed [1] = 1420 U/min (!)
[2] = 1375 U/min (!)
[3] = 1420 U/min (!)
[4] = 1400 U/min (!)
[2] = 0.54 (!)
[3] = 0.68 (!)
[4] = 0.74 (!)
[2] = 0.8 kW (!)
[3] = 1.1 kW (!)
[4] = 1.1 kW (!)

368 Rated voltage correction factor [1] = 100.00 %
[2] = 100.00 %
[3] = 95.27 % (!)
[4] = 100.00 %
[2] = 2231 mOhm
[3] = 1880 mOhm (!)
[4] = 2231 mOhm
[2] = 7.0 %
[3] = 10.0 % (!)
[4] = 7.0 %
[2] = 31.00 %
[3] = 41.84 % (!)
[4] = 31.00 %
[2] = 65.00 %
[3] = 70.76 % (!)
[4] = 65.00 %
[2] = 145.00 %
[3] = 123.05 % (!)
[4] = 145.00 %
716 Idle current [1] = 0.9 A (!)
[2] = 1.7 A (!)
[3] = 3.6 A (!)
[4] = 1.6 A (!)
[2] = 100.00 %
[3] = 108.33 % (!)
[4] = 100.00 %
[2] = 3347 mOhm
[3] = 2180 mOhm (!)
[4] = 3347 mOhm
Encoder 1
SETUP
System Data
Starting Behaviour
05.09.2013 Page 1

[2] = 5.4 A (!)
[3] = 6.0 A (!)
[4] = 5.1 A (!)
624 Frequency Limit [1] = 4.60 Hz (!)
[2] = 4.60 Hz (!)
[3] = 2.81 Hz (!)
[4] = 4.60 Hz (!)
781 Current during Flux-Formation [1] = 3.0 A (!)
[2] = 5.4 A (!)
[3] = 6.0 A (!)
[4] = 5.1 A (!)
Stopping Behaviour
Auto-Start
Search Run
Positioning
Brake-Control


829 Factor = 1.00


05.09.2013 Page 2
Reference Values
Frequency Limits
418 Minimum frequency [*] = 3.50 Hz
719 Slip limit [*] = 250 % (!)

SOST-Parameters
480 SOST step 1 [*] = 5.00 Hz
481 SOST step 2 [*] = 50.00 Hz
482 SOST step 3 [*] = 5.00 Hz
483 SOST step 4 [*] = 5.00 Hz
Frequency Ramps

SOSP function

497 Divider = 1024

454 Point X1 [*] = 2.00 %
455 Point Y1 [*] = 15.00 % (!)
456 Point X2 [*] = 96.00 % (!)
457 Point Y2 [*] = 100.00 %

551 Voltage 100% = 10.0 V
552 Voltage 0% = 0.0 V
Digital Outputs
05.09.2013 Page 3

Digital Inputs
066 (SOST) Step 2 = 7 - Off (!)
067 (SOST) Step 3/4 = 7 - Off
068 SW-Step 1+ = 71 - S2IND
069 SW-Step 1- = 72 - S3IND
083 Timer 1 = 7 - Off
084 Timer 2 = 7 - Off

Timers
791 Time 1 Timer 1 = 0.00 s/m/h
792 Time 2 Timer 1 = 0.00 s/m/h
794 Time 1 Timer 2 = 0.00 s/m/h
795 Time 2 Timer 2 = 0.00 s/m/h
Logic Function 1
199 Input 1 = 7 - Off
200 Input 2 = 7 - Off
Logic Function 2
202 Input 1 = 7 - Off
203 Input 2 = 7 - Off
Logic Function 3
206 Input 1 = 7 - Off
207 Input 2 = 7 - Off
Logic Function 4
504 Input 1 = 7 - Off
505 Input 2 = 7 - Off
Logic Function 5
818 Input 1 = 7 - Off
819 Input 2 = 7 - Off
Logic Function 6
858 Input 1 = 7 - Off
859 Input 2 = 7 - Off
Logic Function 7
878 Input 1 = 7 - Off
879 Input 2 = 7 - Off
Logic Function 8
883 Input 1 = 7 - Off
884 Input 2 = 7 - Off
Logic Function 9
05.09.2013 Page 4
886 Input 1 = 7 - Off

887 Input 2 = 7 - Off
Logic Function 10
892 Input 1 = 7 - Off
893 Input 2 = 7 - Off
Control Functions
574 Power Limit [*] = 80.00 %
Voltage Controller
Current Controller
[2] = 0.13
[3] = 0.16 (!)
[4] = 0.13
[2] = 10.00 ms
[3] = 2.75 ms (!)
[4] = 10.00 ms
702 Factor P, Ta=125us [1] = 4.00
[2] = 4.00
[3] = 3.28 (!)
[4] = 4.00
703 Factor P, Ta=250us [1] = 2.00
[2] = 2.00
[3] = 1.58 (!)
[4] = 2.00
704 Factor P, Ta=500us [*] = 1.00
705 Factor P, Ta=1000us [1] = 0.50
[2] = 0.50
[3] = 0.14 (!)
[4] = 0.50
706 Factor Tn, Ta=125us [1] = 1.00
[2] = 1.00
[3] = 0.72 (!)
[4] = 1.00
707 Factor Tn, Ta=250us [1] = 1.00
[2] = 1.00
[3] = 0.72 (!)
[4] = 1.00
708 Factor Tn, Ta=500us [*] = 1.00
709 Factor Tn, Ta=1000us [1] = 1.00
[2] = 1.00
[3] = 1.81 (!)
[4] = 1.00
Speed Controller
05.09.2013 Page 5
Field Controller
[2] = 100.0 ms
[3] = 50.0 ms (!)
[4] = 100.0 ms
[2] = 5.4 A (!)
[3] = 6.0 A (!)
[4] = 5.1 A (!)
Special Functions
[2] = 2012070402300 (!)
[3] = 1004000/0,088 (!)
[4] = 2012070402300 (!)
Fan
Brake Chopper
Motor Chopper
[2] = 7.8 A
[3] = 12.0 A (!)
[4] = 7.8 A

Bus Controller
Tandem
Actual Values
250 Digital Inputs = 56 . . . ! ! ! . . . . . . . . . .
254 Digital Outputs = 0 . . . . . . . . . . . . . . . .
05.09.2013 Page 6


224 Torque = 0.0 Nm

Actual Value Memory

296 Peak Value Active Power neg. = 0.0 kW
Error Protocol
Error List
310 Last Error = 00000:00 ; F0000 No Fault
311 Last Error but one = 00000:00 ; F0000 No Fault
312 Error 3 = 00000:00 ; F0000 No Fault
313 Error 4 = 00000:00 ; F0000 No Fault
314 Error 5 = 00000:00 ; F0000 No Fault
315 Error 6 = 00000:00 ; F0000 No Fault
316 Error 7 = 00000:00 ; F0000 No Fault
317 Error 8 = 00000:00 ; F0000 No Fault
318 Error 9 = 00000:00 ; F0000 No Fault
319 Error 10 = 00000:00 ; F0000 No Fault
320 Error 11 = 00000:00 ; F0000 No Fault
321 Error 12 = 00000:00 ; F0000 No Fault
322 Error 13 = 00000:00 ; F0000 No Fault
323 Error 14 = 00000:00 ; F0000 No Fault
324 Error 15 = 00000:00 ; F0000 No Fault
325 Error 16 = 00000:00 ; F0000 No Fault
Error Environment
330 Link voltage [*] = 0.0 V
338 R.m.s Current [*] = 0.0 A
05.09.2013 Page 7

342 Torque [*] = 0.0 Nm
343 Analog Input MFI1A [*] = 0.00 %
353 Heat Sink Temperature [*] = 0.0 deg.C
354 Housing temperature [*] = 0.0 deg.C
356 Warning Status [*] = A0000 No Warning
357 Int Value 1 [*] = 0
358 Int Value 2 [*] = 0
359 Long Value 1 [*] = 0
360 Long Value 2 [*] = 0
05.09.2013 Page 8
FUSE SHEET Job: 502262
Initials: JC
Date: 05/02/2013
Power Supply: 460/3/60

Control Voltage: 48/1/60 Description
Bridge Control Panel – 10D11 & 10D41

-F011 Main Power 70 A TYPE J
-F016.1 Control Transf. -Pri 2 A TYPE CC
-F016.2 Control Transf. –Sec. 3 A TYPE CC
-F1 & F2 CAN Bus protection 0.25 A TYPE GMA
-F014 Bridge Inverter 30 A TYPE CC
Trolley Panel -11D21

-F011 Trolley Inverter 10 A TYPE CC
Hoist-VFC Panel - 11D31

-F041 Hoist Inverter 50 A TYPE J
-F011 DR Board Protection 10 A TYPE J
Note: All Fuses Must Be Replaced With the Same Type as the Original or equivalent
TYPE “CC”: ATDR, ATMR, ATQR, FNQ-R
TYPE “J”: AJT
Rev. 0 –
CABLE SHEET Job: 502262
Initials: J.C
Date: 05/02/2013
CABLE INFORMATION *
Cable Number Size Type
BRIDGE
-W1 4C/#6 ROUND CABLE, INCOMING POWER
-W4 4C/#16 + 4C SHIELDED ROUND CABLE, BRIDGE MOTOR
-W5 4C/#16 + 4C SHIELDED ROUND CABLE, BRIDGE MOTOR
-W12 (2x2x0.25C) + 2x0.75 SHIELDED 2TY ROUND CABLE, P/B CANBUS
TROLLEY FESTOON SYSTEM

-W2 4C/#8 FLAT CABLE, TROLLEY #1 POWER
-W6 2C/#16 + 4C SHIELDED FLAT CABLE, TROLLEY #1 CANBUS
SLIDING PB FESTOON SYSTEM

-W11 2C/#16 + 4C SHIELDED FLAT CABLE, SLIDING P/B CANBUS
TROLLEY
-W9 4C/1.5 mm2 + 4C/0.75 mm2 SHIELDED ROUND CABLE, TROLLEY MOTOR
2
-W20 LIYY 4x0.25 mm RD. CABLE, HST MGS LOAD LINK
2 2
-W64 2C/0.5 mm + 10C/0.14 mm SHIELDED RD. CABLE, HST PULSE ENCODER
Note: * Refer To Interconnection Diagram for cable number location.

Section II - Operating Instructions
DEMAG
Operating Instructions
Demag Cranes with Demag DR Rope Hoist
100810 enUS 229 324 49 720 IS 100

2
22932449.indd/100810
Manufacturer Demag Cranes & Components Corp
29201 Aurora Road
Cleveland, OH 44139-1895)
Telephone: (440) 248-2400 Fax: (440) 248-3086
Internet: http://www.demag-us.com
Contents 0 Foreword 5
0.1 Copyright 5
0.2 Customer Service 5
0.3 Liability for Defects 6
0.4 Limitations of Liability 6
0.5 Definitions 7
1 Safety Instructions 8
1.1 Symbol Description 8
1.2 Appropriate Use 8
1.3 Inappropriate Use 10
1.4 Basic Information on Safety 10
1.5 Selection and Qualification of Operating and Maintenance Personnel 11
1.6 Safety Instructions for Assembly and Disassembly 12
1.7 Safety Instructions when First Putting the Unit Into Service
after Completing Assembly 12
1.8 Safety Instructions for Operation 12
1.9 Safety Instructions for Maintenance 13
1.10 Prescribed Crane Safety Features 15
1.10.1 Additional Safety Features which may be Present Depending
on Operating Criteria (Examples) 15
2 Operation 16
2.1 Prevention of Accidents 16
2.2 Obligations of the Operator 17
2.2.1 Control Devices 17
2.2.2 Cable-Connected Floor Control – Remote Control 17
2.2.3 Attaching Loads 18
2.2.4 Observing the Loads 18
2.2.5 Bumper 18
2.2.6 End of Work 18
3 Taking the Crane Out of Service 19

3.1 Emergency-Stop Button 19
3.2 Taking the Crane Out of Service on Finishing Work 19
3.3 Taking the Crane Out of Service for Maintenance and Repair Purposes 19
4 Weather Influence and Dirt Accumulation 20

4.1 General 20
4.2 Cranes Sometimes Operating Outdoors 20
4.3 Cranes Operating Outdoors 20
4.4 Influence of Weather and Dirt on Runways 20
5 Maintenance 21
5.1 Inspection Before Operation 22
5.2 Inspection and Maintenance Schedule 23
5.3 Hoist Trolley 24
22932449.indd/100810
5.4 Crane bridge 24

5.5 Tightening Torque Requirements 24
5.6 Control 25
5.7 Power Supply 26
3
6 Manufacturer, Service and Spare Parts Contact Information 27
6.1 Manufacturer / Customer Service 27
6.2 Spare Parts 27
6.3 Service 27
7 Disassembly and Disposal 28

7.1 Disassembly 28
7.2 Disposal 28
8 Sound Pressure Level of Cranes 29

9 Electromagnetic Compatibility 31
10 Crane Inspections 32
10.1 Inspection Regulations 32
10.2 Crane Inspections 32
10.2.1 Frequent Inspection 32
10.2.2 Periodic Inspection 32
10.2.3 Initial Inspection and Load Test for Which the Owner is Responsible 33
11 Technical Description 34
11.1 Crane Types and Subassemblies 34

11.2 General 36
11.3 Main Subassemblies 36
11.3.1 Crane Girder 36
11.3.2 Monorail Hoist 36
11.3.3 Double-Rail Trolley 36
11.3.4 Crane Travel Unit 36
11.4 Crane Control System 37
12 Erection and Assembly 38
12.1 Delivery 38
12.2 Crane Runway Tolerances 38
12.3 Assembling the Crane when Supplied as Subassemblies 39
12.4 Bolted Connections 40
12.4.1 DFW-L-E, DFW-L-Z and DFW-L-T with Side Connection 40
12.4.2 KTD-E 41
12.5 Tightening Torques 43
12.5.1 Standard Bolted Connections 43
12.5.2 High-Tensile Bolted Connections 44
12.5.3 Verbus Ripp / Durlock Bolted Connections 44
12.6 Example for Installing the Crane on the Runway 45
12.6.1 Single-Girder Crane 45
12.6.2 Double-Girder Crane 45
13 Putting into Service for the First Time Following Assembly on site 46
13.1 Notes and Inspections 46

22932449.indd/100810
14 Sample Checklist 47
4
0 Foreword
You have purchased a Demag crane. This crane has been built in accordance with
German and European standards and regulations. The crane complies with the
statutory regulations e.g. EC directive 98/37/EC.
Demag cranes are of modular design. The main assemblies include:
• Crane bridge
Crane girder
Travel units
Motors
Gearbox
• Trolley
Load handling attachments
Hoist unit
Travel units
Motors
Gearbox
• Electrical equipment
Power supply
Regulating devices
Control devices
Control pendant
Ground-level station
These operating instructions are designed to provide the owner with appropriate
instructions for safe and correct operation and to facilitate maintenance.
Every individual given the task of transporting, installing, commissioning, operating,
maintaining and repairing our cranes and their additional equipment must have read
and understood
• the operating instructions,
• the safety regulations and
• safety instructions in the individual chapters and sections.
The operating instructions must be available to the operating personnel at all times in
order to prevent operating errors and to ensure smooth and trouble-free operation of
the cranes.
0.1 Copyright These operating 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 compensatory damages.
All industrial rights reserved.
0.2 Customer Service The aftersales package will provide you with all technical information for proper
maintenance and proper inspection for Demag products.
Should you have any questions regarding our products, please refer to one of
our authorized service providers, the relevant Demag representative, or to our
main office.
Please state the pertinent serial number, order number, and model designation (see
22932449.indd/100810
test and inspection booklet, crane capacity plate) in any correspondence or for spare
part orders. Specifying this data ensures that you receive the correct information or
the required spare parts. The telephone number of our head office is given on page 3.
5
0.3 Liability for Defects These operating instructions must be read carefully before installing and putting the
crane into operation.
We assume no liability for damage and malfunctions resulting from failure to comply
with the operating instructions and/or improper service.
Claims of liability for defects must be made by quoting the order number and serial
number immediately on detecting the defect.
Any liability claims for defects are void in the event of:
• inappropriate use, overloading beyond rated capacity, side pulling of the load,
excessive jogging, damage to pushbuttons and operator control interfaces from
impact, environmental exposure not specified in original order, lack of
maintenance, lack of lubrication or use of improper lubricants.
• faulty devices or equipment connected or attached to the product 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.
• improper service or improper maintenance.
0.4 Limitations of Liability Wearing parts are not subject to liability for defects.
• Normal wear of any part is not covered by warranty.

• Brake linings, wire ropes, rope guides, and sheaves are excluded from
warranty coverage.
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 further
development of the cranes which are the subject of these operating instructions.
The information, illustrations and descriptions contained in these operating
instructions are therefore only intended for information purposes.
The descriptions and illustrations contained in this documentation do not necessarily
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
approved 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, our liability for defects and liability obligations
for any defects pertaining to the products supplied or faults in the documentation
delivered or any negligence on our part are exclusively based on the stipulations of
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.
22932449.indd/100810
6
0.5 Definitions Owner
Owners (employer, company) are defined as persons who own the crane and who use it
appropriately or allow it to be operated by suitable persons.
Operating personnel/operator
Operating personnel or operators are defined as persons entrusted by the owner of
the crane with operation of the crane.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner 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 cranes 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 cranes.
Cranes
Cranes are systems used for lifting, lowering and moving loads. This definition also
applies to rail-mounted lifting equipment.
22932449.indd/100810
7
1 Safety Instructions
1.1 Symbol Description The following symbols and recommendations indicate potential safety hazards or
causes of damage or provide useful information.
Safety at work symbol
This symbol appears in the operating instructions next to all instructions relating to
safety at work wherever a potential hazard to life and limb exists.
Follow these instructions at all times and be particularly vigilant and cautious.
Pass on safety instructions to all persons entrusted with working on the crane, the
runway and the power supply system.
In addition to the safety instructions, observe all general safety regulations and
accident prevention regulations at all times.
Warning against electrical hazards
Contact with live parts can result in immediate death. Protective covers (e.g. covers
and enclosures) 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. This
applies in particular to non-positive locked load handling attachments e.g. magnet
and vacuum systems. In each case the special safety and operating instructions
contained in the operating instructions for the load handling attachment in question
must be complied with.
Operating hazard for the installation
This symbol indicates information on the appropriate use of machinery. In the
operating instructions, it indicates all warnings which, if not complied with, may result
in damage to the crane or the load.
1.2 Appropriate Use Cranes are only intended for lifting, lowering and moving loads and may be used both
as stationary or travelling units.
Cranes may only be operated when in perfect working order by trained operating
personnel in accordance with the relevant safety and accident prevention regulations
and codes of practice. This also includes compliance with the operating and
maintenance conditions specified in the operating instructions. It is assumed that the
line voltage and frequency at the power feed to the crane is within the permissible
tolerances according to DIN IEC 60038.
Cranes are industrial equipment operated with a rated voltage of up to 1000 V
from high-voltage supply systems. Any use exceeding the scope of the operating
conditions specified in the operating instructions and/or agreed in the contract
between manufacturer and owner is not permitted.
Power feed is via a power supply system (mobile cables, open or enclosed conductor
systems, cable drums). These systems are live up to the terminals of the main
switches (mains connection switch, isolating switch) on the cranes (see Fig.
411 270 44). The relevant main switches must be switched off and secured when
maintenance/repair work is carried out.
During operation or when the main switch is not switched off, electrical components
inside enclosures, motors, switchgear cabinets, load handling attachments, terminal
boxes, etc., carry dangerous voltages. This voltage may cause fatal injuries.
Serious personal injury or damage to property may occur in the event of:
• unauthorized removal of covers,
• inappropriate use of the crane,
22932449.indd/100810
• incorrect operation
• insufficient maintenance,
8
• 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.
After actuating an Emergency Off switch or an Emergency-Stop button in the event

of danger, such switches/buttons must not be reset until the cause of the dangerous
situation has been eliminated.
Example Crane power feed

Switch and main switch arrangement
(single-pole arrangement shown)
3 4 5
2 6
3/PE~
TN-S system acc. to DIN VDE 0100 part 300
(control and special voltages are generated via transformers)
1 Mains connections switch Mains connection

(Emergency Off/Emergency-Stop) switch on the crane
runway (workshop,
2 Power supply
building)
3 Isolating switch for drives
4 Isolating switch for special circuits
5 Isolating switch for magnet installations 1
6 Control pendant
(Emergency-Stop button) Power supply system
Conductor lines
2 Flat cables
Cable drum
Isolating switch
Special circuit for
lighting equipment, Isolating switch for
temperature control Isolating switch magnet installations with
devices, ... for drives stand-by battery
4 3 Crane switch 5
-K012 Main contactor with Contactor
remote actuation
Pushbutton
EMERGENCY OFF Fuse links

quickest-possible switch off Emergency
22932449.indd/100810
in the event of unexpected stop button

danger(s) Switch
EMERGENCY-STOP
stops a dangerous movement -K012 6 Current collector
41127044.eps 9
1.3 Inappropriate Use Certain work and practices are prohibited when using the crane as they may involve
danger to life and limb and result in lasting damage to the crane, 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
transporting persons.
• Lifting the load when the rope is in slack condition.
• Lifting the load at full speed.
• Manipulating electrical equipment.
1.4 Basic Information on Persons under the influence of drugs, alcohol or medicines which affect reactions
must not install, operate, put into service, maintain or repair cranes.
Safety
Any conversions and modifications to the installation must comply with the techni-
cal safety requirements. Work on electrical equipment of cranes may only be carried
out by qualified electricians in accordance with electrical regulations. In the event of
malfunctions, crane operation must be stopped, switched off and the relevant main
switches locked immediately. Malfunctions must be eliminated immediately. The crane
may not be put into operation again until the cause of the defect has been rectified.
National accident prevention regulations and codes of practice and general safety
regulations must be observed when operating cranes. Important information and
instructions are marked by corresponding symbols. Follow these instructions and/or
safety regulations in order to avoid accidents and damage.
The operating instructions must be kept available at the place where the crane is in
use at all times. They include significant aspects and appropriate excerpts from the
relevant guidelines, standards and regulations. The owner must instruct his personnel
appropriately.
Any failure to comply with the safety instructions stated in these operating instructions
can result in death or personal injury.
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 the crane is used and follow the
instructions therein when working with the equipment. The crane may still constitute
a danger to life and limb if it is installed, operated, maintained or used improperly by
personnel which have not been trained or specially instructed.
The operating instructions must, if required, be supplemented by the owner with
22932449.indd/100810
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. Super-
vising and reporting obligations as well as special operating conditions must also be
taken into consideration.
10
Personnel assigned to working with the crane must have read and understood
the operating instructions and, in particular, the chapter on Safety Information. All
activities relating to cranes which are not described in these operating instructions
may only be carried out by specialist personnel specifically trained for the
particular crane.
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
the cranes are only operated when in proper working order and that all relevant safety
requirements and regulations are complied with.
Cranes must be taken out of service immediately if functional 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 operator/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, jewelry including rings or long hair loose.
Injury may occur, for example, by being caught or drawn into the mechanism.
All safety and hazard information and recommendations on the crane, e.g. at
access points and mains connection switches must be maintained in complete
and legible condition. Inching 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 the crane which may impair safety
in any way must not be carried out without the written approval of Demag. This also
applies to the installation and adjustment 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 and accessories may be used. Observe prescribed
deadlines or those specified in the operating instructions for routine checks/
1.5 Selection and inspections.
Qualification of For independent operation or maintenance of the crane, the owner may only
Operating and employ persons:
Maintenance Personnel • who are mentally and physically suitable,
• who have been instructed in the operation and maintenance of the crane and 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.
In general practice, no person should be permitted to operate a crane:
(a) Who cannot speak the appropriate language or read and understand the
printed instructions;
(b) Who is not of legal age to operate this type of equipment;
(c) Whose hearing or eyesight is impaired (unless suitably corrected - with good
depth perception);
(d) Who may be suffering from heart or other ailments which might interfere with
the operator’s safe performance;
(e) Unless the operator has carefully read and studied the operation manual
supplied by the Crane Manufacturer;
(f) Unless the operator has been properly instructed;
(g) Unless the operator has demonstrated his instructions through practical
operation;
22932449.indd/100810
(h) Unless the operator is familiar with hitching equipment and safe rigging
practices.
11
1.6 Safety Instructions • Installation and disassembly work may only be performed by experienced
technicians per CMAA #78 Standards and Guidelines for Professional
for Assembly and Services Performed on Overhead and Travelling Cranes and Associated
Disassembly Hoisting Equipment.
• 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
regulations.
• 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
conductors, screening elements or anti-friction bearings, serious damage may
be caused to these or other components.
• Installation and disassembly work must be prepared and carried out so that
crushing and shearing hazards are excluded.
• The working and danger area must be made safe.

1.7 Safety Instructions
• First check that the voltage and frequency specified on the data plates match the
when First Putting the owner’s mains power supply
Unit into Service after • All clearance dimensions and safety distances (see approval drawing) must be
Completing Assembly checked before putting the unit into service.
• When putting the unit into service, it may be necessary to perform work in the
danger zone.
• 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.
• It must be ensured that only trained personnel are employed for putting the unit
into service.
• To compensate any settling, all bolted connections must be tightened one to two
months after first putting the crane into service.
The operator must check the function of the brakes and emergency limit stop devices
1.8 Safety Instructions for before starting work.
Operation All instructions and measures described in the 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.
Cranes 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 cranes 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
occurring to parts of the installation and equipment which makes immediate
stoppage necessary.
22932449.indd/100810
After an “Emergency Off or an Emergency-Stop”, the operator must not switch

on and restart the crane 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.
12
Cranes must be switched off immediately in the event of the following faults:
• In the event of damage to electrical devices and cables as well as parts of the
insulation.
• In the event of brake and safety device failure.
• In the event of damage to:
– lifting ropes
– lifting chains
– load hook
– load handling attachments
– any other load-bearing parts
If the lifting movement is switched off while the load is being lifted, this may indicate
response by the load detector. In this case a load already lifted must be deposited
immediately.
Before switching on/putting into operation of the crane it must be ensured that nobody
is endangered by operation of the crane.
If the operator notices persons who may be exposed to a risk to health or personal
safety by operation of the equipment, he must suspend operation immediately and
may not resume operation again until the persons are outside the danger zone.
Before putting the crane into operation, the operator must be satisfied that the
installation is in safe and correct operating condition.
Work on cranes may only be carried out when instructions to this effect have been
issued, when operation and function of the crane have been explained and when the
working and danger zone has been made safe. Cooling devices, such as ventilation
openings, may not be rendered permanently inoperative (e.g. covered or closed).
Special local conditions or special applications can lead to situations which were not
known when this chapter was written. In such cases, special safety measures must
be implemented by the owner.
1.9 Safety Instructions for Maintenance measures are defined as regular maintenance, inspection and repair
work.
Maintenance
Mechanical and electrical repairs and maintenance work may only be carried out by
appropriately trained personnel (experienced technicians) per CMAA #78.
Adjustment, maintenance and inspection activities and inspection deadlines including
specifications concerning replacement of parts/assemblies prescribed in the operat-
ing instructions must be observed.
Ensure that all electrical components are de-energized before commencing work on
electrical installations and devices. When all work on the crane has been completed,
operation of the crane must not resume until the owner has given approval to this
effect.
Unauthorized persons must be prohibited from carrying out work on machinery or
parts of the crane. Before starting all maintenance work, the crane must be switched
off and taken out of service and secured against accidental or unauthorized putting
into operation (restarting). Switches must be locked.
It must be ensured that:
• the crane is switched off and checked that it is de-energized and, in special cases,
isolated,
• moving parts are stationary and stopped,
• moving parts cannot start moving while maintenance work is being carried out,
22932449.indd/100810
• the power supply cannot be accidentally restored as long as the crane has been
taken out of service for maintenance and repair purposes
• Ensure that operating and auxiliary materials as well as spare parts are disposed
of in a safe and environmentally sound way.
13
Instructions for repair work in the course of operation
The danger zone must be marked off with red/white safety chains or safety tape and
indicated with warning signs.
Mobile cranes, forklifts and other machinery are often required to complete the
work. Each Employee has the responsibility for the safe operation and use of any
such equipment prior to operation. Mobile cranes, forklifts, scissors lifts, boom lifts,
and other machinery shall only be operated by trained, licensed (where required)
individuals. Refer to manufacturer’s requirements for specific operating procedures
and requirements. All equipment shall be in good operating condition with all required
inspection and maintenance documentation available.
Work areas should, wherever practical, be identified by highly visible signs, barriers or
other appropriate means to alert others that overhead work is being performed.
All ladders shall be used in compliance with the manufacturer’s recommendations.
Care shall be taken to secure the ladder to prevent falling or slipping.
Service providers should have a Fall Protection Policy.
In each individual case, the owner or the person specified by him must check whether
the relevant work may be carried out in the course of operation without risk of
personal injury owing to the particular local conditions.
Use only calibrated and appropriate tools and auxiliary materials for maintenance and
repair work.
If there is a risk of objects falling, the danger zone must be made safe.
Maintain a sufficient safety distance to moving or rotating parts to prevent clothing,
parts of the body or hair becoming entangled.
Avoid naked flames, extreme heat and sparks in the vicinity of cleaning agents and
flammable parts or parts liable to deformation (e.g. wood, plastic parts, oil, grease) in
electrical installations – non-compliance may result in fire hazard. Harmful gases may
evolve or insulation may be damaged.
Additional instructions for repair work on electrical equipment

Only genuine fuse links with specified amperage and tripping characteristics may
be used.
Defective fuse links must not be repaired or bridged and must only be replaced by
fuse links of the same type.
Switch off the crane immediately in the event of electrical power supply malfunctions.
Work on the electronic and electrical components or equipment may only be carried
out by qualified electricians.
If inspection, maintenance and repair work is to be carried out on parts of the product,
these must – if prescribed by regulations – be isolated. First verify the safe isolation
of the parts from the supply before commencing work.
The electrical equipment of the crane must be inspected and checked at regular
intervals. Defects, such as loose connections, damaged cables and worn contactor
contacts must be rectified immediately.
Since it is possible that after a longer period of operation the switching points of
relays (time, frequency and monitoring relays) change due to ageing of the com-
ponents, the relay switching points in circuits relevant to safety must be checked
at regular intervals.
Electrical equipment must be replaced as a preventive measure on reaching the limit
of its theoretical duration of service (service life).
If work has to be carried out on live parts, a second person must be available in order
to actuate the Emergency-Stop button or mains connection switch/isolating switch for
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voltage disconnection in an emergency.
14
The second person must be familiar with resuscitation measures.
Only use insulated tools.
Before disconnecting and connecting electrical plug-and-socket connections, always

disconnect them from the supply (this does not apply to mains connections, provided
they do not represent a dangerous contact voltage in the sense of the safety
regulations).
Service providers should have a Lockout / Tagout policy. The purpose of this policy
is to protect Employees against unexpected release of energy including electrical,
pneumatic, hydraulic, chemical and other potential energy resources.
1.10 Prescribed Crane

Safety Features
General
• Bumpers on the cranes and at the ends of the cross-travel rails designed
according to DIN 15018
• Brake devices for all drives, active also in the event of driving gear standstill,
Emergency-Stop, Emergency Off and power failure
Cranes with cable-connected control pendants

• For max. long and cross-travel speeds up to 175 ft/min
• Lockable mains connection switch (on the runway)
• Lockable isolating switch (on the crane)
• Remotely-controlled crane switch main contactor in conjunction with a lockable
Emergency-Stop button
• Emergency limit switch for highest and lowest hook position
• Operating limit switch for highest and lowest hook position if the end positions
are approached in normal operation (must be possible to check function of the
emergency limit switch)
• Long and cross-travel limit switches if the limits of travel are approached in normal
operation.
1.10.1 Additional Safety Features Additional requirements for cranes with remote control
which may be Present Depend- • Recommended long and cross-travel speeds less than or equal to 320 ft/min
ing on Operating Criteria (higher speeds are possible)
(Examples) • Long and cross-travel limit switches to switch off fast travel speeds before limits of
travel are reached
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15
2 Operation
2.1 Prevention of Observe relevant national safety regulations and codes of practice when
operating and maintaining the crane. (Ref. OSHA 1910.179, ASME B30.2,
Accidents ASME B30.11, ASME B30.16, ASME B30.17, and CMAA Crane Operator’s Manual)
In the interests of safety, therefore, it is essential that these regulations and codes of
practice are explained carefully to all persons assigned to operating/maintaining cranes.
The safety regulations and codes of practice must be available to the operator at
all times.
2.2 Obligations of the Observe the following instructions and recommendations:

Operator • The operator must check the function of the brakes and emergency limit stop
devices – with the exception of slipping clutches – before starting work.
• The operator must visually inspect the crane for obvious defects, proper function,
deterioration, wear, and rope reeving.
• The operator must pay attention to the assignment of the control device and crane
in the case of remotely controlled cranes.
• The operator must inform the safety officer/supervisor responsible and his
successor when crane operators are changed about all defects, damage
and malfunction.
• The operator must stop operation of the crane immediately if any defects which
prejudice safety or endanger the crane/crane equipment are detected.
• Control devices must only be actuated from the cab/control position.
• The crane must not be parked above or below sources of heat.
• Do not exceed capacity.
• Maintain firm footing while operating.
• Rope free of kinks and not wrapped around load.
• Attach load only with slings or lift devices.
• Slings clear any obstacles.
• No kinks in rope.
• No twisted lines.
• Hook not swinging.
• No sudden speed changes.
• No travel with someone on the load.
• Test hoist brakes close to ground.
• Check hoist limit switch at beginning of every shift as a minimum
• Be familiar with hand signals
• Make sure no one is on the crane.
• Make sure controls are off when turning on at E-Stop switch.
• If power fails during operation, engage E-Stop.
• Be familiar with equipment so problems can be recognized and reported.
• Contact other cranes and stops with extreme caution.
• Hook brought over load without swinging.
• No contact with obstacles.
• Avoid side pulls.
• Avoid moving loads over people.
• Test hoist holding brakes close to floor for all heavy loads.
• Do not leave a suspended load unattended.
• Do not use upper limit as an operating control
• Inspect wire rope visually.
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• Do not attempt to lengthen the wire rope or repair a damaged wire rope.
• Inspect hook.
• Inspect hook latch.
16
• Report missing or illegible labels.
• Do not operate if tagged out of order.
• Be familiar with operation.
• Be familiar with equipment.
• Center crane hook over load.
• Verify slings or lift devices are in bowl of hook.
• Verify latch is not supporting load.
• Verify hook tip is not supporting load.
• Verify load is balanced.
• Verify rope is in drum grooves.
• Do not divert attention.
• Do not lift until personnel and self are clear of load.
• Ensure load is free to move.
• Remove rope slack slowly.
• Ensure load will clear all obstacles.
• Avoid reversing direction quickly.
• Avoid swinging load.
• Avoid running trolley into stops.
• Avoid running crane into stops.
• Leave at least 2 wraps of rope on drum.
• Activate warning device when starting movement or approaching people.
• Verbally warn people when there is no warning device.
• Do not lower until area is clear.
• Block loads if slings are to be removed.
• Exercise care when removing slings.
• Position hook above head level for storage.
• Obey all stop signals.
• Do not adjust or perform maintenance unless qualified.
• Do not use crane as a limiting device to measure load weight.
• Do not allow a welding electrode to be touched to the wire rope.
• Do not perform or allow anyone to perform any work on a suspended load that
requires a worker to be positioned under a suspended load.
• Exercise common sense.
2.2.1 Control Devices Switch the crane on by unlatching the Emergency-Stop button
(crane switch actuation).
The crane operator must ensure that:
• all control devices are in zero position before enabling the energy supply to the
drives,
• the control devices are in zero position and the energy supply is disabled before
leaving the cab/control position,
• the remote control unit is secured against unauthorized operation (switching-on)
before putting the unit down.
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2.2.2 Control Pendant The operator selects the lifting and travel motions, and if necessary the functions of
Cable-Connected Floor Control the additional facilities, by means of the control unit. The control unit must be treated
– Remote Control with care. Recharge the rechargeable batteries of remote control units in good time.
17
2.2.3 Attaching Loads Heavier loads than those specified on the safe working load plate must not be
picked up.
The deadweight of load handling attachments which are not a permanently connected
integral part of the crane is part of the payload. When attaching the load, ensure
that loads are picked up in such a way that they cannot accidentally fall over, fall
apart, slide or roll away. In this context, refer to the relevant regulations and codes of
practice pertaining to the application and loading of chain and rope slings.
The operator must not move loads attached by hand until he has received a clear
sign from the person attaching the load, the marshaller or another responsible person
appointed by the owner.
If signals have to be used for communication with the operator, they must be agreed
between the person responsible and the operator.
The operator must not handle loads if he recognizes that they are not appropriately
attached. The operator must keep the control unit within hand’s reach as long as a
load is suspended from the crane.
End positions which are limited by emergency limit stop devices or slipping clutches
only must not be approached in normal operation.
If the hoist operating limit switches fail and the emergency limit switches are
approached, the hoisting or lowering motion and the crane switch main contactor
are switched off (double-circuit system).
A load already lifted can then only be deposited by additionally pressing the
“Emergency limit switch check” function unit in the control device.
The fault must be eliminated before starting up the crane again.
Press the Emergency-Stop button immediately if the lowering speed is too high
(falling load), which may occur in the case of malfunctions. Stop crane operation until
the fault is completely eliminated. If possible without danger, safely deposit loads
beforehand.
The operator must guide push-travel and semi-driven cranes in such a way that he
can bring motions to a stop without danger.
2.2.4 Observing the Loads The operator must observe the load or, in the case of no load, the load handling
attachments during all crane movements. If it is not possible to observe the load
or the load handling attachments, the operator may only control the crane in
accordance with the signs given by a marshaller. This does not apply for program-
controlled cranes. The operator must give warning signs as required. Do not handle
suspended loads above persons. He must not transport loads above persons when
using load handling attachments which retain the load by means of magnet, friction or
suction forces without an additional load securing device.
2.2.5 Bumper The crane and trolley hoist are fitted with elastic bumpers to limit the forces transmit-
ted by the crane and/or trolley hoist when approaching the bridge or cross-travel limit
stops and/or adjacent cranes/trolleys/hoists.
Adjacent cranes and trolleys are also fitted with appropriate elastic bumpers. The
condition of bumpers must be inspected regularly (cracks and lasting deformation
indicate that they no longer function correctly).
2.2.6 End of Work Move the crane to the predetermined parking position on finishing work.
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Set down and switch off load handling attachments such as grabs or magnets.
Finally, switch the crane off and engage the wind drift safety devices, if fitted
(see also the “Taking the crane out of service when finishing work” section).
18
3 Taking the Crane Out of Service
3.1 Emergency-Stop It must be possible to interrupt the electrical power supply to all drive units from
the operating position. This is done by actuating the Emergency-Stop button in
Button conjunction with the crane switch (load switch), with the exception of facilities such as
e.g. magnet systems.
3.2 Taking the Crane At the end of work, the operating personnel must interrupt the power supply to the
crane. The installation is disconnected from the mains by switching off the mains
Out of Service connection switch or the isolating switch.
on Finishing Cranes which are periodically exposed to the wind must be parked in the building
Work on finishing work.
Cranes operating exclusively outdoors are equipped with wind drift safety devices
which must be engaged during longer crane downtimes and on finishing work. See
also chapter “Weather Influence and Dirt Accumulation”.
3.3 Taking the Crane The mains connection and/or isolating switches (when two or more cranes operate
on the same runway) must be switched off and secured against accidental and
Out of Service unauthorized restoration of the power supply when maintenance and repair work is
for Maintenance performed. Also refer to the “Safety Instructions” chapter.
and Repair Engage the wind drift safety device on cranes which are exposed to the wind.
Purposes Following completion of maintenance and repair work, operation of the installation
must not resume until the owner has given approval to this effect.
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19
4 Weather Influence and Dirt Accumulation
4.1 General Our cranes are intended for use in the following operating conditions:
• 14° to 104° F ( -10° to 40° C ) ambient temperature
• Air humidity up to 80%
• Installation height up to 3300 ft (1000 m) above sea level
Other operating conditions are possible after clarification of the measures required to
be taken.
Crane operation must be stopped if safe crane operation (controlled handling of
crane, load handling attachments and load) can no longer be guaranteed due to
adverse weather conditions.
First deposit loads safely.
During thunderstorms it is forbidden to walk on crane runway(s) and crane(s). It is
also forbidden to leave the cab, if any.
4.2 Cranes Sometimes A wind drift safety device is not necessary for cranes operating mostly indoors and
only some of the time outdoors.
Operating Outdoors
When a storm or strong winds are approaching, the operator must move the crane
into shelter in the building in good time.
4.3 Cranes Operating Cranes operating all or most of the time outdoors are equipped with wind drift
safety devices.
Outdoors
The wind drift safety devices must be engaged during longer crane downtimes and
when strong winds or storms are approaching.
Cranes operating outdoors should be kept under shelter when not in operation.
4.4 Influence of Weather For safety reasons all runways must be kept clear of oil, grease and/or dirt, as such
contamination impairs the start-up and braking of cranes and trolleys.
and Dirt on Runways
For the same reason all runways must also, if necessary, be cleared of ice and snow
before starting operation.
Check the function of current collectors and the power supply before starting up and,
if necessary, de-ice them in a disconnected state.
Viscous oil (e.g. in gear units) impair or prevent crane or trolley start-up. De-ice frozen
brakes on lifting and travelling gears before starting work or, if necessary, after long
downtimes and apply the brakes “warm”.
Precautionary measures to ensure safe crane operation are the responsibility of

the owner.
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20
5 Maintenance
Preventive Maintenance shall be performed based, as a minimum, on the crane

manufacturer’s recommendations.
Maintenance procedures shall include, as a minimum, the following precautions:

The crane to be maintained shall be moved to a location where it will cause the least
interference with other cranes and operations in the area.
All controllers shall be at the off position.
The main electrical disconnect switch shall be open and locked in the open position.
Follow appropriate lockout/tagout procedures.
Warning or “out of order” signs shall be placed on the crane and shall also be placed
on the floor beneath or on the hook so as to be visible from the floor.
Where other cranes are in operation on the same runway, rail stops or other suitable
means shall be provided to prevent interference with the idle crane. Additionally, other
crane operators on the same runway and in adjacent runways shall be notified of the
out-of-service crane.
After adjustments, maintenance, or repairs have been made, the crane shall not be
operated until all guards have been reinstalled, safety devices reactivated and main-
tenance equipment removed.
Adjustments, maintenance, or repairs to correct any unsafe conditions shall be dis-
closed by the inspection reports or by operating personnel before operation of the
crane is resumed. Adjustments, maintenance, or repairs shall be done only by quali-
fied personnel in accordance with CMAA #78.
Maintenance Records
Records shall be kept on file evidencing adjustments, maintenance, and repairs that
have been performed. Maintenance records should be retained for the life of the
equipment.
Maintenance records should document routine and preventive maintenance activities
as well as adjustments, maintenance and repairs that result from inspections.
Safety Hazards
Safety Hazards shall be reported to the responsible person, in written format, imme-
diately upon discovery. Reports should include specific identification of the hazard,
and a recommendation(s) for remediation of the hazard.
Maintenance Issues
Maintenance issues shall be reported to the appropriate supervisor or responsible
person, in written format, within a reasonable time from discovery. Damage, safety
replated issues and/or imminent equipment failure must be reported immediately.
Reports should include specific identification of the item and a recommendation(s)
for remediation of the item. Unsafe conditions disclosed by the inspection should be
corrected before operation of the crane is resumed.
If required, our after-sales service will carry out inspection of your cranes. In this
case, we recommend you conclude an inspection and maintenance agreement.
These operating instructions must be used to identify deviations/damage which could
impair regular crane operation.
Observe the contents of the “Taking the crane out of service for maintenance and
repair purposes” section in the “Taking the crane out of service” chapter when
performing maintenance and repair work.
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21
The specified inspection intervals apply to cranes in single-shift operation. Cranes
which are used in multiple-shift operation or which are exposed to special ambient
conditions in hardening shops, galvanizing facilities, casting shops, etc. require
shorter inspection intervals.
The stress group and group of mechanisms classifications are documented in the
crane test and inspection booklet.
The prescribed regular checks and inspections are not included in these operating
instructions. These specifications are included in the operating instructions of the
components fitted.
Maintenance work must only be performed by qualified personnel.
Training by the manufacturer is required for some maintenance activities and is
available by contacting Demag.
The electrode holder and ground must be connected to the same assembly when
welding work is carried out. If the current flow is returned via protective conductors,
screening elements or anti-friction bearings, serious damage may be caused to these
or other components.
Crane component assemblies to be inspected are listed as follows, e.g.
• Trolley/monorail hoist with hoist unit and travel units
• Crane bridge with travel units
• Control
• Regulating devices
• Control devices
• Control pendant
• Power supply
• Crane runway.
Other subassemblies, if fitted, are documented separately and must be checked.
To compensate any settling, all bolted connections must be tightened one to two
months after first putting the crane into service.
5.1 Inspection Before The operator must carry out inspections in accordance with the following instructions
before starting work. The crane must be taken out of service immediately if the crane
Operation operator detects any defects relating to operating safety and reliability.
Such defects include, for example:
• brake or emergency limit switch failure,
• damage to the rope,
• unusual noises in the gearbox, etc.
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22
Visual checks before turning on power:
1. Look at the crane and major components for damage.
2. Look for tags or out-of-order signs, and do not attempt to operate if present.
3. Look for loose objects or parts on crane or under it.
4. Look for oil leakage on crane and floor due to crane.
5. Look at the drum for proper spooling of wire rope.
6. Look at the reeving of wire rope or load chain for proper pattern.
7. Look at the visible portion of the sheave grooves for imprinting onto surface.
8. Look at visible rope for damage, breaks, elongations, and/or kinks.
9. Look at the hook, safety latch, and other lifting devices for damage.
10. Look at the control cable for damage and check labels are present and legible.
11. Look at the pendant and pushbuttons for damage.
12. Make sure there is proper lighting.
Function tests before turning on power:

1. Make sure the E-Stop is in the power off position and depress the buttons on
pendant for all crane motions to be sure E-Stop is working properly and that no
pushbuttons are sticking.
2. Manipulate hook latch for proper function, and check for latch not hanging up.
Function check:
1. Set E-Stop to the power on position.
2. Activate and test all audible and visible warning devices.
3. Move hoist down and up at all speeds.
4. Move trolley left and right.
5. Move bridge forward and away.
NOTE: This procedure checks the brakes and movements should be smooth and
stopping should be expedient.
6. EVERY SHIFT, raise the hoist to check the upper limit switch. Take care not to
create a two-block condition if the limit fails. Move the hook slowly.
7. Listen for unusual sounds.
Brake test under load:

1. On first lift with load after checking above items, raise load above ground a few
inches and hold. This tests the holding brake on the hoist.
Reporting deficiency found during inspection:

1. Report any deficiencies to supervisor immediately.
5.2 Inspection and

The specified inspection and maintenance intervals (see table) apply to normal crane
Maintenance Schedule service conditions.
If routine maintenance reveals that the intervals are too long, they should be adapted
to the specific operating conditions.
For repairs, use only genuine Demag parts (see component parts list).
222932449.indd/100810
The use of spare parts not approved by Demag renders any warranty claims void.
23
5.3 Hoist Trolley Refer to the operating instructions on the following pages for maintenance
instructions with inspection intervals. Furthermore the relevant safety and health
codes and standards and directives must be complied with.
The component assemblies fitted are listed in the individual “Technical Description”
chapters of the corresponding cranes.
The hoist and travel units used are standard Demag products which require little
maintenance.
Components which are subject to wear (brakes, ropes, load hooks, etc.) must be
checked and inspected as specified in the relevant operating instructions and re-
paired as required.
The inspection intervals apply to single-shift operation.
5.4 Crane Bridge Component Type of inspection Inspection criteria Inspection

interval
Months
3 6 12
Crane girder Visual check - mechanical damage x
- check welds for cracks
- corrosion protection
Travel rail/travel Visual check - wear x
flanges - check welds for cracks
- flange deformation
Limit stops Visual check - damage
x
- tight fit
Wind drift safety Visual check - damage x
devices - tight fit
- function
Limit switches Function check - switching-off
x
- run-on path
Safety interlock Visual check - see Operating Instructions
x
Function
Bolted connections Check tightening - Tightening torques/prop-
crane girder/travel torques and property erty classes, data see HV
units class self-adhesive label close x
to the bolted connection
Connections/ Check tightening - see Chapter 12

fittings torques x
Travel units Visual check - maintenance instructions

Function with inspection intervals
Travel wheel flange see operating instructions x
wear of the components
5.5 Tightening Torque For torque requirements of bolted connections also see tables in Section 12.5.
Requirements
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24
5.6 Control The relevant international and national electrical codes of practice and regulations
must be observed in order to maintain the condition of the entire electrical equipment.
Electrical power installations with a rated voltage of up to 1000 V must be inspected
by an experienced technician in accordance with these guidelines and at suitable
intervals.
Component Inspection criteria Inspection
interval
Months
3 6 12
Isolator - check electrical function
x
- locking device
Crane switch/main contactor - Emergency-Stop actuation
x
- main contactor cut-off
Control pendant - mech. damage
- electrical function x
- fixing of strain relief device
Remote control units - see manufacturer’s operating instruc-
x
tions for maintenance instructions
Component Inspection criteria Inspection

interval
Months
3 6 12
Fuse links - check specified amperage and trip-
ping characteristics
x
- check close-tolerance bolts on screw
cap for tight fit
Contactors - check for contact erosion
- check connections for tight fit
x
- check easy movement of magnet
system
Transformers - check connections for tight fit x
Electrical components - protective measures x
Control devices, electrical - check connections and devices for
equipment tight fit x
- check electrical settings
Hoist limit switches, anti- - check function by approaching/tripping
collision devices, by-pass - check run-on paths
control system, reflectors/ - check fittings for tight fit
light barriers - check correct connection orientation
x
- regularly remove dirt accumulation (at
shorter intervals, if required)
- carry out regular function checks (at
shorter intervals, if required)
Load detectors - according to operating instructions x
Magnet installation, back-up - maintenance according to operating
battery, fill level instructions x
- visual check
Warning devices - functions
x
- visual check
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Drive control systems - see Operating Instructions x

Timer, frequency, monitoring - functions
relays - operating processes depending on x
time and frequency 25
5.7 Power Supply Component Inspection criteria Inspection
interval
Months
3 6 12
Power supply to the crane - refer to the operating instructions for
maintenance instructions x
Power supply line to the - refer to the operating instructions for

hoist trolley. maintenance instructions x
Remote control system - refer to the operating instructions for

maintenance instructions x
Fixed cabling, moving - damaged cables

connecting cables - check screwed glands for tight fit and
leaks
- check connections on screw x
terminals/plug-and-socket
connections for tight fit
- check strain relief device
Warning and notice signs - check condition
x
- legibility
5.8 Crane Runway Component Type of Inspection criteria Inspection

inspection interval
Months
3 6 12
Mains connection - electrical function
switch - locking attachment x
Foundations Visual check - cracks in the floor x

Supports, brackets, Visual check/ - see Chapter 12
travel rails, flanges tightening torques - cracks in welds x
- mech. deformation
Rail joints Visual check - offset and fastening x

Track suspensions Visual check/ - mechanical damage of
tightening torques suspension rods
- securing element of ball x
nut
- connections
End stops Visual check/ - damage
x
function
Corrosion Visual check
x
protection
The owner must be informed if inspection of the crane reveals excessive wear of the
travel wheels/wheel flanges.
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To compensate any settling, all bolted connections must be tightened one to

two months after the crane is first put into service and during routine inspec-
tions.
26
6 Manufacturer, Service and Spare Parts Contact Information
6.1 Manufacturer / Demag Cranes & Components Corp

Customer Service 29201 Aurora Road
Cleveland, OH 44139-1895
Telephone: (440)-248-2400 (9:00 AM to 5:00 PM Eastern)
Fax: (440) 248-3874
Demag Cranes & Components Corp.

6.2 Spare Parts
29201 Aurora Road
Cleveland, OH 44139-1895
Telephone: (800)-756-8221 (9:00 AM to 5:00 PM Eastern)
Fax: (800)-945-7278
e-mail: parts@demag-us.com
Demag spare parts sets reduce maintenance requirements and ensure functional
reliability, a long service life, and high product availability. Quotation requests or
orders for spare parts sets can be submitted to your local Demag Dealer, Parts
Distributor, or Service Provider. Use our Website for assistance in locating your
regional Demag Parts and Service Contact.
For Quotations, please include a crane or component serial number, as well as the
original Demag crane or component sales order number.
For safety reasons, only Demag original spare parts and/or Demag approved OEM
parts and accessories may be used for maintenance and repair work on Demag
cranes and components.
6.3 Service Demag Service can be located around the clock. Please use our web site
at: http://www.demag-us.com to locate your regional North American Demag
Service Provider.
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27
7 Disassembly and Disposal
7.1 Disassembly Observe relevant safety regulations and codes of practice when disassembling
Demag cranes, see also “Safety instructions” chapter.
Disassembly may only be carried out by appropriately instructed personnel.
The owner must appoint a specialist to supervise the disassembly work, issue
instructions and monitor the measures to be carried out.
Isolate the installation in accordance with the relevant electrical regulations
and codes of practice.
Secure the disassembly area to prevent adjacent cranes accidentally being driven
into it and mark off with barriers at floor level.
Replace the gear unit air vent screws by plug screws.
Only use reliable tools and disassembly tools, equipment and auxiliary materials (also
see the “Erection and assembly” chapter for the individual cranes in these operating
instructions).
If the crane is to be used again, select tools for disassembly and carry out the
disassembly work so that no damage occurs.
Refer to the approval drawing for the weight of the crane.
Disassembly is mainly carried out in reverse order to assembly, also see the “Erection
and assembly” chapter for the crane in these operating instructions.
To avoid danger of accidents, disassembly work must not commence until all persons
concerned in the surrounding area have been informed.
The owner or his appointed agent must release the working area again once the
disassembly work has been completed.
Demag Cranes & Components has experienced specialist personnel and suitable
equipment available for carrying out the disassembly work on your behalf.
7.2 Disposal Waste materials resulting from assembly, installation, maintenance, repair and
disassembly work must be disposed of appropriately and in accordance with
the relevant laws, regulations and codes of practice.
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28
8 Sound Pressure Level of Cranes
The sound emitted by the drives on the crane does not exceed the sound pressure
level of 85 dB(A) permitted at the operator’s workplace.
Approximate calculation
The total sound pressure level of a crane is calculated from the sound pressure levels
of the individual components such as,
• hoist unit
• cross-travel drive(s)
• long-travel drives
• further individual components such as slewing gear, for example, depending on
the mode of operation
Calculation of the total sound pressure level of the crane is based on the sound
pressure levels specified in the operating instructions of the individual components.
The sound pressure level of the individual components is measured according to
DIN 45635.
Influence of distance to source of sound on the sound pressure level
To take structural influences into account, for example the reflection of sound waves
from walls, a reduction of approx. 3dB(A) in the sound pressure level is calculated
each time the distance to the source of sound is doubled (empirical value in normal
enclosed areas).
Add the sound pressure level increase calculated from the sound pressure level
difference to the largest previously calculated sound pressure level.
Measuring point
-3 dB(A)
-6 dB(A)
Sound source
Sound pressure reduction in

relation to the distance from the
1m sound source
2m
4m
41120044.eps
Sound pressure level summation

Several sources are measured in such a way that pairs of sound sources are
taken together to be measured in stages and added logarithmically to make up a sum
total level. Further sound sources can then be added logarithmically to the previously
calculated sum total level.
Table for Logarithmic Addition of Two - for same sound pressure the sound pressure level increases by approx. 3,0 dB(A)
Sound Pressure Levels - for sound pressure level
1 dB(A) the sound pressure level increases by approx. 2,5 dB(A)
difference of
2 2,1
3 1,8
4 1,5
5 1,25
6 1
7 0,8
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8 0,6
9 0,5
10 0,4
Add the sound pressure level increase calculated from the sound pressure level
difference to the largest previously calculated sound pressure level. 29
Example for calculating the total sound pressure level of a crane installation
Crane span 40 ft.
Hoist unit (a)
Long-travel drive (c) Cross-travel unit (b) Long-travel drive (c)
Distance to source of
sound ≥12 ft.
Crane runway height 17 ft.
ft.
24
6 ft.
42662644.eps
Distance to source of sound 3 ft. 6 ft. 12 ft. 24 ft. Source of dB(A) a+b a+b+c
sound
Hoist unit dB(A) 78 75 72 - a 72 1)
73,5
Cross travel unit dB(A) 74 71 68 - b 68 1) 75,4
77 74 71 68
2 x long travel unit dB(A) c 71 2) -
77 74 71 68
Total sound pressure level for the crane installation = 75.4 dB(A)
Explanation
1. Superimposition of hoist unit and cross-travel drive (a + b)
Calculated difference: 72 dB(A) – 68 dB(A) = 4 dB(A)
This difference according to the table for logarithmic addition results in a sound
pressure level increase of ∆ dB(A) = 1.5 dB(A) over the higher level.
This results in a total sound pressure level for the hoist unit and cross-travel drive
of 72 dB(A) + 1.5 dB(A) = 73.5 dB(A) (a).
2. Total sound pressure level of the long-travel drives (c)
Both long-travel drives have a sound pressure level of 68 dB(A). According to the
table for logarithmic addition, this results in a sound pressure level increase of
3 dB(A). Thus the total sound pressure level of the long-travel drives is
68 dB(A) + 3dB(A) = 71 dB(A) (b)
3. Superimposition of [(a + b) + (c)]
Calculated difference: 73.5 dB(A) -71 dB(A) = 2.5 dB(A)
This difference according to the table for logarithmic addition results in a sound
pressure level increase of ∆ dB(A) = 1.9 dB(A) over the higher level.
4. Total sound pressure level of the crane:
The total sound pressure level is calculated as follows:
73.5 dB(A) +1.9 dB(A) = 75.4 dB(A)
22932449.indd/100810
1) Individual sound pressure level

30 2) Sum of sound pressure levels for two long-travel drives
9 Electromagnetic Compatibility
Consequences for cranes

European guidelines for electromagnetic compatibility.
Electromagnetic compatibility (EMC) is defined as the ability of an electrical or
electronic device to function without failure in an electromagnetic environment
without influencing other devices or causing interference in the surroundings beyond
certain limits.
When investigating the electromagnetic interference which is caused by operating
an electrical device or which may affect it, a distinction is made between sources
of interference and potentially susceptible devices. A source of interference is a
generator (transmitter) of electromagnetic interference which is either directly emitted
or dissipated to the environment via cables and wiring. A source of interference may
be, for example, switched inductivity in a contactor, an electronic device (pulse-
controlled AC converter) or lightning. A potentially susceptible device absorbs part of
the electromagnetic energy and suffers interference or may even be damaged. Many
electronic devices are both sources of interference and susceptible devices.
EMC regulations and standards specify a maximum level of interference which an
electronic device must not exceed as a source of interference when installed and
used in a certain environment, or against which the device must be resistant.
All equipment supplied or put into service as of 1 January 1996 which meets
the requirements of the EMC guideline must be marked with the CE conformity
symbol of the European Union. The basis for the declaration of conformity are the
documented EMC measurements which have to be compiled within the scope of
the quality assurance system. They must document that the product or alternative
product meets the specified requirements in accordance with the EMC guidelines.
This documented qualification has to be proven each time the product is modified. To
achieve the specified EMC, manufacturers are required to fit devices with filters or to
provide screening.
Plant and switchgear manufacturers and owners are obliged to design and implement
installations in line with EMC requirements. Unavoidable interference energy must be
dissipated directly to earth (ground). Coupling must be avoided as far as possible.
In state-of-the-art electronic systems, more and more devices are being used which
operate at low voltages and high pulse frequencies. Additional HF interference
suppression measures are required for these installations. Allowing for EMC as early
as possible saves costs. The implementation of decoupling measures in good time
is also important as measures which are not allowed for at the planning stage are
impossible to create at a later date.
Therefore, before an item of equipment or an installation is built, a concept must be
developed which defines the interfaces and includes the quantitative specifications for
these interfaces.
This is simply general information and recommendations which should be taken into
consideration.
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31
10 Crane Inspections
10.1 Inspection Regulations National, state, and local inspection regulations must be observed. Refer to OSHA
1910.179, ASME B30.2, CMAA #78, B30.11, B30.16, B30.17, and CSA B167
as applicable.
Inspection reports shall specifically identify the equipment inspected, including its
location, manufacturer’s serial number and owner’s equipment number.
Inspection work may only be performed by qualified inspectors per CMAA #78
Standards and Guidelines for Professional Services Performed on Overhead and
Traveling Cranes and Associated Hoisting Equipment.
10.2 Crane Inspections The Frequent inspection is a visual and operational inspection performed as often as
daily, based on service, environmental and application factors, and determined by a
qualified person.
10.2.1 Frequent Inspection The Frequent Inspection shall be performed by a qualified Inspector. The qualified
Inspector shall determine whether conditions found during the inspection constitute a
hazard and whether a more detailed inspection is required.
Hooks and wire ropes shall be inspected at minimum monthly intervals and
documented with a certification record which includes date of inspection, the
signature of the person who performed the inspection and the serial number or
identifier of the hook or wire rope inspected.
Scope of Frequent Inspection shall include, but not be limited to items in Section
10.2.1 and Section 5.1
10.2.2 Periodic Inspection A Periodic inspection is a detailed visual and operational inspection whereby
individual components are examined to determine their condition. The Periodic
Inspection is performed as often as quarterly based on service, environmental and
application factors as determined by a qualified person.
The Periodic Inspection shall be performed by a qualified inspector. The qualified
Inspector shall determine whether conditions found during the inspection constitute a
hazard and whether a more detailed inspection is required.
Reports for Periodic Inspections shall be kept on file by the owner/Purchaser and, if
applicable, the service provider.
Proof of Inspection (tags, etc.) shall be affixed to the inspected equipment by the
inspector. Proof of inspection shall be plain sight and shall contain the date of the
last inspection, name of the inspecting company, if applicable, and the individual that
performed the inspection.
Scope of Periodic Inspection should include, but not be limited to, the items in
Sections 5.1, 5.4, 5.5, 5.6, and 5.7.
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32
10.2.3 Initial Inspection and Load New, reinstalled, altered, repaired, and modified cranes shall be inspected prior to
Test for which the Owner is initial use.
Responsible
• Furthermore the testing must determine that the planned rated and test loads
are taken up safely, the resulting forces can be transferred, the crane works
properly and the safety devices are effective.
• Load tests are conducted at 125% of rated load and are required.
• Copies of all test reports should be kept in a crane logbook and retained for
the lifetime of the equipment.
• To conduct the proper load test:
(1) Hoist the test load a distance to assure that the load is supported by the
crane and held by the hoist brake(s).
(2) Transport the test load by means of the trolley for the full length of
the bridge.
(3) Transport the test load by means of the bridge for the full length of the
runway in one direction with the trolley as close to the extreme right-hand
end of the crane as practical, and in the other direction with the trolley as
close to the left-hand end of the crane as practical.
(4) Lower the test load, and stop and hold the test load with the brake(s).
22932449.indd/100810
33
11 Technical Description
11.1 Crane Types and Demag cranes are overhead lifting equipment constructed of standardised
component assemblies. Their steel structure is designed and built according to DIN
Subassemblies 15018 and other relevant standards.
Crane Types
EDKE
3 2
1 8 5 4 7 6 5
42662544.eps
1 Monorail hoist with drive 4 Control pendant 7 Electrical equipment crane

2 Crane girder 5 Power supply crane, monorail hoist 8 Electrical equipment monorail hoist
3 Travel unit with drive 6 Crane runway - with lifting limit switch
- with load detector
22932449.indd/100810
34
EKKE
3 2 10
9 1 8 11 5 7 6
4 4
42662244.eps
1 Monorail hoist with drive 4 Control pendant 7 Electrical equipment crane

2 Crane girder 5 Power supply 8 Electrical equipment monorail hoist
- with load detector
ZKKE
3 7 2 2 5 1
22932449.indd/100810
6 4 8
1 Crab with drive 4 Control pendant 7 Electrical equipment crane
2 Crane girder 5 Power supply 8 Electrical equipment trolley
- with load detector 42662344.eps
35
11.2 General The subassemblies of Demag cranes are described in these operating instruction:
Refer to the type designations and sizes in the approval drawing and, if applicable,
the crane test and inspection booklet in order to find the individual subassemblies
in the enclosed publications more easily. Here you can also find information on the
classification of the crane supporting structure and the monorail hoist/trolley.
11.3 Main Subassemblies

11.3.1 Crane Girder The steel structure of the single-/double-girder crane is designed to DIN 15018.
The classification can been seen from the approval drawing and the crane test and
inspection booklet.
The crane girder and the travel units are connected by high-tensile bolts.
The perfect crane alignment geometry (prerequisite for good operating
characteristics) is guaranteed by exact machining of the connecting surfaces, exact
survey and precise adjustment in the factory.
The crane girder is a rolled steel section or a box girder construction which is
resistant to bending and torsion for the other crane types.
11.3.2 Monorail Hoist The monorail hoist travels on the lower flange of the crane girder.
The technical description includes the enclosed operating instructions.
11.3.3 Double-Rail Trolley The trolley runs on two travel rails which are fixed to the upper flanges of the crane
girders. The technical description includes the enclosed operating instructions of the
double-rail trolley.
Depending on the type, the trolley is driven by a central drive or by individual travel
drives (see approval drawing).
11.3.4 Crane Travel Units Refer to the approval drawing and to the crane test and inspection booklet for the
travel unit type used and to the relevant enclosed operating instructions/component
parts lists for a technical description.
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36
11.4 Crane Control System Cable-connected floor control with a control pendant or remote control
Refer to the approval drawing and the test and inspection booklet for the type of
control system fitted to the crane.
The sliding floor-level control pendant can travel along the crane girder and is located
Sliding Floor Control
independently of the trolley. It allows the operator to move freely, to avoid obstacles
and to maintain safety distances at an optimum position in relation to the load. This
type of control is permitted for travel speeds up to 175 ft/min.
41127244.eps
Remote control systems allow the operator to independently control the crane from
Remote Control
any position.
This type of control is permitted for travel speeds up to 320 ft/min.
41127344.eps
The fixed-point floor control system is used where the operating or travel path runs
Fixed-Point Floor Control
parallel to the crane runway. In this case direct load guidance by the operator is not
always possible.
This type of control should be used only for cranes with small span dimensions and is
suitable for travel speeds up to 175 ft/min.
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37
12 Erection and Assembly
Read and comply with this chapter before erection and assemblywork is carried out.
Refer to “Safety instructions for assembly and disassembly” in the “Safety
instructions” chapter.
A coordinator must be appointed before erection and assembly. Knowledge of

assembly procedures and appropriate tools are absolutely essential for carrying out
erection and assembly work.
Modifications to our subassemblies require our prior written approval. 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 conductors, screening
elements or anti-friction bearings, serious damage may be caused to these or other
components.
Erection and assembly work may involve an increased risk of accident.
We recommend you have erection and assembly work carried out by Demag
trained specialists.
Complex, engineered cranes should only be erected and assembled by or with the
help of Demag.
12.1 Delivery The level of crane assembly at delivery depends mainly on:
• dimensions of crane components
• assembly options purchased
• national and local traffic laws and restrictions.
For information on a specific crane configuration please contact customer service
(Section 6.1)
12.2 Crane Runway Minimum requirements for runway installation and alignment tolerances must be met
according to CMAA #70, Sec. 1.4 and Table 1.4.2-1 and CMAA #74, Sec. 1.4 and
Tolerances Table 1.4.1-1
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38
12.3 Assembling First unload the main girder and place it on beams at a height at which the trolley/
monorail hoist can be mounted on level ground. In addition, refit the power supply
the Crane to the monorail hoist/trolley and the mobile control system which may have been
Supplied as removed for transport reasons.
Subassemblies
Secure the main girder against falling over – risk of accident.
The counterbores in the end carriages and the compensating washers fixed in the
main girder must be free of rust, dirt, oil, paint and other contaminants prior to
assembly.
In accordance with the stencilled assembly marks, place the end carriages in position
against the main girder and secure them.
Use a pin to check alignment of the bore holes for the high-tensile bolted
connections (never use fingers - risk of injury).
Fit a high-tensile washer onto each high-tensile steel bolt included in the scope of
supply and insert the bolts into their respective holes from the inside by passing them
through the access holes in the end carriages. Fit another HV high-tensile washer on
the opposite side before bolting on the HV high-tensile nut. Ensure that the bevelled
side of the HV high-tensile washer faces the bolt head/nut
Then tighten the nuts using a torque wrench to the tightening torques specified
in table, section 13.5.2.
Lost or damaged high-tensile bolts, high-tensile nuts and high-tensile washers
must only be replaced by items bearing the high-tensile symbol (HV) according
to DIN EN 14399-4/14399-6 and the material designation (see section “High-
tensile bolted connections”).
It must be ensured that
• black bolts are only used with black nuts and black washers,
• galvanized bolts are only used with galvanized nuts and galvanized washers as a
set from one manufacturer.
Place a washer under the head of each bolt and under each nut as indicated in the
“High-tensile bolted connections” section.
Ensure that the side of the washer stamped with HV faces away from the
underside of the bolt head or the nut to avoid cracks forming in the bolts.
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39
12.4 Bolted Connections
12.4.1 DFW-L-E, DFW-L-Z and DFW-L- For tightening torques, see the “High-tensile bolted connections” table on page 44.
T with Side Cconnection
HV mark HV mark
Bevel under bolt Bevel on nut side Bevel on nut

head side
Bevel under bolt

head
1 2 4 2 3 1 2 4 2 3
tp=20 tp=12 - 15
Distance washers (4) are tacked to the main girder.
tp = Plate thickness travel unit connection wall

65120644.eps
Only permanently marked connecting elements with the following DIN

designations may be used:
Preferred range M 20 (galvanized).
1 Hexagon bolt M 20 x 85 x 46 (Special length of thread 46 mm), DIN EN 14399-4

Strength class 10.9 HV tZn
Demag part no.: 152 802 99
2 Washer 21 x 37 x 4, DIN EN 14399-6

Strength class C 45 V HV tZn
3 Hexagon nut M 20, DIN EN 14399-4

Strength class 10 HV tZn
4 Distance washer 22 x 50 x 10,

Minimum tensile strength 520 N/mm²
22932449.indd/100810
40
12.4.2 KTD-E For tightening torques, see the “High-tensile bolted connections” table on page 44.
High-tensile connection sur-

4 2 1 face free from paint, grease
and rust
U21 = 5,25
U17 = 4,45
4
tg2
∑t
∑t
∑t
tg1
tg
tg
8
4
4
2
2 3
The mounting position of the bolts may vary, i.e. the
bolts may be fitted from above or from underneath
depending on the model and crane type.
42761144.eps
Only permanently marked connecting elements with the following DIN

designations may be used:
1 Hexagon bolt M 16 x 55, DIN EN 14399-4
Demag part no. 150 707 99




The mounting position of the bolts depends on the crane type and varies, see
adhesive label on the travel unit
22932449.indd/100810
41
2 Washer 17 x 30 x 4, DIN EN 14399-6
Strength class HV tZn
2 Washer 21 x 37 x 4, DIN EN 14399-6

Strength class HV tZn


4 Washer U17 x 32 x 36, DIN 6918

Strength class C45tZn HV
4 Washer U21 x 40 x 44, DIN 6918

Strength class C45tZn HV
22932449.indd/100810
42
12.5 Tightening Torques Solid shaft bolts (without high-tensile bolts) with metric standard thread to DIN 13,
part 13. Tightening torques to VDI 2230, sheet 1, July 1986.
12.5.1 Standard Bolted Connections
For other friction coefficients see VDI 2230, sheet 1, table 1, page 70, July 1986.
µG = 0,12 as average friction value in the thread.
Thread M5 M6 M8 M 10 M 12 M 16 M 20 M 24 M 27 M 30
Tightening torque
Property class
Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm
µk 0.08 4.3 7.4 18.0 36 61 145 300 510 750 1000
µk 0.10 4.9 8.5 20.5 41 71 170 350 600 880 1190
8.8
µk 0.12 5.5 9.0 23.0 46 79 195 390 670 1000 1350
µk 0.14 6.1 10.4 25.0 51 87 215 430 740 1100 1500
µk 0.08 6.3 10.9 26.0 52 90 215 420 730 1070 1450
µk 0.10 7.3 12.5 30.0 60 104 250 490 850 1250 1700
10.9
µk 0.12 8.1 14.0 34.0 68 117 280 560 960 1400 1900
µk 0.14 8.9 15,5 37.0 75 130 310 620 1060 1550 2100
µk 0.08 7.4 12.5 31.0 61 105 250 500 850 1250 1700
µk 0.10 8.5 14.5 35.0 71 121 300 580 1000 1450 2000
12.9
µk 0.12 9.5 16.5 40.0 79 135 330 650 1120 1650 2250
µk 0.14 10.4 18.0 43.0 87 150 370 720 1240 1850 2500
Thread M5 M6 M8 M 10 M 12 M 16 M 20 M 24 M 27 M 30
Tightening torque
Property class
FtLbs. FtLbs. FtLbs. FtLbs. FtLbs. FtLbs. FtLbs. FtLbs. FtLbs. FtLbs.
µk 0.08 3.2 5.5 13.3 27 45 107 222 377 555 740
µk 0.10 3.6 6.3 15.2 30 53 126 259 444 651 881
8.8
µk 0.12 4.1 6.7 17.0 34 58 144 289 496 740 999
µk 0.14 4.5 7.7 18.5 38 64 159 318 548 814 1110
µk 0.08 4.7 8.1 19.2 38 67 159 311 540 792 1073
µk 0.10 5.4 9.3 22.2 44 77 185 363 629 925 1258
10.9
µk 0.12 6.0 10.4 25.2 50 87 207 414 710 1036 1406
µk 0.14 6.6 11.5 27.4 56 96 229 459 784 1147 1554
µk 0.08 5.5 9.3 22.9 45 78 185 370 629 925 1258
µk 0.10 6.3 10.7 25.9 53 90 222 429 740 1073 1480
12.9
µk 0.12 7.0 12.2 29.6 58 100 244 481 829 1221 1665
µk 0.14 7.7 13.3 31.8 64 111 274 533 918 1369 1850
Friction coefficients for mating of materials

µk = friction value in the head contact surface
µk Bolt head material Matching material
0,08 Steel, black, pressed or turned AIMg, bright, cut, dry
0,1 Steel, black, pressed or turned, oiledSteel, galva-

Steel, bright, cut, dryGG/GTS, bright, cut, dry
nized, pressed, dry or oiled
22932449.indd/100810
0,12 Steel, black, pressed, dry Steel, bright, cut, dry
0,14 Steel, black, pressed, oiledSteel, galvanized, GG/GTS bright, cut, drySteel, galvanized, cut,
pressed, dry dry
43
12.5.2 High-Tensile Bolted High-strength hexagon head bolts with large widths across flats for structural steel
Connections bolting according to DIN EN 14399-4 and 14399-6. With metric standard thread
according to DIN 13, part 12 and 15 (supporting material steel).
Thread Property Prestressing forcesFW Tightening torque MA
class
1) 2) 1) 2)
Black & oiled Hot-dip galvanized Black & oiled Hot-dip galvanized
& lubricated with & lubricated with
MoS2 MoS2
kN kps kN kps Nm FtLbs. Nm FtLbs.

M 16 93.3 21.0 100 22.5 284 210.2 250 185.0
M 20 145.6 32.7 160 36.0 554 410.0 450 333.0
M 22 10.9 180.1 40.5 190 42.7 762 563.9 650 481.0
M 24 209.8 47.2 220 49.5 958 708.9 800 592.0
M 27 272.8 61.3 290 65.2 1420 1050.8 1250 925.0
12.5.3 Verbus Ripp / Durlock Bolted Assembly prestressing forces FM and tightening torques MA for locking bolts and nuts
Connections according to works standard 011 891 99 and 011 892 99 (VERBUS RIPP system and
DURLOCK)
Thread Property Prestressed forces
class FW Tightening torque MA for steel supporting materal
Rm < 800 N/mm² (116 ksi) GG, GGG, GD AlDi 12 Cu
N lbs Nm FtLbs. Nm FtLbs. Nm FtLbs.

M 5 9,000 2,020 11.0 8.1 9.0 6.7 9.0 6.7
M 6 12,600 2,830 19 14 16 12 18 13
M 8 23,200 5,220 42 31 35 26 45 33
100 (10.9)
M 10 37,000 8,320 85 63 75 56 75 56
M 12 54,000 12,140 130 96 115 85 120 89
M 16 102,000 22,930 330 244 300 222 330 244
12.9
M 20 180,900 40,670 720 533.0 720 533.0 - -
(DURLOCK)
Rm = Minimum tensile strength in N/mm²
See relevant drawings and maintenance instructions for product-specific

tightening torques.
22932449.indd/100810
1) Values to DIN 15018 part 1 page 20 of November 1984

44 2) Values to DIN 18800 part 7 page 3 of May 1983 and DAst 010 of June 1976
12.6 Example for Installing
the Crane on the
Runway
12.6.1 Single-Girder Crane The assembly tools and lifting tackle must be suitable for the deadweight of the crane.
Refer to the approval drawing for the weight.
An installation jig (fig. 651 207 44) clamped to the upper flange can be used for
installing the crane.
Alternatively, nylon or wire rope slings appropriate for the weight of the crane must be
used (ensure edges are protected).
65120744.eps
12.6.2 Double-Girder Crane The assembly tools and lifting tackle must be suitable for the deadweight of the crane.
Alternatively, nylon or wire rope slings appropriate for the weight of the crane must be
used (ensure edges are protected).
Use appropriate means to prevent the main girders being pressed together when
lifting double-girder cranes (ensure edges are protected).
22932449.indd/100810
41127744.eps
45
13 Putting into Service for the First Time Following Assembly
on Site
13.1 Notes and Inspections Adjust the limit switches to allow for run-on.
Adjust any additional operating limit switches fitted to hoist units so that they operate
before the emergency limit switches come into operation.
Optimize the factor settings of all adjustable control units to meet specific application
requirements. The settings must be entered into the circuit diagram by the person
responsible for commissioning and notification of the settings sent to the design
department of Demag Cranes & Components.
Check the protective earth conductor along its entire length for continuity, correct
marking and connection.
Check that the fuse links fitted are of the correct amperage and have the correct
tripping characteristics, see specifications in the equipment list.
Replace the plug screws at the highest points of the gearboxes with the air vent
screws provided.
When assembly has been completed, check the clearance of the crane and crab or
travelling hoist along their entire length of travel.
Carefully check, for example, that the crane travels smoothly over splices in the
runway, that the current collectors have good contact, that the trailing cable system
runs easily and that safety distances to parts of the building and machinery are main-
tained.
Before putting the crane into service for the first time, the insulation resistance and
loop impedance must have been measured (EN 60204).
To compensate any settling, all bolted connections must be tightened one

to two months after the crane is first put into service and during routine
inspections.
22932449.indd/100810
46
14 Sample Checklist
Crane no._______________ Inspection regulations: see accident prevention regulations BGV D6, VDE 0100 part 726
and other relevant regulations
Inspection
remark
Power supply data: voltages, frequency (see approval drawing) checked
Bolted connections checked checked

in particular high-tensile bolts on end carriage (high-tensile washers checked for correct fit:
checked
bevel facing bolt head/nut)
Guide roller spacing adjusted, screwed connection (torque) checked checked
Crane, crab and runway end buffers installed and correctly positioned checked
Crane and crab end approach dimensions checked (see approval drawing) checked
Hook height checked (see approval drawing) and reset if necessary checked
Gearbox checked for leaks, air vent screws fitted checked
Chain/rope reeving, rope mounting checked (rope wedge, rope clamp) checked
Chain/rope lightly oiled checked
E
Chain/rope and cable deflectors mounted (if part of crane equipment) checked
Emergency and operating limit switches (for lifting and lowering) adjusted checked
Long and cross travel limit switches adjusted (if applicable) checked
PL
Optical crane distancing adjusted (if applicable) checked
Control pendant height and remote control strain relief (if applicable) checked checked
Control panel symbols match actual crane travel movements checked
Direction of movement symbols attached (for remote control units only) checked
M
Accessibility, marking and availability of “mains connection switches” and “emergency-off switches”
Check protective earth conductor along entire length for correct marking and connection
Cable entry glands in terminal boxes correctly wired
checked
checked
checked
(If optimized, enter values in wiring diagram and
Control and regulating devices checked
SA
inform DCC)
Overload measuring system checked
inform DCC)
Relay settings checked
inform DCC)
Resistor settings checked
inform DCC)
Check and tighten terminals (not clamp terminals, however) checked
Safety distances to other parts of the building and machinery are maintained checked
Smooth running over splices in the runway and of power supply lines checked
Brake check carried out: lifting and lowering (run-on allowed for) checked
Brake check carried out: long and cross travel (run-on allowed for) checked
Speed checks: lifting, lowering, long and cross travel checked
Crane signs (on crane and load handling attachments, load capacity observed) checked
Paint coat checked and touched up where required checked
Operation of wind drift safety device (for cranes operating outdoors) tested checked
(Strain relief, torque setting, travel direction, smooth running, checked

Cable length, 2 reserve windings required at lowest hook position) checked
Warning device (if available) checked
Assembly/workplace tidied (packing material disposed of in accordance with regulations) completed

Handover including power supply and permanently laid supply line on:
Handover without power supply and with provisionally laid supply line on:
22932449.indd/100810
Remarks:
Date: Name: Signature:

47
48
Notes
22932449.indd/100810
22932449.indd/100810
Printed in the USA
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Subject to change. Not liable for errors or omissions.
49
Operating instructions
Demag DR-Pro rope hoist
EZDR 5 - EZDR 10
double-rail crab
43312244.eps
141212 en GB 214 961 44 720IS 813

Original operating instructions
Manufacturer
Demag Cranes & Components GmbH
PO Box 67
58286 Wetter (Germany)
Telephone +49 (0)2335 92-0
Fax +49 (0)2335 92-7676
www.demagcranes.com
Email: info@demagcranes.com
Please fill in the following table before first putting the unit into service. This provides you with definitive documentation of your
Demag DR rope hoist and important information if you ever have to contact the manufacturer or his representative.
Owner
Where in use
Range
Serial number
Main hoist motor number
Operating voltage
Control voltage
Frequency
Wiring diagram number
Tab. 1
Further documents are available for sub-assemblies/components in addition to these operating instructions. These possible
sub-assemblies/components are listed below. The corresponding documents are supplied as necessary or can be ordered
separately.
Documents1) Order no.: Classification

Spare parts lists
EZDR-Pro 5 217 129 44 721IS 813
Spare parts list for Demag rope hoist
EZDR-Pro 10 217 124 44 721IS 813
Technical data / catalogues
Demag EZDR 5 - EZDR 10 rope hoist 203 648 44 714IS 813
Assembly instructions, clamp-fitted
KP-S 70 and KP-S 100 203 652 44 714IS 888
buffer
Operating, assembly, fitting instructions
DSE-10R control pendant 214 795 44 719IS 975
DRC-10 radio control system 214 920 44 719IS 975
DRC-J radio control system 214 975 44 719IS 975
Motor assembly instructions – Z motor range 214 228 44 719IS 910
DRS 112 – 260 wheel block assembly instructions 214 276 44 719 IS 845.5
Demag test and inspection booklet for cranes and hoist units 206 124 44 720IS 100
Tab. 2
214 961 44/141212
2 1) The documents can be ordered from the relevant Demag office.

Table of contents
1 General........................................................................................................................................................................ 7
1.1 EZDR-Pro 5 - 10 double-rail crab ................................................................................................................................ 7
1.2 Information on the operating instructions .................................................................................................................... 7
1.3 Symbols/signal words.................................................................................................................................................. 7
1.4 Liability and warranty................................................................................................................................................... 8
1.5 Copyright ..................................................................................................................................................................... 8
1.6 Spare parts .................................................................................................................................................................. 9
1.7 Terms and definitions .................................................................................................................................................. 9
1.8 Test and inspection booklet....................................................................................................................................... 10
1.9 After-sales service ..................................................................................................................................................... 10
1.10 Disposal of machine parts ......................................................................................................................................... 10
2 Safety ........................................................................................................................................................................ 11
2.1 General...................................................................................................................................................................... 11
2.2 Safety signs on the machines ................................................................................................................................... 11
2.2.1 Safety signs for fitting the rope socket ...................................................................................................................... 11
2.2.2 Safety signs for adjusting the thrust rocker ............................................................................................................... 12
2.3 Intended use.............................................................................................................................................................. 12
2.4 Hazards that can be caused by the machine ............................................................................................................ 14
2.5 Responsibility of the owner ....................................................................................................................................... 15
2.6 Operating personnel requirements............................................................................................................................ 16
2.7 Personal protection equipment.................................................................................................................................. 16
2.8 Emergency stop device ............................................................................................................................................. 16
2.9 Regular inspections................................................................................................................................................... 17
2.10 Inspection regulations ............................................................................................................................................... 17
3 Technical data ........................................................................................................................................................... 18
3.1 Explanation of size designations/type assignment ................................................................................................... 18
3.2 Selection criteria........................................................................................................................................................ 19
3.2.1 Specification of the rope hoist ................................................................................................................................... 19
3.3 Selection table ........................................................................................................................................................... 20
3.4 Hoist motor technical data ......................................................................................................................................... 21
3.4.1 DR 5 motor data with pole-changing hoist drives...................................................................................................... 21
3.4.2 DR 10 motor data with pole-changing hoist drives.................................................................................................... 21
3.4.3 DR 5 - DR 10 motor key data for inverter operation.................................................................................................. 22
3.5 Motor key data for inverter-controlled cross-travel drive ........................................................................................... 23
3.5.1 DR 5, DR 10 cross-travel drives, 2/1 - 4/1 - 4/2 reeving ........................................................................................... 23
3.5.2 DR 10 cross-travel drives, 6/1 reeving ...................................................................................................................... 23
3.5.3 Calculation example .................................................................................................................................................. 23
3.6 Hook dimension C ..................................................................................................................................................... 24
3.7 Gearbox oil filling ....................................................................................................................................................... 24
3.8 Operating conditions ................................................................................................................................................. 25
3.9 Noise emission .......................................................................................................................................................... 26
3.10 Paint finish ................................................................................................................................................................. 27
3.11 Weight ....................................................................................................................................................................... 27
3.12 Track girder requirements ......................................................................................................................................... 28
3.12.1 Runway ..................................................................................................................................................................... 28
3.12.2 Travel unit.................................................................................................................................................................. 29
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3.13 Control system .......................................................................................................................................................... 29

4 Design and function................................................................................................................................................... 30
4.1 Design ....................................................................................................................................................................... 30
4.2 Arrangement of assemblies....................................................................................................................................... 30 3
4.3 Drives ....................................................................................................................................................................... 31
4.3.1 Hoist and travel drive................................................................................................................................................. 31
4.3.2 Gearbox/rope reeving components ........................................................................................................................... 31
4.4 Geared limit switch .................................................................................................................................................... 31
4.5 Integrated controls..................................................................................................................................................... 32
4.6 Control pendant operating element ........................................................................................................................... 32
4.6.1 Overview ................................................................................................................................................................... 32
4.6.2 DSE-10R ................................................................................................................................................................... 33
4.6.3 Principle..................................................................................................................................................................... 33
4.6.4 Wiring ........................................................................................................................................................................ 33
4.6.5 Display....................................................................................................................................................................... 33
4.6.6 IrDA infrared interface ............................................................................................................................................... 33
4.6.7 Connecting the control cable..................................................................................................................................... 34
4.7 Overload protection ................................................................................................................................................... 34
4.8 Type plate (example)................................................................................................................................................. 35
5 Transport, packing, storage....................................................................................................................................... 36
5.1 Safety instructions ..................................................................................................................................................... 36
5.2 Transport inspection .................................................................................................................................................. 36
5.3 Packing...................................................................................................................................................................... 36
5.4 Storage ...................................................................................................................................................................... 36
6 Installation and putting into operation for the first time .............................................................................................. 37
6.2 Assembly of travelling hoists ..................................................................................................................................... 38
6.2.1 Overview ................................................................................................................................................................... 38
6.2.2 Checking dimensional accuracy of the tracks ........................................................................................................... 39
6.2.2.1 Tolerance of the individual girder .............................................................................................................................. 39
6.2.2.2 Twisting ..................................................................................................................................................................... 39
6.2.2.3 Tolerance of the crab track gauge............................................................................................................................. 40
6.2.2.4 Gradient of the crab rails ........................................................................................................................................... 40
6.2.2.5 Difference in rail height.............................................................................................................................................. 41
6.2.2.6 Rail level difference ................................................................................................................................................... 41
6.2.3 Fitting the end stops/clamp-fitted buffers .................................................................................................................. 42
6.3 Assembly and alignment of the travelling hoists ....................................................................................................... 42
6.3.1 Assembly instructions................................................................................................................................................ 42
6.3.2 Aligning the travelling hoist on the crane................................................................................................................... 42
6.3.3 Assembly of adjusting jig A ....................................................................................................................................... 44
6.3.3.1 Assembly of the adjusting jig on the roller side (preparation of adjusting jig for assembly) ...................................... 44
6.3.4 Assembly of adjusting jig B ....................................................................................................................................... 45
6.3.4.1 Version a: Fixing with threaded pin guide for EZDR with one travel drive (inside).................................................... 45
6.3.4.2 Version b: Fixing with two clamps for EZDR with two travel drives (outside)............................................................ 47
6.3.5 Adjustment for horizontal alignment .......................................................................................................................... 49
6.3.6 Disassembly of adjusting jigs A and B ...................................................................................................................... 50
6.3.7 Assembly and adjustment of the guide rollers........................................................................................................... 52
6.3.8 Final adjustment of the thrust rocker ......................................................................................................................... 56
6.4 Connecting the electrical equipment ......................................................................................................................... 58
6.4.1 Wiring ........................................................................................................................................................................ 58
6.4.1.1 General...................................................................................................................................................................... 58
6.4.1.2 Frequency inverter .................................................................................................................................................... 58
6.4.1.3 Control cable and line voltage connection................................................................................................................. 59
6.4.2.1 Direct connection to the machine .............................................................................................................................. 59
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6.4.2.2 Connection to the KBK trailing cable trolley .............................................................................................................. 60

6.4.3 Checking the direction of movement ......................................................................................................................... 60
6.5 Rope reeving ............................................................................................................................................................. 61
4 6.5.1 Reeving methods ...................................................................................................................................................... 61
6.5.2 Reeving methods for the rope hoist .......................................................................................................................... 61
6.5.3 Fitting MGS/ZMS overload protection ....................................................................................................................... 62
6.5.3.1 MGS/ZMS overload protection, 2/1, 4/1 and 6/1 reeving .......................................................................................... 62
6.5.3.2 ZMS overload protection, 4/2 reeving ....................................................................................................................... 63
6.5.4 Fitting the rope .......................................................................................................................................................... 63
6.5.5 Bottom block reeving................................................................................................................................................. 64
6.5.5.1 2/1 reeving................................................................................................................................................................. 64
6.5.5.2 4/1 reeving................................................................................................................................................................. 66
6.5.5.3 4/2 reeving................................................................................................................................................................. 69
6.5.5.4 6/1 reeving, EZDR-Pro 10 ......................................................................................................................................... 72
6.6 Putting into operation for the first time....................................................................................................................... 75
6.6.1 Checks before putting the unit into operation for the first time .................................................................................. 75
6.6.2 Inspection regulations ............................................................................................................................................... 75
6.6.3 Geared limit switch ................................................................................................................................................... 75
6.6.3.1 Geared limit switch function ...................................................................................................................................... 75
6.6.3.2 Setting the cut-out points........................................................................................................................................... 77
6.6.3.3 Set the upper cut-out points ...................................................................................................................................... 77
6.6.3.4 Set the lower cut-out points....................................................................................................................................... 78
6.6.4 Overload test with 125% ........................................................................................................................................... 79
6.6.5 Travelling hoist travel characteristics and run-on paths when stopping .................................................................... 79
7 Operation .................................................................................................................................................................. 80
7.2 Switching on .............................................................................................................................................................. 81
7.2.1 Checks when starting work ....................................................................................................................................... 81
7.2.2 Visual check .............................................................................................................................................................. 81
7.2.3 Check the limit switches ............................................................................................................................................ 82
7.2.4 Check strain relief elements ...................................................................................................................................... 82
7.2.5 Check operation of the brake .................................................................................................................................... 83
7.2.6 Check hook safety catch ........................................................................................................................................... 83
7.3 Control pendant switch assignment .......................................................................................................................... 84
7.4 Switching off ............................................................................................................................................................. 84
7.5 Stopping operation in an emergency......................................................................................................................... 84
8 Maintenance ............................................................................................................................................................. 85
8.3 Maintenance schedule .............................................................................................................................................. 86
8.4 Wire ropes ................................................................................................................................................................. 88
8.5 Discarding the wire rope............................................................................................................................................ 89
8.6 Wear limits on rope sheaves ..................................................................................................................................... 90
8.7 Fitting the rope, single groove ................................................................................................................................... 91
8.7.1 Unwind rope .............................................................................................................................................................. 91
8.7.2 Fitting the rope .......................................................................................................................................................... 92
8.8 Fitting the rope, more than one groove ..................................................................................................................... 96
8.8.1 Unwind rope .............................................................................................................................................................. 96
8.8.2 Fitting the rope, more than one groove ..................................................................................................................... 96
8.9 Shortening the wire rope ........................................................................................................................................... 97
8.10 Lubricating the wire rope ........................................................................................................................................... 97
8.11 Regular inspections and monitoring measures for load hooks.................................................................................. 98
8.12 Travel wheel wear ..................................................................................................................................................... 99
8.13 Oil change ............................................................................................................................................................... 100
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8.14 General overhaul (GO) ........................................................................................................................................... 100

9 Malfunctions ............................................................................................................................................................ 101
9.1 Safety instructions ................................................................................................................................................... 101
5
9.2 Conduct when malfunctions occur .......................................................................................................................... 101
9.3 Conduct after malfunctions have been eliminated .................................................................................................. 101
9.4 Malfunctions, causes and remedy ........................................................................................................................... 102
10 Actual duration of service ........................................................................................................................................ 103
10.1 Calculating the actual duration of service................................................................................................................ 103
Declaration of conformity.......................................................................................................................................................... 104
.................................................................................................................................................................................................. 105
Declaration of incorporation ..................................................................................................................................................... 106
Index......................................................................................................................................................................................... 107
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6
1 General
1.1 EZDR-Pro 5 - 10 double-rail crab

You have purchased a Demag product.
This Demag rope hoist was manufactured in accordance with the relevant European standards and regulations.
The rope hoist complies with the statutory regulations of, for example, EC directive 2006/42/EC.
Demag rope hoists are of modular design. Their main assemblies include:
● Gearbox
● Hoist motor
● Integrated electrical equipment
● Rope reeving components
● Control pendant
● Travel unit
The following data always apply for all ranges. Any differences for individual ranges are specially marked.
1.2 Information on the operating instructions

These operating instructions are designed to provide the owner with appropriate instructions for safe and correct
operation and for maintenance. These operating instructions are an integral part of the rope hoist.
Every individual given the task of transporting, installing, commissioning, operating, maintaining and repairing our
rope hoists and additional equipment must have read and understood the items listed in the following:
● the operating instructions
● the safety regulations
● the safety instructions in the individual chapters and sections.
The operating instructions must be available to the operating personnel at all times in order to prevent operating
errors and to ensure smooth and trouble-free operation of our products. They must be kept available in the imme‐
diate vicinity at all times. The rope hoist may only be operated by personnel who are fully familiar with the operat‐
ing instructions.
If special designs or additional options are 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 questions, please contact the manufacturer.
Based on Machinery Directive 2006/42/EC, the rope hoist is also designated as a machine in the sense of a
complete machine in the following. This always refers to all possible DR rope hoist types.
For a Demag rope hoist delivered ready for operation in the sense of a complete machine, we confirm conformity
with the requirements of Directive 2006/42/EC by means of the attached EC declaration of conformity.
A declaration of incorporation is enclosed for partly completed Demag rope hoists which are assembled with addi‐
tional parts to create a machine ready for operation. The declaration of incorporation refers to the scope of deliv‐
ery of the partly completed or non-assembled machinery. Before the unit is put into operation, the user must take
additional measures to fulfil the safety requirements for the machine and issue the declaration of conformity for
the machine when it is ready for operation.
1.3 Symbols/signal words

Important safety information and instructions in these operating instructions are marked by corresponding sym‐
bols and signal words.
Safety instructions and information must be followed. Follow these instructions with care to avoid any accidents,
injuries or damage.
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Any locally applicable accident prevention regulations and general safety regulations must also be followed.
The following symbols and instructions warn against possible injuries or damage and are intended to assist you in
your work.
7
DANGER
This warning symbol indicates an immediate danger that can result in severe injuries or death.
– Follow these instructions at all times and be particularly careful and cautious.
WARNING
This warning symbol indicates a possibly dangerous situation that might result in severe injuries or death.
CAUTION
This warning symbol indicates a possibly dangerous situation that might result in medium or slight injuries or ma‐
terial damage.
Operating hazard for the machine

● This symbol indicates information on the appropriate use of the machine.
● Failure to follow these instructions may result in malfunctions, damage or pollution of the environment.
1.4 Liability and warranty

All information included in these operating instructions has been compiled on the basis of the relevant regulations,
state-of-the-art engineering principles and our many years of experience.
These operating instructions must be read carefully before starting any work on and with the machine, especially
before the machine is put into service for the first time. We assume no liability for any damage which results
from the following:
● Non-compliance with the operating instructions
● Inappropriate use of the machine
● Operation by insufficiently trained personnel
● Unauthorised conversions
● Any technical modifications
Wearing parts are not subject to liability for defects.

We reserve the right to incorporate technical modifications within the scope of improving the operating character‐
istics and further development of the machine.
1.5 Copyright
These operating instructions must be treated confidentially. They are only intended to be used by people who
work with or on the machine.
Any and all content, texts, drawings, images and any other information are protected within the sense of copyright
law and are subject to further industrial rights. Any misuse is an offence.
No part of this documentation, in whole or in part, may be reproduced, distributed, shown in public or used in any
other way without specific prior consent. Infringements are an offence resulting in obligatory compensatory dam‐
ages. Further rights reserved.
214 961 44/141212
8
1.6 Spare parts
Only genuine Demag spare parts may be used.
CAUTION
Incorrect or defective spare parts may cause damage, malfunctions or complete failure of the machine.
Only use genuine spare parts or parts approved by Demag.
Only genuine Demag spare parts may be used for safety-relevant wear parts. Examples: brake, motor, ...
The use of unauthorised spare parts renders null and void any claims for warranty, service, damages or liability
against the manufacturer or his appointed personnel, dealers and representatives.
1.7 Terms and definitions

Manufacturer
The manufacturer is the person who:
1. manufactures machinery under his or her own name and places it on the market for the first time;
2. resells machinery made by other manufacturers under his or her own name, whereby the reseller is not con‐
sidered to be the manufacturer, provided the name of the manufacturer (as defined in 1.) appears on the
equipment;
3. imports machinery into Germany and places it on the market for the first time or
4. exports machinery to another member state of the European Union and hands it over direct to an owner in
that country
Owner
Owners (employer, company) are defined as persons who own a machine and who use it as intended or allow it
to be operated by suitable and trained persons.
Operating personnel/machine operator
Operating personnel or machine operators are defined as persons entrusted by the owner of a machine with oper‐
ation of the equipment. The operating personnel must be trained by the owner in accordance with the tasks to be
performed.
Trained person
Trained persons are defined as persons who, owing to their technical training, knowledge and experience of elec‐
trical machines as well as knowledge of the relevant valid standards, codes of practice and regulations, are able
to assess the tasks given to them and to identify and eliminate potential hazards.
Specialist personnel are defined as persons assigned by the owner of a machine to carry out special tasks such
as installation, setting-up, maintenance and fault elimination. Specialist personnel must be trained by the owner
before any work is carried out on or with the machine.
Qualified electrician
Qualified electricians are defined as persons who, owing to their technical training, knowledge and experience of
electrical machines as well as knowledge of the relevant valid standards, codes of practice and regulations, are
able to assess the tasks given to them and to identify and eliminate potential hazards. Qualified electricians must
be trained by the owner in accordance with the tasks to be performed.
Experienced technicians are defined as persons who, owing to their technical training and experience, have suffi‐
cient knowledge in the field of machines. They must be familiar with the relevant national industrial safety regula‐
tions, codes of practice, accident prevention regulations, directives and generally accepted engineering standards
enabling them to judge the safe operating condition of machines.
Assigned expert engineer (in the Federal Republic of Germany according to BGV D8, Section 23, for determining
214 961 44/141212
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 the machine (S.W.P. = safe working period) and to
carry out a general overhaul of the machine.
9
Authorised expert engineer (according to BGV D6, Section 28 in the Federal Republic of Germany)
In addition to the expert engineers of the Technical Supervisory and Inspection Board, an authorised expert engi‐
neer for the inspection of machines is defined as an expert engineer authorised by the Industrial Employers’ Mu‐
tual Insurance Association.
Design limit
For selection of the crane, the size is defined in accordance with the application and the customer specifications.
The design limits of the crane must not be exceeded.
Rope hoists
Rope hoists are systems used for lifting and moving loads, such as cranes, crabs and travelling hoist units, rail
systems.
Crabs and travelling hoists
A crab or travelling hoist is a mobile crane assembly for changing the situation of the lifting rope (on the load at‐
tachment side). Depending on the type, the crab/travelling hoist carries one or several return sheaves for the lift‐
ing rope or directly the hoist unit. The crab/travelling hoist travels along a girder.
1.8 Test and inspection booklet

A test and inspection booklet filled in with all details must be available for every rope hoist. The results of the reg‐
ular tests and inspections must be entered into the test and inspection booklet and must be certified by the in‐
spector. Test and inspection booklet order no.: Tab. 2, Page 2.
1.9 After-sales service

Our after-sales service will provide you with technical information on our machines, etc.
Please keep the serial or order number (see test and inspection booklet, 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.
The relevant Demag after-sales service centre is given, for example, on the back page of the rope hoist test and
inspection booklet.
Manufacturer’s address:
PO Box 67
Telephone +49 (0)2335 92-0
Fax +49 (0)2335 92-7676
www.demagcranes.com
1.10 Disposal of machine parts

Unless a return or disposal agreement has been concluded, recycle separated components after proper removal:
● Scrap any remaining metallic material
● Dispose of plastic elements for recycling
● Separate and dispose of any other components by material type
Electric scrap, electronic components, lubricants and other auxiliary materials are subject to special disposal
regulations and may only be disposed of by certified companies.
National disposal regulations must be considered regarding environmentally friendly disposal of the machine. Fur‐
ther information can be obtained from corresponding local authorities.
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10
2 Safety
2.1 General
The ‘Safety’ chapter provides an overview of all important safety aspects for optimum protection of personnel as
well as safe and trouble-free operation of the machine.
At the time of its development and manufacture, the machine was built according to generally accepted engineer‐
ing standards and is considered to be safe to operate. The machine may still be a cause of danger if it is not used
correctly or as intended by suitably trained personnel.
Knowledge of the contents of the operating instructions is one of the requirements necessary to protect personnel
from hazards and to avoid malfunctions and, therefore, to operate the machine safely and reliably.
Any conversions, modifications or additions to the machine are prohibited unless approved by Demag in writing.
These operating instructions describe operation with one travelling hoist; operation of several travelling hoists on
one crane girder or tandem operation of cranes are not included in these operating instructions.
2.2 Safety signs on the machines
2.2.1 Safety signs for fitting the rope socket

Any pictograms, signs or labels on the rope hoist must be obeyed and must not be removed. Pictograms, signs or
labels that are damaged or no longer legible must be replaced immediately.
Adhesive labels
Fig. 1
1 Rope clamp
Fitting the rope socket  "Fitting the rope socket for 2/1", Page 65
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11
2.2.2 Safety signs for adjusting the thrust rocker
43235844.eps
Fig. 2
Adjusting the thrust rocker  "Final adjustment of the thrust rocker", Page 56.
2.3 Intended use

The machine may only be used as intended and in compliance with the requirements for the owner and the fol‐
lowing limitations as specified in these operating instructions. Any other use may result in a danger to life and limb
and/or cause damage.
● EZDR rope hoists are only designed for lifting loads. The maximum safe working load is the load capacity
specified on the capacity plate. This must not be exceeded. The maximum safe working load includes the lifted
load and dead load (e.g. load handling attachments).
● Rope hoists may only be installed, operated, maintained and removed when in perfect working order by trained
personnel in accordance with the relevant safety and accident prevention regulations. Personnel must meet
the requirements according to  "Operating personnel requirements", Page 16.
● Intended use also includes compliance with the safety instructions as well as any other instructions on assem‐
bly/disassembly, commissioning, function/operation, maintenance/fault elimination as well as compliance with
the instructions on safety devices, protection against hazards and any possible remaining hazards.
● The rope hoist may only be used subject to the permissible technical data,  "Technical data", Page 18. In
particular, the maximum permitted load according to these operating instructions must not be exceeded.
● The rope hoist must be maintained regularly and appropriately by trained personnel in line with the specified
deadlines and checked according to  "Maintenance schedule", Page 86. Wearing parts must be replaced in
good time in accordance with the frequency and intensity of use.
● Loads must never be pulled at an angle, pulled or dragged and fixed loads must never be pulled free.
● Transporting people with or people riding on the machine is always prohibited, this does not apply to equip‐
ment specially designed for transporting people (see intended use of lifting equipment).
● Molten masses must not be lifted or transported with Demag hoist units as standard.
● As standard, Demag hoist units are not intended or rated for tandem operation.
● UVV/BGV D8, Section 23 (2) and BGV D6, Section (1) guidelines must be not be ignored.
No liability for inappropriate use
The manufacturer is exempt from any liability for use other than the purpose which is technically possible and ac‐
214 961 44/141212
ceptable according to these operating instructions. In particular, the manufacturer assumes no liability for damage
due to inappropriate or any other prohibited use of the machine in the sense of the "Intended use" section.
No liability for structural modifications
12
The manufacturer is not liable for any unauthorised structural modifications which have not been agreed with him.
This includes incorrect connection of the machine to devices or equipment that do not belong to our scope of de‐
livery, or the installation or use of third-party accessories, equipment, sub-assemblies or spare parts that are not
approved by the manufacturer.
Depending on the type and scope of the machine, it may be necessary to have an inspection carried out by an
expert engineer before it is handed over to the owner.
The machine is designed for operation indoors and at temperatures ranging from - 10° C to + 45° C. At extreme
temperatures and in aggressive atmospheres, the owner must implement special measures after consulting De‐
mag.
Use of the control pendant
Lifting and lowering and, if applicable, cross-travel and long-travel motions are controlled by means of the corre‐
sponding control elements on the control unit. The slow speeds are intended for attaching the load, lifting it free
and depositing it. Loads can be precisely positioned at slow speeds.
Short transport times can be achieved at higher speeds. They are suitable for travelling without a load or with a
safely suspended load if no hazard can be caused by the faster motion sequences.
Inching must be avoided at fast speeds, as it causes increased wear and load sway.
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13
2.4 Hazards that can be caused by the machine
The machine has been subjected to a risk analysis. The design and execution based on this analysis corresponds
to state-of-the-art engineering principles. However, residual risks remain.
The machine is operated with high electrical voltage.
DANGER
Live components
Danger to life and limb.
Electrical energy may cause very severe injuries. Danger to life caused by electrical current if the insulation or
individual components are damaged.
– Switch the machine off and secure it against restoration of the power supply before any maintenance,
cleaning or repair work is carried out.
– Switch the power supply off before any work is carried out on the electrical equipment. Check to ensure
that the components to be replaced are de-energised.
– Do not remove any safety equipment or render it inoperative by modifications.
WARNING
Crushing hazard
Body parts can be crushed when loads are lifted or lowered.
Ensure that nobody is present in the immediate danger zone when loads are lifted or lowered.
WARNING
Suspended load. Falling parts.
Danger to life and limb if lifted loads are dropped.
Keep out of the danger zone at all times.
– Keep a sufficient safety distance.
– Never step under a suspended load.
Certain work and practices are prohibited when using the machine as they may involve danger to life and limb
and result in lasting damage to the machine, e.g.:
● Unsafe load handling (e.g. swinging/throwing the load).
● Do not handle suspended loads above people.
● Do not pull or drag suspended loads at an angle.
● Do not pull free any fixed or obstructed loads.
● Do not exceed the maximum permitted load.
● Do not leave suspended loads unsupervised.
● Do not allow load-supporting means (ropes/chains) to run over edges.
● Do not use load-supporting means (ropes/chains) as a load bearing sling.
● Do not allow loads to drop when the load-supporting means (ropes/chains) are in a slack condition.
● Do not subject the control switch to inappropriate mechanical loads.
● Do not allow the control cable to wind around the rope.
● Do not allow motion of the load hook in the bottom block to be obstructed. No twisting (torsion) may be caused
in the rope.
Do not work with twisted ropes, especially with 2/1 reeving.
● Do not manipulate electrical equipment.
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● Transporting people is not permitted unless the machine is specifically approved for transporting people.
● Do not lift the load at full speed.
14
● Vibration from the load being transported (e.g. when the load is deposited on vibrating machinery) must not be
transmitted.
● Avoid any collisions with stationary equipment and structures; runways must be designed in such a way that
the entire travel path of the crane is always free of obstructions.
2.5 Responsibility of the owner

Information on safety at work refers to the regulations of the European Union that apply when the machine is
manufactured. The owner is obliged to ensure that the specified industrial safety measures comply with the latest
rules and regulations and to observe new regulations during the entire service life of the machine. Local industrial
safety legislation and regional regulations and codes of practice applicable at the site of operation of the machine
must be observed outside the European Union.
General safety, accident prevention and environmental protection regulations that apply where the machine is in
operation must be observed and complied with in addition to the safety instructions contained in these operating
instructions.
The owner and any personnel authorised by him are responsible for correct operation of the machine and for
clearly defining responsibilities for installation, operation, maintenance and cleaning. The operating instructions
must be followed in full and without any limitations.
Special local conditions or applications may lead to situations which are not considered in these operating instruc‐
tions. In such cases, the required safety measures must be defined and implemented by the owner. Necessary
measures may also relate, for example, to the handling of hazardous materials or tools and the provision/wearing
of personal protection equipment. The operating instructions must, if required, be supplemented by the owner with
instructions relating to the organisation of work, working procedures, authorised personnel, supervising and re‐
porting obligations, etc. For further information, see  "Safety instructions", Page 80.
Furthermore, the owner must ensure that
● any further working and safety instructions resulting from the risk assessment of the machine workplaces are
specified in operating procedures.
● personnel who work with or on the machine are provided with appropriate first-aid equipment. The personnel
must be trained in the use of the first-aid equipment.
● the operating instructions are always kept available in the immediate vicinity of the machine for installation, op‐
erating and maintenance personnel.
● the personnel are trained in accordance with the work to be performed.
● the machine is only operated when in safe and proper working order.
● the safety devices are always kept freely accessible and are checked regularly.
● the national regulations for use of the machine are observed.
● any specified regular checks and inspections are carried out on time and are documented.
● the operating/travel area is adequately illuminated.
● suitable and tested load handling attachments are provided and used.
The owner is urged to develop procedures and guidelines for any malfunctions, to instruct users and to affix these
instructions at a suitable place where they can be easily seen.
214 961 44/141212
15
2.6 Operating personnel requirements
Only authorised and trained personnel may work on the machine. The personnel must have received instruction
on the machine functions and any hazards that may occur.
Every individual given the task of working on or with the machine must have read and understood the operating
instructions before any work on the machine starts.
Persons under the influence of drugs, alcohol or medicines which affect their reactions must not work on or with
the machine.
Age and job-specific regulations relevant at the place where the machine is operated must be observed for the
selection of any personnel.
Personnel are obliged to report to the owner without delay any changes to the machine that impair safety.
For independent operation (machine operator) or maintenance (maintenance fitter) of the machine, 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 the machine and who have proven their qualifi‐
cation to the owner in this respect.
2.7 Personal protection equipment

When work is carried out on or with the machine, the following is recommended to be worn according to the own‐
er's risk assessment:
● Protective clothing, closely fitting working clothes (low tear strength, no loose sleeves, no rings or any other
jewellery, etc.).
● Safety shoes to protect against falling parts and against slipping.
● Gloves for handling the wire rope.
● Safety helmet to be worn by everybody in the danger zone.
2.8 Emergency stop device
DSE-10R
43249344.eps
Fig. 3
WARNING
Unauthorised, negligent or accidental switching-on.
Check to ensure that the reason for the emergency stop has been eliminated before the machine is switched on
again.
The emergency-stop device must not be used to switch the machine off in normal operation.
214 961 44/141212
The machine is fitted with an emergency-stop device (1) to prevent damage and injuries. This is located on the
control unit. The emergency-stop operating function must be checked regularly.
16
2.9 Regular inspections
The owner of the machine may be obliged to carry out regular inspections by national industrial safety legislation
and regional regulations. In Germany, this is specified by the accident prevention regulations for winches and
hoists (BGV D8) and the accident prevention regulations for cranes (BGV D6), for example. These specify 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 tests and inspections must be kept.
The owner is obliged to ensure that the machine complies with the latest rules and regulations and to observe
new regulations at all times.
If no comparable inspection regulations or requirements apply at the place where the machine is operated, we
recommend compliance with the above-mentioned regulations.
2.10 Inspection regulations

Notes on inspections in accordance with:
● UVV accident prevention regulations for winches, lifting and towing devices, BGV D8
● UVV Cranes, BGV D6
● EN 14492-2 – Cranes; Power-driven winches and hoists; Part 2: Power-driven hoists
● prEN 15011 Cranes – Bridge and gantry cranes
The EC Machinery Directive requirements are therefore also fulfilled.
214 961 44/141212
17
3 Technical data
3.1 Explanation of size designations/type assignment

E Z DR-Pro 5- 3,2 4/1 6 Z 6/1 400 00 - 50 - 30 1400 45
Rail head width [mm]
Track gauge [mm]
Max. cross-travel speed [m/min]
Frequency [Hz]
Electrical equipment code  Tab. 4, Page 18
Operating voltage [V]
Lifting speed [m/min]
Motor type: Z = Cylindrical rotor
Hook path [m]
Reeving
Load capacity [t]
Range
Demag rope hoist
F = Foot-mounted hoist
K = Low-headroom monorail hoist
U = Standard-headroom monorail hoist
Z = Double-rail crab
E = Electric travel trolley
Tab. 3
Electrical equipment Use

code
00 Prepared for electrical equipment provided by the customer.
01 EZDR with internal electrical equipment for operation on a crane. Crane bridge enclosure and DSE-10R control pendant
with control cable included.
02 EZDR with solo electrical equipment for use as a solo travelling hoist. DSE-10R control pendant with control cable inclu‐
ded.
03 As for code 01 but control via a DRC radio control system.
05 EZDR with fitted ‘DPC’ parallel interface.
Tab. 4 Electrical equipment code list
214 961 44/141212
18
3.2 Selection criteria
3.2.1 Specification of the rope hoist
The size of the hoist is determined by the load spectrum, average operating time per working day, load capacity
and reeving.
1. What are the operating conditions?
2. What is the specified safe working load?
3. To what height must the load be lifted?
4. What is the required lifting speed?
5. Do the loads need to be lifted and lowered with great accuracy?
6. Is horizontal load travel necessary?
7. How is the hoist to be controlled?
The group is determined by the load spectrum and operating time.
Load spectrum Average operating time per working day in hours

1 Light 4-8 8-16 more than 16
2 Medium 2-4 4-8 8-16
3 Heavy 1-2 2-4 4-8
4 Very heavy 0.5-1 1-2 2-4
FEM 2m 3m 4m
Group of mechanisms to
ISO M5 M6 M7
Tab. 5
The load spectrum (in most cases estimated) can be evaluated in accordance with the definitions (see below):
1. Light
Hoist units which are usually subject to very small loads and in exceptional cases only to maximum loads.
2. Medium
Hoist units which are usually subject to small loads but rather often to maximum loads.
3. Heavy
Hoist units which are usually subject to medium loads but frequently to maximum loads.
4. Very heavy
Hoist units which are usually subject to maximum or almost maximum loads.
Load spectra
1. 2. 3. 4.
43241444.eps
Fig. 4
L Load d Small dead load

LZ Operating time e Small to medium dead load
a Full load f Heavy dead load
b Medium partial load g Very heavy dead load
214 961 44/141212
c Small to medium partial load
19
Selection table
Group of mechanisms to FEM/ISO 2m/M5 3m/M6 4m/M7 2m/M5 3m/M6 4m/M7 2m/M5 3m/M6 4m/M7
2)
Reeving arrangement 2/1, 4/2 4/1 6/13)

Range Load capacity [t]
DR 5 2.5 2 1.6 5 4 3.2 - - -
DR 10 5 4 3.2 10 8 6.3 16 12.5 -
Tab. 6
Calculation example
Load capacity 5t
Load spectrum ‘Medium’ from table
Lifting speed 6 m/min
Creep lifting speed 1 m/min
Reeving 4/1
Average hook path 3m
No. of cycles/hour 20
Working time/day 8 hours
Tab. 7
The average operating time per working day is estimated or calculated as follows:
Operating 2 x average hook path x no. of cycles/hour x working time/day

=
time/day = 60 x lifting speed
Operating 2 x 3 x 20 x 8
= 2.66 hours
time/day = 60 x 6
Tab. 8
For the medium load spectrum and an average daily operating time of 2.66 hours, the table above shows group
2m. For a load capacity of 5 t and 4/1 rope reeving, the following table indicates hoist size DR 5 - 5.
3.3 Selection table

Range Group of mechanisms4) Load capacity Hook path Lifting speed [m/min]
FEM ISO [t] [m] V1 V2 V3 5)
2/1
2m M5 2.5
3m M6 2 12; 20 12/2 18/3 1-25
4m M7 1.6
4/1
2m M5 5
DR 5
3m M6 4 6; 10 6/1 9/1.5 0.5-12.5
4m M7 3.2
4/2
2m M5 2.5
3m M6 2 9.9 12/2 18/3 1-25
4m M7 1.6
214 961 44/141212
2) Gearbox service life 20% higher than the FEM full-load service life
3) 6/1reeving only on DR 10
20 5) The Prohub function enables loads weighing up to one third of the rated capacity to be lifted at 1.5 times the rated speed.
2/1
2m M5 5
3m M6 4 12; 20 10/1.7 1-18 5) 1-25
4m M7 3.2
4/1
2m M5 10
3m M6 8 6; 10; 20 5/0.8 0.5-9 5) 0.5-12.5
4m M7 6.3
DR 10
6/1
2m M5 16
3m M6 12.5 6; 7; 13.3 2.7/0.4 0.4-6 5) -
4m M7 10
4/2
2m M5 5
3m M6 4 5.8; 11.35; 25.2 10/1.7 1-18 5) 1-25
4m M7 3.2
Tab. 9
3.4 Hoist motor technical data
3.4.1 DR 5 motor data with pole-changing hoist drives

Design is in accordance with the VDE regulations and the FEM design rules to meet the high demands made on
electric hoists. Required supply cable conductor cross sections and fuse links.
Main/creep lifting F6
DR 5 range No. of Lifting PN CDF n Starts/h Rated current IN and cos cos
poles speed start-up current IA for
50 Hz 400 V
Motor size [kW] % [rpm] IN [A] IA [A] φN φA
ZBR 100 D 12/2 - 12 12/2 0.8 20 410 240 5.7 9 0.55 0.75
B050 2 6/1 5.3 40 2780 120 11 55 0.88 0.85
ZBR 132 D 12/2 - 12 18/3; 1.4 20 400 240 9.6 15.0 0.54 0.68
B140 2 9/1.5 8.9 40 2870 120 18.0 120.0 0.89 0.85
Tab. 10 Main/creep lifting motor data
Required supply cable conductor cross sections/fuse links
DR 5 range Mains connection delay fuse link 6) for Supply lines 7) for 5% voltage drop ∆U and start-up current IA for
50 Hz 400 V 50 Hz 400 V (∆U 20 V)
Motor size A mm 2 m
ZBR 100 D 12/2 25 1.5 19
ZBR 132 D 12/2 50 2.5 15
Tab. 11

214 961 44/141212
5) The Prohub function enables loads weighing up to one third of the rated capacity to be lifted at 1.5 times the rated speed.
6) Fuse links also apply in conjunction with a cross-travel motor.
7) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ. 21
50 Hz 400 V
12 10/1.7; 1.4 20 400 240 9.6 15.0 0.54 0.68
ZBR 132 D 12/2 -
2.7/0.4;
B140 2 8.9 40 2870 120 18.0 120.0 0.89 0.85
5/0.8
50 Hz 400 V 50 Hz 400 V (∆U 20 V)
Motor size A mm² m
ZBR 132 D 12/2 50 2.5 15
Tab. 13
3.4.3 DR 5 - DR 10 motor key data for inverter operation

electric hoists.
Inverter-fed hoist motor acceleration current = 1.2 x rated current I(A).
Inverter-fed hoist motor rated cos phi = 1.0
Range Reeving Lifting Group of Motor key data Hoist out‐ Inverter
speed mecha‐ put
nisms
[m/min] FEM/ISO Type Brake No. of % CDF n for P hoist Type Rated cur‐
poles 87 Hz [kW] rent at
[rpm] 2 kHz [A]
2m/M5 ZBR 132 B4 2530 11.4 DIC-4-025 25
2/1, 4/2 1-25 3m/M6 B140 4 60 9.1 DIC-4-025 25
ZBR 112 A4 2540
4m/M7 7.3 DIC-4-017 16.5
DR 5
2m/M5 ZBR 132 B4 2530 11.4 DIC-4-025 25
4/1 0.5-12.5 3m/M6 B140 4 60 9.1 DIC-4-025 25
ZBR 112 A4 2540
4m/M7 7.3 DIC-4-017 16.5
2m/M5 ZBR 132 C4 16.3 DIC-4-040 40
1-18 3m/M6 B140 4 60 2530 13.1 DIC-4-032 32
ZBR 132 B4
4m/M7 10.4 DIC-4-025 25
2/1, 4/2
2m/M5 50 2520 21.3 DIC-4-040 40
1-25 3m/M6 ZBR 132 C4 B140 4 17.9 DIC-4-040 40
60 2530
4m/M7 13.8 DIC-4-032 32
DR 10
2m/M5 ZBR 132 C4 15.9 DIC-4-040 40
0.5-9 3m/M6 4 60 2530 12.8 DIC-4-032 32
ZBR 132 B4
4m/M7 10.1 DIC-4-025 25
4/1 B140
2m/M5 50 2520 21.1 DIC-4-040 40
0.5-12.5 3m/M6 ZBR 132 C4 4 17.0 DIC-4-040 40
60 2530
4m/M7 13.4 DIC-4-032 32
Tab. 14
The inverter housing is not attached to the hoist unit and is included in the delivery as a separate item.
● The inverter housing has to be attached by the customer.
● The standard cable measures approx. 3 m in length.
● The inverter housing measures (H x W x D) 600 x 880 x 300 mm.
● When the inverter housing is installed, a minimum distance of 100 mm must be maintained from the top edge
of the hoist unit.
214 961 44/141212
22
Calculation of cross sections/fuse links for other cable lengths
DR 5/10 range Fuse (time delay) 8) Supply lines 9)

for 50 Hz 400 V for 5% voltage drop ∆U 400 V (∆U 20 V)
Inverter type [A] [mm²] [m]
DIC-4-040 50 6.0 97
DIC-4-032 35 4.0 80
DIC-4-025 35 2.5 65
DIC-4-017 16 1.5 58
Tab. 15
3.5 Motor key data for inverter-controlled cross-travel drive
3.5.1 DR 5, DR 10 cross-travel drives, 2/1 - 4/1 - 4/2 reeving

Acceleration current = 1.5 x rated current I(A).
Rated cos phi = 1.0
DR 5 - 10 range No. of poles CDF n Inverter Inverter

at 120 Hz type rated current at 2
kHz
Motor size % [rpm] I [A]
ZBA 71 B 4 DR B003 4 60 3430 DIC-4-002-C 2.4
Tab. 16
Inverter input voltage: 380 - 480 V, 50/60 Hz
3.5.2 DR 10 cross-travel drives, 6/1 reeving

Rated cos phi = 1.0
DR 10 range No. of poles CDF n Inverter Inverter

kHz
2 x ZBA 80 A 4 DR B007 4 60 2270 DIC-4-007-C 7.3
Tab. 17
3.5.3 Calculation example

Example for calculating the cross-sections Q of the conductors of cables exceeding the length indicated in the
table:
ZBR 100 D2/12, 400 V required length 25 m
Known cross-section x required length

Q= =
Known cable length
1.5 mm2 x 25 m
Q= = 2 mm2
19 m
Tab. 18
214 961 44/141212

3.6 Hook dimension C
C
43248744.eps
Fig. 5
The hook dimensions C specified in the following apply to the top emergency-stop cut-out point.
The emergency limit switch for the top hook position must be set so that dimension C (see table below) is reached
when the switch cuts off the lifting motion.
Range Group of mechanisms Reeving

FEM/ISO 2/1 4/1 4/2 6/1
2m/M5
EZDR-Pro 5 3m/M6 530 440 430 -
4m/M7
2m/M5
660 520
EZDR-Pro 10 3m/M6 530 740
4m/M7 760 630
Tab. 19 Hook dimension C from girder running surface
In connection with an operating limit switch, hook dimension C is increased with reference to the operating switch-
off point.
3.7 Gearbox oil filling

The quantity of oil needed in the gearbox depends on the EZDR 5, 10 range. Before it is delivered, the gearbox is
filled according to the order.
Under normal operating conditions, the oil does not have to be changed until a general overhaul is carried out.
Under exceptional conditions, e.g. increased ambient temperatures, we recommend that oil changes be adapted
to suit these conditions.
Oil change
First clean the gearbox parts and gearbox casing thoroughly with commercially available cleaning agents, then
the gear oil can be drained. Then fill with the new gearbox oil. The required quantity and grade of oil can be seen
in the table below.
Range EZDR 5 EZDR 10

HG hoist gearbox [litres] 4.7 7.2
FG travel gearbox [litres] 0.65 1.1
Tab. 20
At ambient temperatures of -10 °C to +45 °C, CLP 220 EP gear oil should be used, e.g. Esso SPARTAN EP.
Order no.: 472 902 44 = 1.0 kg
214 961 44/141212
24
3.8 Operating conditions
Ambient temperature range -10 to +45 °C
Max. air humidity 80 %
Max. altitude/air pressure 1000 m above sea level
Tab. 21
CAUTION
Safe operation is only possible under the conditions specified above.
Please contact the manufacturer for any other operating conditions.
CAUTION
The rope hoist may be damaged if it is operated outdoors in poor weather.
If it is operated outdoors, provide the rope hoist with a cover to protect it from the weather and keep travelling
hoists under shelter when they are not in use.
214 961 44/141212
25
3.9 Noise emission
Noise emission measurement according to DIN 45635
-3 dB(A)
-6 dB(A)
1m
2m
4m
43311444.eps
Fig. 6 Sound pressure reduction in relation to the distance from the sound source
A Measuring point
B Sound source
The sound pressure level of a rope hoist can be seen in the following table.
Sound pressure level LpAF in relation to the load capacity and size of the rope hoist at a distance of 1 m:
Type Hoist unit

EZDR Pro Max. noise emission level LpAF in dB(A), measured at a distance of 1 m10)
No load Under load
Main lifting speed Main lowering speed Main lifting speed Main lowering speed
5 70 dB 70 dB 73 dB 77 dB
10 77 dB 78 dB 77 dB 79 dB
Tab. 22
Type Cross travel

EZDR Pro Max. noise emission level LpAF in dB(A), measured at a distance of 1 m 10)
No load Under load
Left V2 Right V2 Left V2 Right V2
5 68 dB 68 dB 71 dB 72 dB
10 67 dB 66 dB 67 dB 67 dB
Tab. 23
The specified values (emission values) were measured under maximum load.
214 961 44/141212
26 10) All noise level data are subject to a tolerance of ± 2 dB (A).

The following structural influences were not considered in the measurements:
● transmission of noise via steel structures
● reflection of noise from walls, etc.
The sound pressure level is reduced by approx. 3 dB(A) each time the distance is doubled.
3.10 Paint finish

The machine is supplied in the following standard colours:
RAL 5009 azure blue

Hoist unit
RAL 7001 silver grey
RAL 1007 chrome yellow
Bottom block
RAL 9005 jet black
Hook RAL 9005 jet black
RAL 5009 azure blue
Travel unit
Tab. 24
3.11 Weight
EZDR 5, weights in kg
Reeving 2/1 4/1 4/2

Drum length H12 H20 H12 H20 H20
Hoist motor 12/2 4 12/2 4 12/2 4 12/2 4 12/2 4
-pole -pole11) -pole -pole11) -pole -pole11) -pole -pole11) -pole -pole11)
Track gauge LKa 1400 1400 1400
Deadweight 490 510 510 530 510 530 530 560 -
Deadweight 530 550 550 570 550 570 600 550 550 570
Deadweight 560 580 580 600 580 600 600 630 580 600
Tab. 25 Deadweight from the sum total of the individual loads
Reeving 2/1 4/1 4/2

Hoist motor 12/2 4 12/2 4 12/2 4 12/2 4 12/2 4
Deadweight 608 646 632 669 647 684 674 717 -
Deadweight 648 686 672 709 687 724 714 757 807 850
Deadweight 678 716 702 739 730 767 757 800 850 893
Reeving 4/2
Drum length H12 H20 H40
Hoist motor 12/2-pole 4-pole13) 12/2-pole 4-pole13) 12/2-pole 4-pole13)
Track gauge LKa 1400
Deadweight 647 684 - -
214 961 44/141212
11) With frequency inverter

13) With frequency inverter 27
Reeving 4/2
Deadweight 687 724 714 757 807 850
Deadweight 717 754 744 787 837 880
3.12 Track girder requirements
3.12.1 Runway
32138533-dor
Fig. 7 Runway paint finish
The running surfaces must only be given a primer coat.
Minimum requirements for runways:

● Do not use beams with profile sections and cross-sections that are smaller than the minimum dimensions
specified in our brochures for track girders of double-rail crabs as otherwise deformation of the girders might
occur. Permissible deviations in dimension and shape of the track girder according to DIN EN 10034.
The special travel unit requirements are listed in accordance with the ranges in the following chapter  "Travel
unit", Page 29:
- Dimensional accuracy of the tracks
- Tolerance of the individual girder, of the crab track gauge
- Difference in rail height
- Gradient of the crab rails
● Hoist travel on track beams must in no way be obstructed by protruding suspension bolts, screw heads, butt
straps, clamping plates, etc.
● Track gradients should not exceed 2%.
● Appropriately dimensioned end stops must be fitted at both ends of the runway.
● Track joints must be clean and smooth. Bolted joints must be outside the travel area of the travel wheels (ob‐
serve maximum web thickness).
214 961 44/141212
● Fitting the cross-travel unit  "Checking dimensional accuracy of the tracks", Page 39.
28 13) With frequency inverter

● The running surfaces of rails and track beams must only be given a primer coat of 40 µ in the area of the
wheels and guide rollers. Travel characteristics would be impaired by a top coat ( Fig. 7, Page 28).
● Rails and track beams should be kept clean; oil, grease, ice and dirt on the running surfaces will cause travel
wheels to skid.
3.12.2 Travel unit

The travel units have a fixed width.
Available track gauges for EZDR 5 and 10 units are 1400 mm, 2240 mm and 2800 mm.
Before installing the travel unit on the track, it must be checked for dimensional accuracy,  "Checking dimen‐
sional accuracy of the tracks", Page 39.
Do not use the double-rail crab to pull free, pull or drag loads on the ground.
It must never run against the buffer stops at full speed, as otherwise damage or accidents may occur.
3.13 Control system

Crane and crab control using CANopen Safety CAN-bus technology:
● Redundant control system with two controllers that monitor each other
● Transmission of all safety-relevant signals acc. to CANopen Safety
● Permanent or cyclic monitoring of all safety functions
● Safety concept uses crane contactor as second entity for switching off
● On-board analysis and service system permits crane monitoring (optional)
● Minimum cabling required, therefore reduced weight and space
● Flexible adaptation due to modular PCB concept
● Cross-travel inverter and braking resistor integrated in the lower electrical enclosure
● Alternative control units can be plugged in
● Programmable functions:
- Load spectrum recorder to determine the remaining safe working period
- MGS/ZMS overload protection (ZMS optional)
- Load summation for two crabs
- Slack rope cut-off (optional)
- Load display with selectable unit (t, kg, lbs, T)
- SGDM / BER function
- Co-ordinated and safe operation of two crabs or two hoist units
- Synchronous operation of two hoist units with frequency inverter
- Area-related load and speed reduction (optional)
- Various by-pass control/pass-through control types (optional)
- Operating limit switch, rope limit switch, limit switch for phase-sequence error (optional)
- Holding and catching brake (optional)
● Integrated monitoring features
- Phase sequence
- Brake application
- Brake wear
- Speed
- Overheating
- Contactor switching statuses
214 961 44/141212
- Limit switch sequence
29
4 Design and function
4.1 Design
1 2
10 3
43245644.eps
Fig. 8
1 EZDR double-rail crab 7 4/1 bottom block

2 Travel motor 8 Hoist motor
3 Travel unit 9 Rope drum
4 Thrust rocker 10 Electrical equipment cover with integrated elec‐
5 Hoist gearbox trical equipment and geared limit switch
6 4/1 top block
Demag EZDR-Pro double-rail crabs are manufactured in two ranges, each with three groups of mechanisms.
4.2 Arrangement of assemblies

The design is characterised by parallel arrangement of the rope drum and the hoist motor. The gearbox and the
electrical equipment housings constitute the two central assemblies of the rope hoist. These two components are
bolted together to form the hoist unit frame by means of three connecting rods.
The crab frame consists of a welded steel structure for accommodating the hoist unit and the rope reeving com‐
ponents as well as the travel wheels and the cross-travel drive.
214 961 44/141212
30
4.3 Drives
4.3.1 Hoist and travel drive
Demag ZBR cylindrical-rotor motors with separately controlled DC brakes are used as hoist drives. They are de‐
signed in accordance with the design rules of the FEM, to meet the high demands made on electric hoists. ZBR
hoist motors feature IP 55 type of enclosure (for motor and brake).
A creep lifting speed of 1/6 of the main lifting speed is obtained by using a 2/12-pole motor.
Demag ZBA brake motors with separately controlled brakes are used as travel motors. Type of enclosure of the
ZBA travel motors is IP55.
4-pole travel motors which are controlled by a frequency inverter are used. The speed is infinitely variable.
4.3.2 Gearbox/rope reeving components

The torque of the motor is transmitted direct to the helical gearbox . The hoist gearbox (5) accommodates all gear
stages of the three-stage gearing. It is also the basis of the rope hoist.
The drum, rope sheaves and rope comply with the following design rules:
● FEM 9.661
● ISO 4308-1
● prEN 13001-3.2
4.4 Geared limit switch

Motions are limited at the upper and lower hook positions by the geared limit switch. In general, the geared limit
switch is provided with 4 contacts. The contacts are assigned in the factory as stated in the order of the rope
hoist.
The geared limit switch is fitted inside electrical equipment cover (10) of the Demag rope hoist. It switches off the
rope hoist when the top or bottom hook position is reached. The direction of movement can be reversed.
The emergency limit switch must not be approached in normal operation.
Operating limit switches are required where the end positions are approached regularly during normal operation.
In such cases, the switches must be adjusted so that the operating limit switch is actuated first and then, i.e. if this
fails to operate, the emergency limit switch is actuated.
Accident prevention regulations require that the crane operator checks the emergency limit switch before starting
work. This can be done by using a solution with a geared limit switch and a 2-stage button on the control pendant.
The operating limit switch can be by-passed by pressing this button. In order to approach the emergency limit
switch, the hoist unit must be switched on and the test button pressed simultaneously.
The 2-stage button must be pressed to move the hook back out of the end position (lowering).
Please refer to the relevant wiring diagram for the functions performed by the geared limit switch.
214 961 44/141212
31
4.5 Integrated controls
43245744.eps
Fig. 9
The electrical equipment cover (1) accommodates the control system for the required connections, powerfeed
and further sensors. The connections are of plug-and-socket design throughout. The cover is locked by means of
twist locks and fitted on hinges.
4.6 Control pendant operating element
4.6.1 Overview
Available control pendants
The rope hoist is controlled by a Demag DSE-10R control pendant of

DSE-10R
plug-in design. The control pendant features an integrated mechatron‐
ics solution for infinitely variable motions in the individual axes.
The control system provides step or variable control according to the
selected drive.
The control pendant housings are made of high-quality thermoplastic
which is highly resistant to impacts. They are resistant to fuels, salt wa‐
ter, grease, oils and lyes.
WARNING
43249444.eps Danger from acids
Fig. 10 Strong mineral (e.g. hydrochloric or sulphuric) acids may
corrode pendant housings.
Avoid contact with these substances.
214 961 44/141212
32
4.6.2 DSE-10R
The rope hoist is controlled by a Demag DSE-10R control pendant.

Demag rope hoists are generally fitted with emergency limit switches
and a test button (2-stage) in the DSE-10R control pendant. The test
button can be used to by-pass the ‘lifting’ operating limit switch to check
4
the emergency limit switch. The control pendant is fitted according to
2  "Connecting the control cable", Page 59.
The control pendant should be suspended so that the bottom edge is
approx. 1 m above floor level. Suspend the control pendant in such a
1 way that the arrow symbols on the buttons indicate the correct direc‐
tions of movement.
3 The control pendant is generally of plug-in design for service and main‐
tenance-friendly installation.
43237044.eps
Item Function
Fig. 11 1 Emergency-stop button
2 Test button
3 Buttons to control the motion axes
4 Display
Tab. 28
● The two-stage test button (2) can be used to by-pass the ‘lifting’ op‐
erating limit switch to check the emergency limit switch.
● Service data or the load can be shown in the display (4).
● Only a general load value trend is displayed when standard equip‐
ment is fitted (MGS overload protection and load detection by means
of slip calculation).
● The load value is shown with an accuracy of ± 5 % when special
equipment is installed (ZMS strain gauge carrier link as overload pro‐
tection).
● An additional bumper protects the housing against particularly harsh
ambient conditions.
4.6.3 Principle
The DSE-10R consists of an integrated mechatronics solution, i.e. the mechanical actuating system acts on a
magnet sensor system that evaluates the control commands via an electronic system.
This makes stepless actuation possible in all three motion axes. The integrated DR control system provides step
or variable control in accordance with the optionally selected drives.
4.6.4 Wiring
The integrated DR control system features transmission of the control signals from the DSE-10R control unit to
the DR control system or to the crane control system via a CAN-bus for the first time. This makes it possible to
reduce wiring requirements to a minimum. The number of connection diagrams is reduced to one diagram.
4.6.5 Display
Information on the load value and the service data (min. quantity) is available via the standard display (4)
 Fig. 11, Page 33.
The load value trend is displayed when standard MGS overload protection is used and the load is detected by
means of slip calculation. The load is displayed with an accuracy deviation of a percentage when the optional
ZMS strain gauge carrier link is installed as overload protection.
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4.6.6 IrDA infrared interface

The DSE-10R control pendant is provided with an integrated infra-red interface (IrDA) to read and transmit the DR
rope hoist service data (see control pendant operating instructions,  Further documents, page 2).
33
4.6.7 Connecting the control cable
The control pendant and the mains connection cable must be fitted by the customer in such a way that the con‐
nectors are not subjected to any tensile or transverse forces.
The control cable of the control pendant is provided with vulcanised strain relief wire cords which must be attach‐
ed by the customer.
4.7 Overload protection
MGS ZMS
43237144.eps
Fig. 12
MGS mechanical or ZMS electronic overload protection (option) can be used to protect Demag rope hoists and
supporting structures against overloads.
A summation measuring device, slack rope relay and load display can also be fitted in combination with ZMS
overload protection.
214 961 44/141212
34
4.8 Type plate (example)
2 Baujahr: 20xx Fabrik-Nr.: 96751031 9

3 Gruppe: xx Tragfaehigkeit: xxxx kg 10
4 Baugroesse: xxxx x Hakenweg: xx m 11
5 Getr.i.: xx Haupthub: xx m/min 12
6 Einscherung: xx Feinhub: xx m/min 13
7 Seildurchmesser: xx mm rechn. Seilbruchkraft: xx kN 14
8 Auftrags-Nr.: 000000 - 00000000 - 00 ASN: xx
43237244.eps
Fig. 13
The type plate contains the following information 8 Order number

1 Manufacturer 9 Serial no.
2 Year of manufacture 10 Load capacity [kg]
3 Group of mechanisms to FEM/ISO 11 Hook path [m]
4 Size 12 Main lifting speed [m/min]
5 Gearbox transmission ratio i 13 Creep lifting speed [m/min]
6 Reeving 14 Calculated rope breaking force [kN]
7 Rope diameter [mm]
The type plate of the rope hoist is located on the side of the gearbox housing of the travel motor.
214 961 44/141212
35
5 Transport, packing, storage
5.1 Safety instructions
WARNING
Risk of injury from falling parts
Secure components during transport. Do not step under the suspended load.
CAUTION
Inappropriate transport
The machine may be damaged.
Lift loads only at the marked lifting points. Only use suitable hoisting equipment which has sufficient load capaci‐
ty.
5.2 Transport inspection

● Check that the delivery is complete and for transport damage immediately upon receipt.
● If any transport damage is visible from the outside, only conditionally accept the delivery. Note the scope of
damage in the shipping documents/delivery note of the forwarding company and lodge a claim.
● Lodge a claim for any defects that are not immediately detected as soon as they are discovered, since claims
for damages may only be asserted within the relevant claim notification periods.
5.3 Packing
If no agreement has been made on the return of the packing material, separate the materials according to type
and size and make it available for further use or recycling.
Environmental protection:
● Always dispose of packing materials in an environmentally compatible way and according to locally applicable
disposal regulations.
● If required, utilise the services of a recycling company.
5.4 Storage
Until they are installed, the machine and accessories must be kept closed and may only be stored under the fol‐
lowing conditions:
● Do not store outdoors.
● Store in dry and dust-free places, relative air humidity: max. 60%.
● Do not expose to aggressive media.
● Protect against direct sunlight.
● Avoid mechanical vibrations.
● Storage temperature: -25 °C to +55 °C.
● Avoid strong temperature fluctuations (condensation).
● Oil all bare machine parts (rust protection).
● Check the general condition of all parts of the packing at regular intervals. If required, refresh or renew rust
protection.
● If stored in a damp location, the machine must be packed tight and protected against corrosion (desiccant).
214 961 44/141212
36
6 Installation and putting into operation for the first time
WARNING
Dangerous electric current
Work on electrical equipment may only be carried out by qualified specialist personnel in compliance with the
safety regulations.
– Before starting work, switch off the electrical supply and secure against restoration.
Special information for assembly
a) b)
43311344.eps
Fig. 14 Example of safe assembly
a) Protection for the working area

b) Example of a suitable working platform
WARNING
Risk of injury if incorrectly assembled
Incorrect installation can lead to severe injury and/or damage to property.
Therefore, this work may only be carried out by authorised, instructed personnel who are familiar with the princi‐
ple of operation of the machine in compliance with all safety regulations:
– Ensure sufficient working clearance before starting assembly work.
– Make the working and danger zone safe ( Fig. 14, Page 37).
– If a lifting appliance is used for assembly, only use appropriate attachments for the lifting of persons which
ensure that work is carried out in a safe and stable position ( Fig. 14, Page 37).
– In the course of putting the unit into operation, it may be necessary to render safety devices or features
temporarily inoperative.
214 961 44/141212
– First check that the voltage and frequency specified on the data plates match the owner's mains power sup‐
ply.
– All clearance dimensions and safety distances (see approval drawing) must be checked before putting the
unit into operation.
37
– Work may need to be carried out in the danger zone when the unit is put into operation.
– Wear protective clothing.
– Be careful when working on open components that have sharp edges. Risk of injury.
– Keep the working area clean and tidy. Store any unneeded machine or installation parts and tools in such a
way that there is no risk of them falling.
– Fit components appropriately. Comply with specified bolt tightening torques. Incorrectly fitted components
may fall and cause severe injuries.
– The electrode holder and earth must always be connected to the same assembly when welding work is car‐
ried out as otherwise serious damage may be caused to the machine.
– Attach the rope hoist only at the appropriate connecting points.
– Only carry out installation work when all requirements regarding the installation location are met  "Operat‐
ing conditions", Page 25.
6.2 Assembly of travelling hoists
6.2.1 Overview
b
a
d
c
43245844.eps
Fig. 15
214 961 44/141212
a Single-groove design, 4/1 reeving c Double-groove design, 4/2 reeving

b Single-groove design, 2/1 reeving d Single-groove design, 6/1 reeving
Check that the machine is complete and in perfect technical condition before installation.
38
6.2.2 Checking dimensional accuracy of the tracks
6.2.2.1 Tolerance of the individual girder
The steel girders must be aligned properly before fitting the cross-travel units, therefore, the dimensional accuracy
of the tracks must be checked before fitting.
Lateral deviation
n s
L
2 L
2
L
L
2 L
L
2
43245944.eps
Fig. 16
n = ± 2 mm, maximum lateral deviation

s = ± 2 mm, maximum lateral rail deviation
– Measure lateral girder/rail deviation ‘n’ or ‘s’ by means of a cord, laser or theodolite at half of the girder
length.
6.2.2.2 Twisting
Any twist must be compensated when the connecting plates are fitted.
● Max. permissible twist ‘y’ is 0.5 mm/m
y Calculation based on formula: ymax = 0.5 x LTr
Example for calculating permissible twist ‘y’ for a girder length of 10 m

● ymax = 0.5 x LTr
● y max. = 0.5 mm/m x 10 m = 5 mm
43246144.eps
Fig. 17
214 961 44/141212
39
6.2.2.3 Tolerance of the crab track gauge
b
L + 4 mm
a KA - +2 mm
-2 mm
43246244.eps
Fig. 18
a Track gauge: LKA ± 4 mm

b Centre of web plate
– Check track gauge over the entire travel path.
6.2.2.4 Gradient of the crab rails

a
43246344.eps
Fig. 19
a Max. gradient dimension 1 mm
– Gradient of the crab rails to be measured at points spaced 1 m apart over the entire track gauge.
214 961 44/141212
40
6.2.2.5 Difference in rail height
43246444.eps
Fig. 20
a Max. permissible difference in height 5 mm
– To be measured at points spaced 1 m apart over the entire length of the girder.
The maximum permissible difference in rail height is 5 mm.
6.2.2.6 Rail level difference

5 mm
4 mm
43246544.eps
Fig. 21
∆H = max. 1.5 mm
The maximum permissible difference in height between two measuring points arranged next to each other along
one rail is 1.5 mm.
214 961 44/141212
41
6.2.3 Fitting the end stops/clamp-fitted buffers
Fitting the end stops/clamp-fitted buffers is described in detail in the separate fitting instructions  (203 652 44).
Further details  "Assembly and alignment of the travelling hoists", Page 42.
The double-rail crab must never run against the buffer stops at full speed, as otherwise damage to the hoist unit
or even accidents may occur.
The monorail hoist is counter-balanced by the thrust rocker which presses against the track from below.
6.3 Assembly and alignment of the travelling hoists
6.3.1 Assembly instructions
WARNING
Crushing hazard and risk of injury from falling parts.
Danger to life and limb
Safely support the travel unit on the track girder while it is being installed to avoid any risk of crushing or falling.
Refer to section  "Checking dimensional accuracy of the tracks", Page 39 for special data regarding inspection
of tracks and girders.
Before installing the travel unit on the track, it must be checked for dimensional accuracy, see section  "Check‐
ing dimensional accuracy of the tracks", Page 39.
6.3.2 Aligning the travelling hoist on the crane
They must be aligned using adjusting jigs, .
214 961 44/141212
42
Adjusting jigs
A B
1 2
A B
a)
b)
43449344.eps
Fig. 22
A View of roller-side travel unit 2 Adjusting jig on wheel block side

214 961 44/141212
1 Adjusting jig on roller side a) Version with threaded pin

B View of wheel block-side travel unit b) Version with clamps
43
6.3.3 Assembly of adjusting jig A
6.3.3.1 Assembly of the adjusting jig on the roller side (preparation of adjusting jig for assembly)
– Loosen the star grips (5) and open the clamping device.
3
4
5
43449444.eps
Fig. 23
– Loosen the bolted connection of the profile section (3).
4
43449544.eps
Fig. 24
– Position the adjusting jig in such a way that the plate of the travel unit (6) is located between the clamping
jaws (4) of the adjusting jig.
214 961 44/141212
– Slide the profile sections together until the clamping jaws grip.
– Tighten the bolted connection of the profile section.
44
– Shift the adjusting jig in height until the lower side of the profile sections (3) is slightly above the outer rings
of the travel rollers (7).
3 5
7
43449644.eps
Fig. 25
– Shift the clamping jaws with the star grips.

If required, adapt the length of the adjusting jig to the hoist unit, e.g. in the case of a hoist FI.
– To do this, loosen the bolted connections between the profile sections (1) and (2).
– Move the profile section (2) until the adjusting jig has been adapted to the length of the travel unit.
– Retighten the bolted connections.
Align the adjusting jig with a spirit level in order to avoid a parallax error.
6.3.4 Assembly of adjusting jig B
6.3.4.1 Version a: Fixing with threaded pin guide for EZDR with one travel drive (inside)
– Remove nuts (1) and washers (2) of the adjusting jig.
1 2
3
4
43449444.eps
Fig. 26
214 961 44/141212
45
7 7
8 9 9
5 6
43449844.eps
Fig. 27
– Remove the buffer (5) and the guide roller support (6).
– Unscrew the wheel block screws (7), 4 on each wheel block.
Important. Only loosen the screws, do not unscrew them completely.
– Slacken the pressure rollers (8) or remove them, as required, see hoist unit operating instructions.
– Raise the travel unit on the wheel block side by approx. 5 mm.
– Insert the threaded pints(9) in the wheel block bores.
– Align the wheel blocks to the adjusting jig, as required.
214 961 44/141212
46
2
1 2 10
43449944.eps
Fig. 28
– Tighten nuts (1) with washers (2) to align the wheel blocks (10) with each other.
6.3.4.2 Version b: Fixing with two clamps for EZDR with two travel drives (outside).
– For alignment, use the adjusting jig with clamp (1).
1
2
3
1
43450044.eps
214 961 44/141212
Fig. 29
– Remove the travel drives incl. torque brackets.

47
6 6
9
10
11
8 7 8
4 5
43450144.eps
Fig. 30
– Align the adjusting jig in parallel to the wheel block front side.
– Fix the adjusting jig with the two clamps (8) on the threaded pins of the travel drive fastening arrangement.
– Tighten nuts (9) with washers (10).
In this way, the wheel blocks (11) are aligned flush to each other.
214 961 44/141212
48
6.3.5 Adjustment for horizontal alignment
The following steps apply for both versions (a and b) of view B (assembly on the wheel block side)
– Align both sides of the adjusting jigs A and B parallel (=, see fig.) to each other.
=
A B
43450244.eps
Fig. 31
– Align the wheel blocks centrally on the travel rails (2). Pay attention to the mark (3) on the housing.
3
= = 2
43450344.eps
Fig. 32
– Set the wheel blocks down onto the rail.

– Re-tighten the wheel block screws (1), 4 on each wheel block.
214 961 44/141212
49
CAUTION
Loose connections
Loose connections are a danger to life and limb.
Ensure that the connections are tightened to the specified tightening torque.
– Wheel block screws (1)
DRS 125: 130 Nm
DRS 160: 330 Nm
6.3.6 Disassembly of adjusting jigs A and B

Completion version a
– Remove the adjusting jig A on the roller side.
– Loosen the nuts (1) and remove the adjusting jig B on the wheel block side.
43450444.eps
Fig. 33
214 961 44/141212
50
1
43451044.eps
Fig. 34
Completion version b
– Loosen the nuts (1) and washers (2) on both clamps (3).
– Remove the clamps and the adjusting jig B.
– Fit the two travel drives.
214 961 44/141212
51
6.3.7 Assembly and adjustment of the guide rollers
Fit the guide rollers
43450544.eps
Fig. 35
– Insert the screws (1) and tighten them by hand.

– Check the horizontal alignment of the mounting plate and correct it, if necessary.
– Tighten the bolts.
CAUTION
Loose connections
– Guide roller screws
DRS 125: 130 Nm
DRS 160: 330 Nm
– Fit the buffers (2).

214 961 44/141212
52
Adjust the guide rollers
3
2
43450644.eps
Fig. 36
– Loosen screws (1).

– Adjust the guide rollers (2) to a maximum of 1 mm (0.5 mm per side) play.
To do this, use a feeler gauge, for example.
– Tighten screws (1).
CAUTION
Loose connections
DRS 125: 130 Nm
DRS 160: 330 Nm
– Fit the pressure rollers (3) and adjust them, (see hoist unit operating instructions).
214 961 44/141212
53
Test run along the entire runway
43450744.eps
Fig. 37
– Carry out a test run.

The rollers must not come into contact with the weld seams under any circumstances. Minimum distance to the
weld seams 2.5 mm.
– Check gap between thrust rocker (2) and web plate (3), which must be a minimum of 5 mm.
If the gap is not large enough, the parallel position of the crab must be changed by adjusting the guide roll‐
ers.
214 961 44/141212
54
Final adjustment of the horizontal guide rollers
4 3
x x
2 2 2 1
43247944.eps
Fig. 38 DRS wheel block (shown without buffer)
Adjusting the horizontal guide rollers:

1. Align travel wheel (4) with the centre of rail (3) and then adjust horizontal guide rollers (2).
2. To do this, loosen locking screws (1) and align guide rollers (2) with rail (3) taking ‘dimension x’ into account.
3. Tighten locking screws (1) (pay attention to the tightening torque in the table)  Tab. 29, Page 55.
4. Then check the distance of guide rollers (2) to rail (3).
Size Locking screw tightening torque [Nm] Dimensions in mm

x
DRS 125 130 0.5
DRS 160 330 0.5
Tab. 29
214 961 44/141212
55
6.3.8 Final adjustment of the thrust rocker
S
C
A
6 1 1
5
3
X
43248044.eps
Fig. 39
1 Thrust rocker S Overall height = overall height of rail and upper

2 Lock nut flange
3 Pressure spring x Tensioning dimension
4 Rail A, B, Mounting bore holes
C
5 Girder section/upper flange
6 Bolt
Setting the thrust rocker

1. Determine upper flange and rail dimension (S).
2. Refer to the table for the corresponding mounting bore holes (A, B or C).
214 961 44/141212
3. Fit thrust rocker on crab frame by means of screws (6) via the relevant threaded bore holes (tightening tor‐
que 130 Nm).
4. Adjust pre-tension dimension (x) using locknut (2) to apply the contact pressure of the thrust rocker to the
upper flange.
56
Pre-tensioning of pressure spring and fitting
Mounting for bore hole A Mounting for bore hole B Mounting for bore hole C
Installation Pre-tension dimension X [mm] Installation di‐ Pre-tension dimension X [mm] Installation di‐ Pre-tension dimension X [mm]
dimension DR 5 and 10 DR 10 6/1 mension DR 5 and 10 DR 10 6/1 mension DR 5 and 10 DR 10 6/1
‘S’ [mm] ‘S’ [mm] ‘S’ [mm]
34 3.4 5.3 51 3.8 5.7 71 2.7 4.1
38 4.1 6.2 54 4.3 6.5 75 3.6 5.4
42 4.8 6.8 58 5.0 7.5 79 4.3 6.5
46 5.5 8.3 62 5.7 8.6 83 5.0 7.5
50 6.2 9.3 66 6.4 9.6 87 5.7 8.6
70 7.2 10.8 91 6.4 9.6
95 7.2 10.8
Tab. 30
214 961 44/141212
57
6.4 Connecting the electrical equipment
6.4.1 Wiring
6.4.1.1 General
DANGER
Live components
All wiring and connection work may only be carried out by an instructed and qualified electrician according to the
specifications of the electrical connection diagram included in the supply.
Each machine is provided with a wiring diagram showing details of the controls.
The wiring of the Demag machine complies in all respects with current DIN VDE and accident prevention regula‐
tions. Unauthorised intervention and modifications may result in infringement of these regulations.
The switchgear is designed for extreme conditions. However, its service life depends on usage. Advise operators
that
● inching (i.e. giving short pulses to the motor to obtain small movements) should be avoided as far as possible,
e.g. when attaching a load. It may cause excessive wear and premature failure of the switchgear.
● corrosion on plastic (identifiable by dull, sooty or brittle surfaces) and metal components in enclosed switch‐
gear housings can be caused by too frequent inching.
● corroded parts must be replaced in good time.
6.4.1.2 Frequency inverter

Since the machine is fitted with a frequency inverter, the following additional connection requirements must be
observed:
● Check connection to the public supply network without further measures in accordance with the provisions of
standard EN 61000-3-2.
● Frequency inverters fulfil the emission limit value requirements of product standard EN 61800-3. Increased re‐
quirements resulting from the application environment of the frequency inverter must be met by the use of op‐
tional components.
● Operation in a non-earthed system (IT system) is allowed after the Y capacitors inside the inverter have been
disconnected.
● Fault-free operation with a current-operated e.l.c.b. (earth-leakage circuit-breaker) is ensured with a tripping
current > 30 mA if the following is considered:
- Residual-current-operated circuit-breakers sensitive to all types of currents (type B acc. to EN 50178), when
connecting frequency inverters with two (L1/L2) or three-phase (L1/L2/L3) connection to the power supply.
- The residual-current-operated circuit breaker protects a frequency inverter with a leakage-current reduced
filter or without a radio interference suppression filter.
- The Y capacitors in the inverter must be disconnected. This increases cable-bound emitted interference
(EMC).
Required supply cable conductor cross sections and fuse links  " Hoist motor technical data", Page 21. Please
note that in order to avoid excessive voltage drop, the length of the supply line specified for a given cross sec‐
tion must not be exceeded.
214 961 44/141212
58
6.4.1.3 Control cable and line voltage connection
CAUTION
Electrical connection with incorrect voltage.
A
The electronic equipment may be destroyed if the control
voltage is too high.
If the measured value exceeds or drops below the voltage
specified on the machines by more than 10%, a control
transformer must be connected on the primary side ac‐
B
cording to the table in the circuit diagram (see electrical
43238844.eps
connection diagram).
Fig. 40
– Before starting any connection work, use a voltmeter
to check whether the voltage and frequency specified
on the data plate match the mains supply.
Voltage-changing motors are wired in our works for the operating volt‐
age stated in the order of the Demag rope hoist. The standard control
voltage is 48 V 50/60 Hz.
The diagram shows the mains connection and control voltage sockets
on the rope hoist:
● 4-pole plug-in mains connection, connector A,
● 48 V control voltage and CAN-bus control signal plug connection,
connector B.
Plug in the relevant connectors and tighten the locking screws by hand
to make the connections.
6.4.2.1 Direct connection to the machine
340 875 44
M6
504 419 44
43238944.eps
Fig. 41
Connect the control cable with vulcanised strain relief cords as shown in the diagram. (see separate DSE-10R
control pendant operating instructions and electrical connection diagram).
214 961 44/141212
59
6.4.2.2 Connection to the KBK trailing cable trolley
DSE-10R control pendant adjustment

DSE-10R control pendants are supplied with cable lengths of 6 m or 10 m as standard. The suspension height
can be adjusted by means of a self-locking clamping mechanism to suit individual requirements. Adjust as descri‐
bed below  Fig. 42, Page 60.
1. Loosen clamping mechanism (1).
2. Adjust the required suspension height. Bundle any control cable that is not needed and store it in cable col‐
lector (2).
43239144.eps
Fig. 42
6.4.3 Checking the direction of movement
CAUTION
Error in assembly
Failure to carry out this check may result in severe damage or injury.
The direction in which the rope hoist moves depends on the phase sequence in the power supply. The load hook
must move upwards when the control pendant ‘lifting’ switch is actuated. If this is not the case, two of the supply
cable leads should be swapped over to ensure that the emergency limit switches operate correctly.
If the phases are incorrectly connected, the control system will automatically switch the hoist motor motion off af‐
ter it briefly starts up. Error code 38 appears on the display of the DSE-10R control pendant or on the radio con‐
trol (optional).
Check the top and bottom hook positions and adjust accordingly  "Geared limit switch ", Page 75.
214 961 44/141212
60
6.5 Rope reeving
6.5.1 Reeving methods
2/1 4/1 4/2 6/1
43248144.eps
Fig. 43 EZDR reeving arrangements, 2/1, 4/1, 4/2 and 6/1 reevings
6.5.2 Reeving methods for the rope hoist
General
Demag DR-Pro rope hoists are supplied with the rope separate from the bottom block.
Reeving of the ropes for Demag EZDR-Pro rope hoists with 2/1, 4/1, 4/2 and 6/1 reeving arrangements is shown
in the following sections.
Rope routing for the various reeving arrangements is shown in the following diagrams, in section  "Bottom block
reeving", Page 64.
CAUTION
Cutting hazard
Risk of cutting fingers/hands on sharp edges of the wire rope when it is rolled out.
Always wear protective gloves when working with wire rope.
Care must be taken to keep the rope tight and not to twist it while reeving. Rope routing must always be complied
with.
For single-groove rope drums, the rope is retained by a wedge and a rope socket anchorage that is incorporated
in the rope-retaining crosshead.
Please ensure that the load-bearing end of the rope enters the vertical part of the socket ( Fig. 47, Page 65).
The rope is properly secured if the wedge remains visible above the anchorage and the dead end protrudes by
approx. 10 cm when under load.
The rope can be replaced by Demag service engineers or an authorised specialist company.
The method of securing the rope end by means of this anchorage is absolutely reliable and conforms to the rele‐
vant regulations. An additional safety feature to prevent the dead end of the rope from slipping must be fitted in
214 961 44/141212
accordance with ISO 4309. Fit the required rope clamp as shown in  Fig. 47, Page 65.
61
CAUTION
Danger if incorrectly fitted
Danger to life and limb if the rope is damaged.
The rope must not be secured with a rope clamp fitted over both rope ends. This would cause bruising and un‐
even stress in the carrying fall of the rope and thus lead to its destruction.
Check suspension of the rope socket.
Ensure that the double spring clip is correctly seated when the rope socket is fitted  Fig. 47, Page 65.
Check fitting of the MGS/ZMS overload protection.
Ensure that the retaining ring clicks into the groove of the pin when the retaining ring is fitted  Fig. 47,
Page 65. It must be possible to turn the retaining ring easily after it is fitted. Grease the bearing points with a
suitable adhesive lubricant. Order no.: 472 933 44.
6.5.3 Fitting MGS/ZMS overload protection
6.5.3.1 MGS/ZMS overload protection, 2/1, 4/1 and 6/1 reeving
MGS ZMS
5 5
1
2 1
3
MGS ZMS
3 2
2 4
4
43303444.eps
Fig. 44
1 Pin 4 Spring ring

2 Washer 5 Lever
3 Collar sleeve
Install MGS or ZMS overload protection in the crosshead and the lever as shown in the drawing.
214 961 44/141212
62
6.5.3.2 ZMS overload protection, 4/2 reeving
ZMS
ZMS
2
3
43430844.eps
Fig. 45
1 Pin 2 Washer
3 Spring ring
Install ZMS overload protection in the crosshead and the lever as shown in the drawing.
6.5.4 Fitting the rope
See section  "Fitting the rope", Page 92

214 961 44/141212
63
6.5.5 Bottom block reeving
6.5.5.1 2/1 reeving
43248244.eps
Fig. 46
1 Rope drum 4 Rope socket

2 Bottom block 5 Double spring clip
3 Rope clamp
1. Slide the loose rope end on rope drum (1) through the rope sheave in bottom block (2).
2. Fit and fasten rope socket (4)  "Fitting the rope socket for 2/1", Page 65.
214 961 44/141212
64
Fitting the rope socket for 2/1
9
8
3 4 5 5 6
3
1
6
4
7
7
2 2 10
43238344.eps
Fig. 47
1 Rope wedge 6 Pin

2 Rope clamp 7 Rope socket
3 Double spring clip 8 Lever
4 Washer 9 Crosshead
5 Collar sleeve 10 Wire rope
Secure the rope in rope socket (7) with the rope wedge and rope clamp (2).
– Insert the load-bearing rope together with rope wedge (1) into the vertical part of rope socket (7).
– The dead end of the rope must protrude from rope socket (7) by approx. 10 cm.
CAUTION
The rope must not be secured with rope clamps (2) fitted over both rope ends. This would cause bruising and
uneven stress in the carrying fall of the rope and thus lead to its destruction.
– Fit rope clamp (2).
CAUTION
Tighten to the specified tightening torques.
Incorrectly tightened bolts may loosen or break off.
– DR 5 rope clamp tightening torque: 6 Nm
Range Rope clamp tightening torque [Nm]

DR 5 6
DR 10 33
Tab. 31
214 961 44/141212
65
Fitting the rope socket in the 2/1 crosshead
CAUTION
Danger resulting from incorrect assembly
Ensure that the components are correctly arranged and check fit of double spring clip (3).
– Insert the pin with collar sleeves (5) through crosshead (9), lever (8) and rope socket (7) as shown in the
diagram.
– Fit washer (4) and secure pin (6) with double spring clip (3).
6.5.5.2 4/1 reeving
1 2
4
5
6
43248344.eps
Fig. 48
1 Double spring clip 5 Rope sheave in bottom block

2 Rope socket 6 Rope sheave in bottom block
3 Rope clamp 7 Compensating sheave/return sheave
4 Rope drum
Replacing the rope requires utmost care and a lot of experience. We recommend that the rope be replaced by
Demag service engineers or an authorised specialist company.
1. Slide the loose rope end on rope drum (4) through a rope sheave in bottom block (6).
2. Then lay the rope end over compensating sheave (7).
3. Slide the rope end through the second rope sheave of bottom block (5).
214 961 44/141212
66
Rope arrangement in bottom block
43297444.eps
Fig. 49
– The rope is led into and out of the protective cover through the bore holes (arrows). Push the plastic protec‐
tive covers fully down (shown on the left) when the rope is fitted.
9
8
3 4 5 5 6
3
1
6
4
7
7
2 2 10
43238344.eps
Fig. 50
1 Rope wedge 6 Pin

214 961 44/141212
67
CAUTION
CAUTION

DR 5 6
DR 10 33
Tab. 32
CAUTION
diagram.
– Fit washer (4) and secure the pin with double spring clip (3). 214 961 44/141212
68
6.5.5.3 4/2 reeving
4
3
43248444.eps
Fig. 51
1 Rope drum 4 Bottom block sheave

2 Wire rope 5 Compensating sheave
3 Bottom block sheave
Installing the rope requires utmost care and a lot of experience. We recommend that this work be carried out by
214 961 44/141212
69
Fitting the bottom block for 4/2 reeving
● Fitting the bottom block with cable grip for assembly (1) (part no.:
8 mm - 15 mm dia. 713 990 45)
● Introduce cable grip (1) into bottom block (3).
43238044.eps
Fig. 52
214 961 44/141212
70
● Insert wire rope (2) into the cable grip.
2
● Push the wire rope through one side of the bottom block together
with the cable grip.
Do not pull the cable grip.
● Guide the wire rope through compensating sheave (5,  Fig. 51,
Page 69) and into the second sheave of bottom block (4,  Fig. 51,
3
Page 69).
● Remove the cable grip from the end of the rope.
● Secure the end of the rope to the other end of rope drum (1) with
rope clamps  "Securing the end of the rope, more than one
groove", Page 71.
43238144.eps
Fig. 53
Securing the end of the rope, more than one groove
See section  "Fitting the rope, more than one groove", Page 96
214 961 44/141212
71
6.5.5.4 6/1 reeving, EZDR-Pro 10
1 2
3
4
6 5
43248544.eps
Fig. 54
1 Double spring clip 4 Wire rope

3 Rope drum 6 Rope clamp
Follow the steps described below with the loose end of the rope to reeve the rope for 6/1 reeving (see diagram for
rope routing arrangement):
1. Guide the end of the rope through outer sheave (1) of the bottom block (without removing the bottom block
cover).
6
2
4
1 5
3
214 961 44/141212
43248644.eps
Fig. 55
72
2. Guide the end of the rope over first sheave (2) of the top block.
3. Guide the end of the rope over centre sheave (3) of the bottom block.
4. Guide the end of the rope over second sheave (4) of the top block.
5. Guide the end of the rope over third sheave (5) of the bottom block.
6. Secure the end of the rope in rope socket (6) of the anchorage on the frame,  "Fitting the rope socket for
6/1", Page 73.
7. Wind up the rest of the rope by turning the drum in the lifting direction.
8. Check the setting of the limit switch for the lifting motion and adjust, if necessary,  "Set the upper cut-out
points", Page 77, see hook dimension ‘C’.
9
8
3 4 5 5 6
3
1
6
4
7
7
2 2 10
43238344.eps
Fig. 56
1 Rope wedge 6 Pin

5 Collar sleeve 10 Rope
CAUTION
214 961 44/141212
73
CAUTION
– Rope clamp tightening torque: 33 Nm

DR 10 33
Tab. 33
CAUTION
diagram.
– Fit washer (4) and secure the pin with double spring clip (3).
214 961 44/141212
74
6.6 Putting into operation for the first time
6.6.1 Checks before putting the unit into operation for the first time
The owner is obliged to carry out the following checks before putting the unit into operation for the first time,
 "Regular inspections", Page 17.
Activity See section Check

Check oil level in the hoist gearbox of the rope hoist  "Gearbox oil filling", Page 24 x
Check rope securing devices and rope guide KD14) x
Check strain relieving elements, control cable and control pendant housing for  "Connecting the control cable", Page 59 x
damage
Check spring tension of supporting roller and plastic coat of supporting roller  "Assembly and alignment of the travel‐ x
bearing ling hoists", Page 42
Check electrical switchgear and wiring  "Wiring", Page 58 x
Check operation of the limit switch  "Switching on", Page 81 x
Check operation of the brake  "Check operation of the brake", x
Page 83
Check operation of overload protection device KD14) x
Check lubrication of rope  "Wire ropes", Page 88 x
Check hook and hook safety catch  "Regular inspections and monitoring x
measures for load hooks", Page 98
Check with an overload of 125%  "Overload test with 125%", Page 79 x
Tab. 34
6.6.2 Inspection regulations

Inspection before putting the product into operation for the first time:
● If hoist units are used as cranes, an inspection must be carried out by an expert engineer in accordance with
relevant accident prevention regulations (BGV D6, Section 25) for cranes.
● Hoist units used in accordance with relevant accident prevention regulations for winches, hoists and towing
devices (BGV D8) must be inspected by an experienced technician.
The inspection in accordance with BGV D8 mainly consists of a visual inspection and a function check. It is de‐
signed to ensure that the equipment is in a safe condition and that any defects and damage, e.g. caused by inap‐
propriate handling during transport, are identified and repaired.
In addition, regulations specific to cranes must also be taken into consideration during acceptance and other in‐
spections in accordance with relevant accident prevention regulations for cranes (BGV D6).
6.6.3 Geared limit switch
6.6.3.1 Geared limit switch function

The geared limit switch is fitted in the electrical equipment enclosure of the Demag DR rope hoist. It switches off
the rope hoist when the top or bottom hook position is reached. The direction of movement can be reversed. The
emergency limit switch must not be approached in normal operation. The emergency limit switches trigger the
emergency stop function.
Operating limit switches (optional) are required if the end positions are approached regularly during normal opera‐
tion. In such cases, the switches must be adjusted so that the operating limit switch is actuated first and then, i.e.
if this fails to operate, the emergency limit switch is actuated. The operating limit switch only switches the hoist
unit off.
work. This can be done by using the 2-stage button of the DSE-10R control pendant.
214 961 44/141212
The key-operated button must be pressed to move the hook back out of the end position (lowering).
14) KD = After-sales service 75

Geared limit switch adjustment
1 2
43239444.eps
Fig. 57
1 "Block" adjusting screw

2 "Individual" adjusting screw
A 4 mm hexagon socket key is needed to adjust the geared limit switch.
WARNING
Live components
Before setting the switching points, make sure that live contacts are provided with a guard to protect against ac‐
cidental contact. Allow for run-on.
Operating principle
Each contact is allocated to a cam disk which is infinitely adjustable. The cam disks can be adjusted independent‐
ly by means of "individual" adjusting screws (2).
Adjustment
When ‘individual’ adjusting screw (2) is turned clockwise, the cam disk is also turned clockwise. The switching
point is shifted upwards in accordance with the hook path.
When the screw is turned anti-clockwise, the switching point is shifted downwards. Standard cam disks are de‐
signed in such a way that a maximum useful path and a run-on path are available.
Adjusting individual contacts (2)
The geared limit switch is already permanently connected with the control system via the system connector cable.
Move the load hook of the rope hoist into the specified cut-off position (see section 8.1.1, table 1 for cut-off
points). Turn the "individual" adjusting screw until the contact maker opens the contact to adjust the contacts.
If the run-on path is exceeded, the contact either opens or closes.
Adjusting blocks of contacts (1)
The contacts are adjusted in blocks by means of "block" adjusting screw (1). All cam disks are adjusted together,
while the relative adjustment of the individual contacts remains unchanged. When the "block" adjusting screw is
turned clockwise, the cam disks are also turned clockwise.
For adjustment, please note:
● The geared limit switch is adjusted before leaving the factory to avoid complete unwinding of the rope, only.
214 961 44/141212
● Approach cut-out points several times to check the limit switch functions are operating correctly.
76
6.6.3.2 Setting the cut-out points
The emergency limit switches must be properly adjusted to ensure that accidents are prevented and to avoid
damage to the rope hoist. The emergency limit switches are adjusted before leaving the factory to avoid complete
unwinding of the rope, only. Following installation of the rope hoist, they must be readjusted and checked for the
particular operating conditions.
If you want to set the maximum possible lifting height for your specific operating conditions, the following must be
observed:
● The emergency limit switch for the top hook position must be set so that dimension C is reached when the
switch cuts off the lifting motion, see  "Hook dimension C", Page 24.
● The emergency limit switch for the bottom hook position must be set so that the load hook does not touch the
floor.
The cut-out points of the geared limit switch have already been set to default values when the machine leaves our
factory.
If non-default values are to be set for the cut-out points, proceed in the sequence described in the following.
6.6.3.3 Set the upper cut-out points
WARNING
Incorrect setting
Commissioning work may only be carried out by qualified specialist personnel in compliance with the safety reg‐
ulations. Safety devices must not be rendered inoperative when the unit is put into service. When the unit is first
put into operation, the following must be observed:
– Secure and fence off the working and danger zone.
– Determine the cut-out points for the emergency and operating limit switches (optional)  Tab. 19, Page 24.
– Adjust the cut-out points on the geared limit switch (emergency limit switch and operating limit switch).
CAUTION
Note function of the cut-out positions
The cut-out points must be adjusted so that the operating limit switch (optional) is actuated first and then, i.e. if
this fails to operate, the emergency limit switch is actuated.
– Emergency limit switches must not be approached in normal operation.
– For standard equipment (without operating limit switch):

Adjust dimension C setting for the top hook position. Determine the distance based on the tables  "Hook
dimension C", Page 24.
C
214 961 44/141212
43248744.eps
Fig. 58
77
– For units fitted with emergency and operating limit switches (optional):
The upper emergency-stop cut-off point (emergency limit switch) must be adjusted in such a way that the
permissible cut-off point setting is maintained when the lifting motion has been switched off by the emergen‐
cy limit switch. Determine hook dimension C based on the tables  "Hook dimension C", Page 24.
– Adjust dimension C setting for the top hook position (operating limit switch). Determine the distance based
on the tables  "Hook dimension C", Page 24.
43248744.eps
Fig. 59
6.6.3.4 Set the lower cut-out points
CAUTION
Incorrect adjustment
Ensure that the minimum number of retaining windings are wound on the drum when setting the bottom hook
position.
Range Required rope windings on the drum

2/1, 4/1, 6/1 reeving 4/2 reeving
EZDR-Pro 5
3 3.5
EZDR-Pro 10
Tab. 35
– Use the control pendant to set the bottom hook position for the emergency limit switch so that the load hook
does not touch the floor.
– Set the cut-out points (see above).
214 961 44/141212
78
6.6.4 Overload test with 125%
The switch setting for the overload test is located under the equipment
cover.
789 ● After DIP switch 6 has been switched from OFF to ON, the overload
protection device is de-activated for 15 minutes and limited to 146%
456
AB
CDE so that the crane acceptance test can be carried out at 125%.
23
F0 1
● After 15 minutes or every time the hoist unit is switched off and on
(start-up of the control system) or after switch 6 is reset to OFF, the
789 overload protection device (110%) becomes active again.
456
AB
All DIP switches are set to OFF by default.

CDE
23
F0 1
789
456
AB
CDE
23
F0 1
1
8
7
6
5
4
3
2
ON
43239544.eps
Fig. 60
6.6.5 Travelling hoist travel characteristics and run-on paths when stopping
Small cross-travel movements that can occur when the travelling hoist is braked are caused by load sway. How‐
ever, this results in a reduction of load sway.
This effect is referred to as passive load-sway reduction and is not critical for the travelling hoist or crane.
214 961 44/141212
79
7 Operation
WARNING
Inappropriate operation
Incorrect operation may result in severe injury or damage to property.
The machine may only be operated by authorised and instructed personnel in compliance with all accident-pre‐
vention and safety regulations.
– National regulations for the use of cranes and lifting appliances must be observed and followed.
WARNING
Danger if care obligations are neglected
Danger to life and limb if the machine is operated with little care.
Requirements for operating the machine include:
– All installation/assembly work has been carried out according to the operating instructions.
– The rope must be adequately lubricated.
– The rope must be in good condition. Operation with defective or damaged ropes results in a high risk of
accidents with personal injuries and is therefore prohibited. Risk of damage to the machine.
– Any changes or modifications which prejudice safety must be reported to the nearest person responsible
immediately.
– Repairs may only be carried out by experienced technicians.
WARNING
Falling loads
Any person remaining in this danger zone may suffer serious injury or death.
Only use suitable and tested load handling attachments.
– Observe the operating instructions for the load handling attachment.
– Do not exceed the maximum permissible load capacity of the load handling attachment.
– Do not transport loads above people when using load handling attachments that retain the load by means
of magnet, friction or suction forces without an additional load securing device.
Before starting work:

● Put on protective clothing.
● Ensure that nobody is present in the danger zone of the machine.
● Check operation of the brakes, emergency limit stop devices and emergency stop devices.
During operation:
● Do not approach emergency limit stop devices (e.g. emergency limit switch) in normal operation.
● Do not render safety devices inoperative.
● Adopt a position that ensures a clear view of the danger zone for lifting and travel motions.
● Never touch the ropes while the machine is in operation.
WARNING
Damaged components/malfunctions on the machine
In the event of obvious defects or malfunctions, stop the machine without delay and secure it against switching
on again.
214 961 44/141212
80
CAUTION
Danger due to premature wear/corrosion
Corrosion on plastic (identifiable by dull, sooty or brittle surfaces) and metal components in enclosed switchgear
housings can be caused by too frequent inching. Corroded parts must be replaced in good time.
Advise operators to avoid inching (i.e. giving short pulses to the motor to obtain small movements) as far as pos‐
sible, e.g. when attaching a load. It may cause excessive wear and premature failure of the switchgear.
7.2 Switching on
7.2.1 Checks when starting work
The operator is obliged to carry out the following checks before starting work ( "Regular inspections", Page 17):
Activity Section Check

Visual check  "Visual check", x
Page 81
Check operation of the limit switch  "Check the limit x
switches", Page 82
Check strain relieving elements, control cable and control pendant housing for damage  "Check strain relief el‐ x
ements", Page 82
Check operation of the brake  "Check operation of x
the brake", Page 83
Check hook and hook safety catch  "Check hook safety x
catch", Page 83
Check rope for damage and broken wires  "Discarding the wire x
rope", Page 89
Tab. 36
7.2.2 Visual check

– Check the machine to ensure it is complete. Do not operate the machine if parts have been removed (cov‐
ers, limit stop buffers, ...).
– Check the machine for any visible external damage.
214 961 44/141212
81
7.2.3 Check the limit switches
1. By-pass the operating limit switch by pressing test button (4).
2. Approach the emergency limit switch using motion axis control buttons (3).
3. Simultaneously actuate test button (4) and motion axis control buttons (3) to back away from the emergency
limit switch.
43239744.eps
Fig. 61
7.2.4 Check strain relief elements

– Carry out a visual inspection of the strain relief elements:
The strain relief cords must be firmly attached. No forces must act on the connector when the control pend‐
ant is moved.
43241844.eps
Fig. 62
214 961 44/141212
82
7.2.5 Check operation of the brake
– Raise the load hook and lower it again. The load hook must only run on a short distance when the button is
released.
The load hook must stay at the same height (i.e. it must not lower without a button being actuated) when a
load is attached to it.
Significant run-on or lowering when in the idle position indicates that the brake is worn.
– Make the unit travel to the right/left. Braking of the travelling hoist must be clearly noticeable when the button
is released.
It must not be possible to move the travelling hoist by pulling the ropes to the side.
Significant run-on or the possibility of moving it when in the idle position indicates that the brake is worn.
– Brake linings must be inspected once a year, ⇒ also assembly instructions 214 228 44.
WARNING
Only operate the machine when it is in safe operating condition.
If inspection reveals that a brake slips, the brake must be adjusted or repaired. Do not operate the machine if the
brake slips.
7.2.6 Check hook safety catch
Check the hook safety catch  "Regular inspections and monitoring measures for load hooks", Page 98.
214 961 44/141212
83
7.3 Control pendant switch assignment
The motion directions of the crane/load hook are clearly identified with
fixed symbols regardless of the control pendant type:
Lower load
Lift load
Cross travel to the left
Cross travel to the right
Crane travel backwards
Crane travel forwards

F1/F2: Refer to the control pendant operating instructions for switch as‐
signment
43297844.eps
Fig. 63
7.4 Switching off

1. When work has been completed, position the unloaded bottom block outside the travel area.
2. Press emergency-stop button (1). The emergency-stop button is unlocked by turning it.
3. Switch off the power supply at the mains connection or isolating switch.
43249844.eps
Fig. 64
7.5 Stopping operation in an emergency

1. Press emergency-stop button (1).
214 961 44/141212
43249844.eps
Fig. 65
84
8 Maintenance

The following sections contain a description of maintenance work that is necessary for optimum and uninterrupted
operation of the machine.
WARNING
Risk of injury.
Incorrect maintenance work may result in severe injury or damage to property.
Maintenance work may only be carried out by authorised and instructed specialist personnel in compliance with
all safety regulations.
DANGER
Live components
Electric current may cause danger to life and limb.
Work on electrical equipment may only be carried out by qualified personnel in compliance with the safety regu‐
lations.
Always:
1. Wear personal protection equipment.
2. Fence off the working area.
3. Before starting work, switch off the machine and secure it against switching on again.
4. Switch off the power supply at the mains connection or isolating switch. Check that the system is de-ener‐
gised.
5. Ensure that there is sufficient freedom of movement.
6. Parts of the body can be crushed when working on the machine. Secure the machine/machine parts against
unintended movement and work with the utmost care and caution.
7. Keep the working area clean and tidy. Loose parts or tools left lying around may cause accidents.
8. Reinstall safety devices as required by relevant regulations and check them for correct operation after finish‐
ing maintenance work.
9. Only use genuine Demag spare parts.
CAUTION
Lubricants/oils
Risk of injury resulting from contact with the body/skin. Oils and lubricants are a health hazard.
Contact with these media may result in serious damage to health (poisoning, allergies, skin irritation, etc.)
– Pay attention to the manufacturer's safety data sheets and instructions.
CAUTION
Risk of injury. Risk of slipping.
Leaking oils and lubricants are hazards due to the increased risk of slipping.
Spilt oils and lubricants must be absorbed immediately by means of sawdust or oil absorbent and disposed of in
an environmentally compatible way.
214 961 44/141212
85
Hoists and cranes must be inspected by an experienced technician at least once a year. Regular inspections
mainly consist of a visual inspection and a function check which should include a check to determine the condition
of components and equipment regarding damage, wear, corrosion or other alterations and a check to determine
the integrity and efficiency of safety devices.
It may be necessary to remove parts in order to inspect wearing parts.
Load-bearing media and suspensions must be inspected along their entire length, including those parts which
cannot normally be seen. A function and brake test with a load (test load that is close to the maximum permissible
load capacity) must be carried out.
Updating the test and inspection booklet
● The owner must arrange for all inspections to be carried out and documented in the hoist or crane test and
inspection booklet.
8.3 Maintenance schedule

The specified inspection and maintenance intervals apply to normal operating conditions. If routine maintenance
reveals that the intervals are too long, they should be shortened according to the specific operating conditions.
Check before putting into operation, before starting work and during operation
Activity See section Before the Before start‐ Every 6 Once per
unit is first ing work months year
put into oper‐
ation
Check rope securing devices and rope guide  "Fitting the rope, single
X X X
groove", Page 91
Check spring tension of the support roller and  "Assembly and alignment of
X X
plastic casings of the support roller bearings the travelling hoists", Page 42
Check electrical switchgear and wiring  "Connecting the electrical
X X
equipment", Page 58
Check operation of the limit switch  "Check the limit switches",
X X X
Page 82
Check strain relief elements, control cable and  "Check strain relief ele‐
X X X
control pendant housing for damage ments", Page 82
Check operation of the brake  "Check operation of the
X X X
brake", Page 83KD15)
Check operation of overload protection device KD 15) X X
Check condition of the brake lining KD 15) X
Check lubrication of rope  "Lubricating the wire rope",
X X
Page 97
Check hook and hook safety catch  "Regular inspections and
monitoring measures for load X X X
hooks", Page 98
Check rope for damage and broken wires  "Discarding the wire rope",
X X
Page 89
Tab. 37
214 961 44/141212
86 15) The inspection may only be carried out by Demag Customer Service or by authorised specialist personnel.
Check during operation
put into oper‐
ation
Check adhesive lubricant in bearing points of
return sheaves, crossheads, compensating  "Reeving methods for the
X
sheaves and pins of rope anchorage, re-grease rope hoist", Page 61
as required
Check suspension of the rope anchorage,
check play of the setbolt/pin in counter bore  "Reeving methods for the
X
hole for the retaining plate. rope hoist", Page 61
Check spring clip for correct fit.
Check brake displacement, adjust as required KD 15) X X
X
Check all connections (bolts, weld seams etc.) KD 15) X
Check rope securing devices and play of rope  "Reeving methods for the
X
guide on drum rope hoist", Page 61
X X
Page 89
Lubricate rope  "Lubricating the wire rope",
X
Page 97
Check load hooks for cracks, deformation and  "Regular inspections and
wear monitoring measures for load X
hooks", Page 98
Check hook safety catch for deformation  "Regular inspections and
monitoring measures for load X
hooks", Page 98
Check wear of the travel wheels  "Travel wheel wear",
x
Page 99
Check bottom block KD 15) X
Check securing elements (clips, bolts, etc.) for
KD 15) X
tight fit and corrosion
Check and apply or supplement corrosion pro‐
KD 15) X
tection, as required
Change oil in main hoist gearbox/cross-travel
Every 8 - 10 years
gearbox
Check plastic components of the limit switch for
KD 15) X
corrosion
Check electrical enclosure seals KD 15) X
Check condition of all buffers KD 15) X
Check power supply lines (main and crab pow‐
er supply). For current collectors: Check sliding
KD 15) X
contacts and travel rollers for wear and sliding
contacts for contact pressure
DRS wheel block: Check travel wheel wear and
 214 276 44 X
bolted connections
Tab. 38
WARNING
Danger due to incomplete maintenance.
Danger to life and limb since safe operation of the machine is not ensured.
– Carry out all specified maintenance work appropriately and in time.
– Please contact Demag Customer Service for any work that you cannot carry out yourself.
– Make sure that the entries in the test and inspection booklet of the crane installation are complete.
General overhaul (GO)

214 961 44/141212
The general overhaul should coincide with the annual inspection On reaching the theoretical duration of service
Fit rope hoist-specific Demag GO set X
Tab. 39
87
8.4 Wire ropes
Construction, application and reeving of wire ropes
Range DR-Pro 5
Reeving arrangement 2/1 4/1 4/2
Hook path [m] 12 20 6 10 9.9
Rope structure 16) 17) 16) 17) 16) 17) 16) 17) 16)
Group of 2m/M5 X X X X X
mechanisms to 3m/M6 X X X X X
FEM/ISO 4m/M7 X X X X X
Wire rope di‐
[mm] 9 9 9 9 7
ameter
Theoretical approx.
76.67 91.70 76.67 91.70 76.67 91.70 76.67 91.70 45.8
breaking force [kN]
Minimum
[kN] 63 79.30 63 79.30 63 79.30 63 79.30 39.8
breaking force
[N/
Rope grade 1960 2160 1960 2160 1960 2160 1960 2160 1960
mm²]
Rope length [m] 27.3 43.45 28.1 44.3 46.8
Tab. 40
Range DR-Pro 10
Reeving arrangement 2/1 4/1
Hook path [m] 12 20 40 6 10 20
Rope structure 16) 18) 16) 18) 19) 16) 18) 16) 18) 16) 18)
Group of 2m/M5 X X X X X X
mechanisms to 3m/M6 X X X X X X
Wire rope di‐
[mm] 13 13 13 13 13 13
ameter
Theoretical approx.
164.93 197.9 164.93 197.9 170.3 164.93 197.9 164.93 197.9 164.93 197.9
breaking force [kN]
Minimum
[kN] 132 166.2 132 166.2 129.8 132 166.2 132 166.2 132 166.2
breaking force
[N/
Rope grade 1960 2160 1960 2160 1960 1960 2160 1960 2160 1960 2160
mm²]
Rope length [m] 28.25 44.25 84.5 29.3 45.25 85.25
Tab. 41
Range DR-Pro 10
Hook path [m] 6.7 13.3 6.7 13.3 5.8 11.35 25.2
Rope structure 16) 16) 18) 18) 16)
Group of 2m/M5 X X X
mechanisms 3m/M6 X X X
to FEM/ISO 4m/M7 X X X
Wire rope di‐
[mm] 13 13 9
ameter
Theoretical approx.
164.93 197.9 76.67
breaking force [kN]
Minimum
[kN] 132 166.2 63
breaking force
Rope grade [N/mm²] 1960 2160 1960
Rope length [m] 48.7 88.5 48.7 88.5 31.6 53.8 109.2
Tab. 42
214 961 44/141212
16) Rope structure: 8 x 19 with IWCR steel rope core, LH = left hand ordinary lay rope, bright surface, with pressure sleeve on one end.
19) Rope structure: 16 x 7 with IWCR steel rope core, RH = right hand ordinary lay rope, bright surface, with pressure sleeve at the drum end, with
88 swivel on the free end.
8.5 Discarding the wire rope
The following information on the assessment and maintenance of wire ropes has been compiled on the basis of
German, European and international standards as well as relevant trade literature and is to be regarded only as
the most significant information that is not intended to be complete, but to help the owner of a Demag rope hoist
to become familiar with the subject of ‘Discarding wire ropes’. Furthermore, all national standards, regulations or
any legislation of other countries must be fulfilled and considered together with the above information or they take
priority, as applicable.
Assessment of the discard criteria of wire ropes requires many years of experience and expert knowledge. An
assessment may only be carried out by a Demag service engineer or by a corresponding specialist.
A visual check must always be carried out over the entire length of the rope, including points which cannot nor‐
mally be seen, critical points must be inspected with particular care and attention.
CAUTION
Risk of injury
Risk of injury due to possibly broken wires.
Always wear protective gloves when checking wire ropes.
In order to discover broken strands more easily, the load must be removed from the unit and the rope bent man‐
ually along its entire working length. Run the rope through your hand, which must be protected by a thick glove.
The bending radius should be approximately that of the rope sheaves,
A wire rope must be discarded when its condition is no longer considered to be safe for further operation:
● If there are any structural changes, such as swelling, loosening.
The installation must be stopped immediately if this type of damage occurs.
● When the number of visible broken load-carrying wires in the external strands at the worst spot has reached
the following figures, counted over a reference length of rope of 6 times or 30 times the rope diameter, which‐
ever gives the worst result  Tab. 43, Page 90.
Critical points, for example, include:
1. Rope zones subject to the highest number of alternating bending cycles and in particular to alternative de‐
flection. This also applies to rope zones on compensating sheaves which are subject to a very high number
of reversed bending cycles due to rope swing or uneven winding on rope drums. These rope sections show
increased abrasion and a higher number of broken wires.
2. The zones in which loads are picked up, i.e. rope zones which are on a rope sheave at a preferred load pick-
up point or rope zones which are wound onto or off a rope drum.
3. Rope anchorages that subject the wire rope to a load in addition to normal tensile load. Vibrations in the tran‐
sition area and moisture penetrating into the rope anchorage result in corrosion and broken wires.
4. Rope zones on rope drums. The load pick-up point on the rope drum is subject to increased wear (abrasion,
broken wires and/or structural changes).
5. Rope zones exposed to aggressive media, general weather conditions or high temperatures. Observe the
specifications of the manufacturer of the wire rope and the lubricant used.
The rope may be replaced by Demag service engineers or an authorised specialist company.
214 961 44/141212
89
Wire rope used Group of mechanisms to FEM/ISO
2m/M5, 3m/M6, 4m/M7 2m/M5, 3m/M6, 4m/M7
Rope dia. [mm] Rope structure Number of broken wires over a rope length of Number of broken wires over a rope length of
6 x rope diameter 30 x rope diameter
No. of Rope length No. of Rope length
broken wires [mm] broken wires [mm]
7 42 210
9 20) 13 54 26 270
13 78 390
7 42 210
21) 14 28
9 54 270
13 22) 21 78 42 390
13 23) 10 78 20 390
Tab. 43
8.6 Wear limits on rope sheaves
43240444.eps
Fig. 66
Size Reeving Groove root dia. Rope dia. Min. flange plate thickness Max. depth of strand im‐
[mm] [mm] tmin pressions
[mm]
2/1, 4/1 182 9 5.6 0.5
DR 5
4/2 225 11 5.3 0.4
230 5.6
2/1, 4/1
13 6.3 0.7
DR 10 280
6/1 3.5
4/2 225 11 4.6 0.5
Tab. 44
The cross section of the rope groove must not be less than the specified minimum dimension tmin at any position.
Negative impressions in the rope groove must not exceed the specified maximum dimension.
214 961 44/141212
8.7 Fitting the rope, single groove
8.7.1 Unwind rope
43297544.eps
Fig. 67
CAUTION
Cutting hazard
DANGER
Pre-tensioned components
Pay attention to the following hazards when replacing wire ropes:
– Crushing hazard/cutting hazard
– Shearing hazard
– Hazards arising from gripping or winding
– Hazards arising from drawing-in or entanglement
Before a rope is reeved, the whole length of the rope should be rolled out on the ground. Any twisting of the rope
should be strictly avoided.
214 961 44/141212
91
Securing the end of the rope
1. 2. 3.
4. 5. 6.
7. 8.
43336444.eps
Fig. 68
1. Attach the retaining clip

2. Insert the rope anchorage
3. Attach the rope
4. Close the retaining clip
5. Press the retaining clip into the guide slot of the rope anchorage
214 961 44/141212
6. Fit the hose clamp

7. Tighten the hose clamp
92 8. Check the tight fit of the retainer.

Wind approx. 4 turns of the rope tightly round the drum. To do this, switch on the hoist motor lifting motion and run
the rope through your hand, which must be protected by a thick glove.
Care must be taken to keep the rope tight and not to twist it while reeving.
Then fit the rope guide.
Preparing the rope guide
7
8
9
X 5
6
4
9
43240944.eps
Fig. 69
4 Section with inserted lock nuts 8 Hexagon nut with flange

5 Segment with rope guide rollers 9 Socket head bolt
6 Segment X Rope guide on the connecting rod  Fig. 70,
7 Hexagon bolt Page 93 (11)
– Disassemble rope guide
Fitting the rope guide
4 5
4 11
6
5
214 961 44/141212
43241044.eps
Fig. 70
93
– Fit the guide of side section (4) on connecting rod (11) – side section (4) rests on the wire rope – see dia‐
gram.
– Place the two segments (5+6) over the rope drum from above. Fit segment with rope guide rollers (5) with
the rollers pointing towards the wire rope on the drum.
– Slide the rope guide sideways until it rests in the empty groove next to the rope on the drum.
The rope guide rollers must now lie over the wire rope.
Fastening the rope guide on the drum
8 7 6 Nm
43241144.eps
Fig. 71
CAUTION
Loose connections
– Tightening torque = 6 Nm
– Fasten the rope guide with hexagon bolt (7) and hexagon nut with flange (8).
Tightening torque = 6 Nm
– Check:
It must be possible to move the fitted rope guide on the drum by hand.
214 961 44/141212
94
Attaching the rope guide to the connecting rod
6 Nm
4 9
10
43241244.eps
Fig. 72
– Slide the rope guide until the bore holes in the segment with guide rollers (5) coincide with the bore holes in
side section (4).
CAUTION
Loose connections
– Insert the two socket head bolts (9) and secure using side section (4).
– Lift the rope guide rollers with a screwdriver to press them against the rope.
– Remove split pin (10).
214 961 44/141212
95
8.8 Fitting the rope, more than one groove
8.8.1 Unwind rope
43297544.eps
Fig. 73
CAUTION
Cutting hazard
DANGER
– Shearing hazard
8.8.2 Fitting the rope, more than one groove
Fitting the rope anchorage
Attaching the rope,  "Securing the end of the rope", Page 92 .

Introducing the rope
– Slide the other end of the rope through a rope sheave in the bottom block using the cable grip,  "Fitting the
bottom block for 4/2 reeving", Page 70.
– Then guide the wire rope through the compensating sheave and through the second sheave of the bottom
block.
214 961 44/141212
96
Fastening the rope on the drum
A B
40 Nm
43334844.eps
Fig. 74
A Rope anchorage on the gearbox side

B Rope anchorage on the switchgear-box side
CAUTION
Loose connections
Secure the end of the rope to the rope drum with rope clamps (B).
– Remove the cable grip from the end of the rope and fasten the end of the rope to the other end of the rope
drum with rope clamps (1).
– Wind approx. 4 turns of the rope tightly round the drum. To do this, switch on the hoist motor lifting motion
and run the rope through your hand, which must be protected by a thick glove.
– Then fit the rope guide  "Fitting the rope guide", Page 93
8.9 Shortening the wire rope

The rope must not be cut or shortened at or separated from aluminium end sleeve (2) or the twisted rope end. If,
in exceptional cases, it is necessary to shorten the wire rope, this must be done in compliance with engineering
standards.
8.10 Lubricating the wire rope

Grease the rope with a suitable lubricant and preservative, e.g. Cedracon. Ensure that the agent reaches the inte‐
rior of the rope structure, part no. 665 013 44.
Grease the bearing points of the top block, crosshead, compensating sheave, the pin of the rope anchorage and
the guide rod of the rope guide with a suitable adhesive lubricant, part no. 472 933 44.
214 961 44/141212
97
8.11 Regular inspections and monitoring measures for load hooks
If a check or inspection reveals that these components are worn beyond the dimensions shown in  Fig. 75,
Page 98 and the table, or if deformations and cracks can be seen in these parts, the affected parts must be
replaced at once with genuine spare parts.
Load hook inspection
Range DR 5 DR 10
Reeving 2/1, 4/2 4/1, 6/1 2/1, 4/2 4/1, 6/1
a2 Group of mecha‐ 1Am/M4 ... 2m/M5 ... 1Am/M4 ... 4m/M7
a nisms to FEM/ISO 4m/M7 4m/M7 3m/M6
Hook size 1.6 2.5 2.5 4 5
a Hook opening 40 41 41 49 55
a1 56 63 63 71 80
a2 Nominal dimen‐ 45 50 50 56 63
a1
sion 24)
a2 Maximum dimen‐ 49.5 55 55 61.6 69.3
sion
h2
h2 Nominal dimen‐ 48 58 58 67 75
sion25)
43240044.eps
h2 Minimum dimen‐ 45.6 55.1 55.1 63.6 71.2
Fig. 75 sion
Tab. 45
Check the hook safety catch for correct operation and for any damage.
214 961 44/141212
24) Permissible variation: +10%

98 25) Permissible variation:-5%
8.12 Travel wheel wear
DRS 125, 160
s s
d1
43312644.eps
Fig. 76
➨ Wear indicators
The wear indicator on the flange facilitates preventive inspections of the installation.
The travel wheel must already be replaced even if only one segment of the wear indicator is open, as shown in
the lower part of the diagram.
Tread wear
Travel wheels must be replaced when the following limit values are reached:
Travel wheel rated diameter Remaining smallest flange width s Smallest travel wheel diameter Maximum difference in travel
d1 wheel diameters for coupled
wheels
[mm] Dimensions in [mm]
125 6.0 18.4 0.1
160 7.0 153.4 0.15
Tab. 46
The new wheel blocks have to aligned horizontally when wheel blocks are replaced. They must be aligned using
214 961 44/141212
adjusting tools/jigs,  "Aligning the travelling hoist on the crane", Page 42.
99
8.13 Oil change
The hoist and travel gearboxes are filled with the required quantity of lubricant before leaving the factory. In nor‐
mal cases, it is not necessary to change or supplement it.
Gearbox filling quantities  "Gearbox oil filling", Page 24.
CAUTION
Oil leaks are an operating hazard.
Oil leaks/loss of oil in the course of operation may cause damage to or total failure of the machine. If this occurs,
stop the machine and notify Service.
8.14 General overhaul (GO)

The owner is obliged to carry out a general overhaul when the theoretical duration of service is reached ( "Reg‐
ular inspections", Page 17):
WARNING
Operating safety at risk
Specified general overhaul intervals must be strictly complied with.
When 90% of the theoretical duration of service has elapsed – after 8 to 10 years if the hoist is correctly classified
– the owner must arrange for a GO general overhaul to be carried out. A general overhaul must be carried out by
the end of the theoretical duration of service.
During the general overhaul, the following parts must be replaced in addition to the checks and work specified in
the inspection and maintenance schedule:
● Gear wheels of the gearbox
● Gearbox bearings
● Motor
● Rope drum
● Gear oil
● Connecting elements
● Switchgear in the control system
The small parts (screws, washers ...) to be replaced when maintenance and assembly work is carried out are not
listed separately.
Therefore, the provisions of the relevant UVV accident prevention regulations and BGV D8 are satisfied.
The installation may continue to be used when an expert engineer has entered the conditions for further utilisation
into the test and inspection booklet. Completion of the general overhaul must be confirmed in the test and inspec‐
tion booklet and a further period of utilisation in accordance with FEM 9.755 must be entered.
The general overhaul may be carried out by Demag expert engineers or an authorised specialist company.
● The general overhaul carried out by the manufacturer or a specialist company authorised by him satisfies the
requirement to be met for continued operation of the machine.
214 961 44/141212
100
9 Malfunctions
WARNING
Risk of injury.
Incorrect elimination of malfunctions may result in severe injury or damage to property.
Malfunctions may only be eliminated by authorised and instructed specialist personnel in compliance with all
safety regulations.
DANGER
Live components
lations.
9.2 Conduct when malfunctions occur

Always:
1. Bring 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. Disconnect the machine from the power supply and secure the machine against reconnection.
3. Inform the person responsible at the location about the malfunction.
4. Have the malfunction and the cause of the malfunction identified and eliminated by authorised specialist per‐
sonnel.
9.3 Conduct after malfunctions have been eliminated
WARNING
Putting into operation again
Before switching on again, check that:
– Malfunction and cause of malfunction have been eliminated.
– All safety devices have been fitted properly and are in perfect condition and working order.
– Nobody is present in the danger zone of the machine.
214 961 44/141212
101
9.4 Malfunctions, causes and remedy
The control system of the DR rope hoist is provided with an intelligent self-diagnosis and fault-finding system.
Warning and error messages are shown direct in the display of the DSE-10R control pendant and/or by means of
acoustic signals.
If a fault occurs, the following instructions for finding faults apply:
Fault Cause Remedy

A Rope hoist and crane travel not functioning. 1 System switched off Check whether unit is switched on
2 Emergency stop actuated Release emergency stop
3 400 V voltage missing Check voltage
4 48 V control voltage missing Check voltage
5 Crane switch contactor has tripped Inform Service
B Rope hoist does not lift or lower, long and 1 Phases swapped Swap phase sequence of powerfeed, in‐
cross travel functioning form Service
2 Brake worn, brake distance too long, lift‐ Inform Service
ing is stopped
3 Brake release signal missing Inform Service
4 Phase missing Check voltage
C Rope hoist only lifts or lowers at low lifting Incorrect geared limit switch setting Set according to the operating instruc‐
speed tions
D1 Rope hoist only lowers and an intermittent 1 Overload lifted Remove overload
acoustic signal is emitted
D2 Rope hoist only lowers, long and cross travel 2 Thermal contact of hoist motor active Allow hoist motor to cool down
possible
E Lifting motion does not reach "top" or "bot‐ Incorrect geared limit switch setting Set according to the operating instruc‐
tom" position, but lifts and lowers tions
F Cross travel not functioning 1 Thermal contact of cross-travel motor ac‐ Allow cross-travel motor to cool down
tive
2 Check cross-travel inverter for ‘Ready’ Open cover of electrical equipment and
status check green operation LED on inverter:
Green = ready,
otherwise inform Service
3 Brake of cross-travel motor does not re‐ Brake or control defective,
lease inform Service
G Crab only travels at slow speed 1 Crab/crane in blocked area (by-pass Leave the blocked area
control) 26)
2 Incorrect fast-to-slow limit switch/area Adjust appropriately
switch setting
3 Incorrect parameter settings Inform Service
H Lifting and cross travel not possible, long 1 Crab circuit breaker has tripped Open cover of electrical equipment and
travel is possible, switching noises of the switch circuit breaker on again
crab electrical equipment main contactor can 2 400 V voltage missing Measure voltage
be heard.
3 Connector loose Check 400 V plug-in connections for tight
fit
4 Broken conductor in the power supply Inform Service
lines
I Long travel is not possible, lifting and cross Crane circuit breaker has tripped Open cover of crane electrical equipment
travel are possible, switching noises of the and switch circuit breaker on again
crane electrical equipment main contactor
can be heard.
J Only long travel is not possible but no Thermal contact 26) Allow long-travel motor to cool down
switching noises of the crane electrical of long-travel motor active
equipment main contactor can be heard.
K Crane only travels at slow speed 1 Crab/crane in blocked area (by-pass Leave the blocked area
control) 26)
2 Check connector of ‘fast-to-slow switch’ Inform Service
L Display in control pendant shows nothing 1 48 V control voltage missing Measure voltage
2 A control voltage fuse has tripped Open cover of crane electrical equipment
and switch fuse on again
214 961 44/141212
lines
Tab. 47
102 26) Optional

10 Actual duration of service
10.1 Calculating the actual duration of service
43249744.eps
Fig. 77
When powered hoist units are used, the owner must determine and record the used share of the theoretical dura‐
tion of service for the hoist, see BGV D8. ( "Regular inspections", Page 17)
The load spectrum is recorded and calculated by means of the control system integrated in the DR unit. The
elapsed duration of service is shown on display (4) of the DSE-10R control pendant. Read the value and enter it
into the test and inspection booklet when the annual inspection is carried out. The value displayed is indicated in
%.
A general overhaul must be arranged to be carried out when 90% of the service life has elapsed (when 10% is
shown on the display).
Safe working period (S.W.P.)

The theoretical duration of service (to ISO 4301/FEM 9.755) in connection with the actual mode of operation
( "Selection criteria", Page 19) results in the safe working period (S.W.P.).
See control pendant operating instructions,  Tab. 2, Page 2, for further information.
214 961 44/141212
103
Original Ident. number / Language
EC conformity declaration for a machine 19964244 / EN
according to Directive 2006/42/EC, Annex IIA Issue Page
0110 1/ 2
Hereby we,

Ruhrstraße 28, 58300 Wetter
declare that the product:
Demag EZDR double-rail crab

Serial no.: xxx xxx xxx
ready for service - as a series product or manufactured to order - after completion of
assembly/being put into service including function check and load test prior to being put
into service to be confirmed on page 2 complies with all relevant requirementsof
EC Machinery Directive 2006/42/EC.
The safety objectives of Low Voltage Directive 2006/95/EC are achieved.

The product additionally complies with the following relevant directives/provisions:
EC EMC Directive 2004/108/EC
e
Applied harmonised standards and/or C standard drafts, in particular:
EN 14492-2 Cranes - Power driven winches and hoists -

pl Part 2: Power driven hoists
EN 60204-32 Safety of machinery - Electrical
equipment of machines - Part 32:
Requirements for hoisting machines
EN 61000-6-2 Electro-magnetic compatibility (EMC), Part 6-2:
Generic standards - Immunity for
industrial environments
m
Generic standards - Emission for
The relevant technical documentation according to Annex VII Part A of Directive 2006/42/EC has
been compiled and will be made available to authorised national authorities by the designated
Sa
authorised representative in response to a justified request.

Authorised representative for technical documentation:
Hans-Jörg Böttcher, Demag Cranes & Components GmbH, 58286 Wetter
Wetter, 25.01.2013
ppa. Dr. Rainer Harkort ppa. Franz Schulte

Head of Plant Wetter Industrial Cranes & Components
Engineering & Development
Industrial Cranes Segment

U02180
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, 58286 Wetter Subject to change. No liability for errors or omissions
0110 2/ 2

-----------------------------------------------------------------------------------------------------------
For assembly / first putting into service including function check
...................................., date ................................................
Company that carries out the work: ................................................
Function in the company: ................................................
Name: ................................................
Signature: ................................................
e
------------------------------------------------------------------------------------------------------------
For the load test in the scope of the acceptance test

pl
...................................., date ................................................

m
Name: ................................................
Signature: ................................................
Sa

U02180
Declaration for fitting partly completed machinery 19964144 / EN
according to Machinery Directive 2006/42/EC, Annex IIB Issue Page
0110 1/ 1
Hereby we,


supplied as partly completed machinery is intended to be incorporated into machinery and its
initial bringing into service is prohibited until the machinery* into which this partly completed
machinery is to be incorporated has been declared in conformity with all relevant provisions of

(* insofar as this machinery is subject to the scope of application)
Basic requirements of the EC Machinery Directive, insofar as they are relevant for the scope of
e
delivery, are met by application of the following harmonised standards or C standard drafts:
Part 2: Power driven hoists
EN 61000-6-2
pl
Electro-magnetic compatibility (EMC), Part 6-2:
m
The safety objectives of Low Voltage Directive 2006/95/EC are achieved

Sa
The special technical documentation according to Annex VII Part B of Directive 2006/42/EC has
Authorised representative for technical documentation
Wetter, 25.01.2013


U02180
Index
A Specialist personnel 9
Switching off 84
After-sales service address 10
Symbols 7
Assigned expert engineer 9
S.W.P. 103
B
T
Block adjustment 76
Trained person 9
C Travelling hoist 10
Cylindrical-rotor motor 31
D
DC brake 31
Design 30
Design limit 10
Drives 31
E
Emergency limit switch 75
Experienced technician 9
Expert engineer 10
G
Geared limit switch 75
General overhaul (GO) 100
H
Helical gearbox 31
I
Individual adjustment 76
M
Machine operator 9
Maintenance 85
Manufacturer 9
Manufacturer’s address: 2
Minimum requirements for runways 28
Model code 18
O
Operating limit switch 75
Operating personnel 9
Operation 80
Owner 9
Q
Qualified electrician 9
214 961 44/141212
S
Signal words 7
Size designations 18 107
The current addresses of our sales offices, subsidiaries and agencies worldwide can be
found on the Demag Cranes & Components GmbH homepage at
www.demagcranes.com/Contact

PO Box 67 · 58286 Wetter (Germany)
Phone +49 (0 )2335 92-0
Fax +49 (0 )2335 92-7676
Printed in Germany
www.demagcranes.com
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, 58286 Wetter (Germany) Subject to change. Not liable for errors or omissions.
Demag DR-Pro rope hoist
EZDR 5 - EZDR 10
double-rail crab
43312244.eps
141212 en GB 214 961 44 720IS 813

Original operating instructions
Manufacturer
PO Box 67
Telephone +49 (0)2335 92-0
Fax +49 (0)2335 92-7676
www.demagcranes.com
Email: info@demagcranes.com
Please fill in the following table before first putting the unit into service. This provides you with definitive documentation of your
Demag DR rope hoist and important information if you ever have to contact the manufacturer or his representative.
Owner
Where in use
Range
Serial number
Main hoist motor number
Operating voltage
Control voltage
Frequency
Wiring diagram number
Tab. 1
Further documents are available for sub-assemblies/components in addition to these operating instructions. These possible
sub-assemblies/components are listed below. The corresponding documents are supplied as necessary or can be ordered
separately.
Documents1) Order no.: Classification

Spare parts lists
EZDR-Pro 5 217 129 44 721IS 813
Spare parts list for Demag rope hoist
EZDR-Pro 10 217 124 44 721IS 813
Technical data / catalogues
Demag EZDR 5 - EZDR 10 rope hoist 203 648 44 714IS 813
Assembly instructions, clamp-fitted
KP-S 70 and KP-S 100 203 652 44 714IS 888
buffer
Operating, assembly, fitting instructions
DSE-10R control pendant 214 795 44 719IS 975
DRC-10 radio control system 214 920 44 719IS 975
DRC-J radio control system 214 975 44 719IS 975
Motor assembly instructions – Z motor range 214 228 44 719IS 910
DRS 112 – 260 wheel block assembly instructions 214 276 44 719 IS 845.5
Demag test and inspection booklet for cranes and hoist units 206 124 44 720IS 100
Tab. 2
214 961 44/141212
2 1) The documents can be ordered from the relevant Demag office.

Table of contents
1 General........................................................................................................................................................................ 7
1.1 EZDR-Pro 5 - 10 double-rail crab ................................................................................................................................ 7
1.2 Information on the operating instructions .................................................................................................................... 7
1.3 Symbols/signal words.................................................................................................................................................. 7
1.4 Liability and warranty................................................................................................................................................... 8
1.5 Copyright ..................................................................................................................................................................... 8
1.6 Spare parts .................................................................................................................................................................. 9
1.7 Terms and definitions .................................................................................................................................................. 9
1.8 Test and inspection booklet....................................................................................................................................... 10
1.9 After-sales service ..................................................................................................................................................... 10
1.10 Disposal of machine parts ......................................................................................................................................... 10
2 Safety ........................................................................................................................................................................ 11
2.1 General...................................................................................................................................................................... 11
2.2 Safety signs on the machines ................................................................................................................................... 11
2.2.1 Safety signs for fitting the rope socket ...................................................................................................................... 11
2.2.2 Safety signs for adjusting the thrust rocker ............................................................................................................... 12
2.3 Intended use.............................................................................................................................................................. 12
2.4 Hazards that can be caused by the machine ............................................................................................................ 14
2.5 Responsibility of the owner ....................................................................................................................................... 15
2.6 Operating personnel requirements............................................................................................................................ 16
2.7 Personal protection equipment.................................................................................................................................. 16
2.8 Emergency stop device ............................................................................................................................................. 16
2.10 Inspection regulations ............................................................................................................................................... 17
3 Technical data ........................................................................................................................................................... 18
3.1 Explanation of size designations/type assignment ................................................................................................... 18
3.2 Selection criteria........................................................................................................................................................ 19
3.2.1 Specification of the rope hoist ................................................................................................................................... 19
3.3 Selection table ........................................................................................................................................................... 20
3.4 Hoist motor technical data ......................................................................................................................................... 21
3.4.1 DR 5 motor data with pole-changing hoist drives...................................................................................................... 21
3.4.2 DR 10 motor data with pole-changing hoist drives.................................................................................................... 21
3.4.3 DR 5 - DR 10 motor key data for inverter operation.................................................................................................. 22
3.5 Motor key data for inverter-controlled cross-travel drive ........................................................................................... 23
3.5.1 DR 5, DR 10 cross-travel drives, 2/1 - 4/1 - 4/2 reeving ........................................................................................... 23
3.5.2 DR 10 cross-travel drives, 6/1 reeving ...................................................................................................................... 23
3.5.3 Calculation example .................................................................................................................................................. 23
3.6 Hook dimension C ..................................................................................................................................................... 24
3.7 Gearbox oil filling ....................................................................................................................................................... 24
3.8 Operating conditions ................................................................................................................................................. 25
3.9 Noise emission .......................................................................................................................................................... 26
3.10 Paint finish ................................................................................................................................................................. 27
3.11 Weight ....................................................................................................................................................................... 27
3.12 Track girder requirements ......................................................................................................................................... 28
3.12.1 Runway ..................................................................................................................................................................... 28
3.12.2 Travel unit.................................................................................................................................................................. 29
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3.13 Control system .......................................................................................................................................................... 29

4 Design and function................................................................................................................................................... 30
4.1 Design ....................................................................................................................................................................... 30
4.2 Arrangement of assemblies....................................................................................................................................... 30 3
4.3 Drives ....................................................................................................................................................................... 31
4.3.1 Hoist and travel drive................................................................................................................................................. 31
4.3.2 Gearbox/rope reeving components ........................................................................................................................... 31
4.4 Geared limit switch .................................................................................................................................................... 31
4.5 Integrated controls..................................................................................................................................................... 32
4.6 Control pendant operating element ........................................................................................................................... 32
4.6.1 Overview ................................................................................................................................................................... 32
4.6.2 DSE-10R ................................................................................................................................................................... 33
4.6.3 Principle..................................................................................................................................................................... 33
4.6.4 Wiring ........................................................................................................................................................................ 33
4.6.5 Display....................................................................................................................................................................... 33
4.6.6 IrDA infrared interface ............................................................................................................................................... 33
4.7 Overload protection ................................................................................................................................................... 34
4.8 Type plate (example)................................................................................................................................................. 35
5 Transport, packing, storage....................................................................................................................................... 36
5.2 Transport inspection .................................................................................................................................................. 36
5.3 Packing...................................................................................................................................................................... 36
5.4 Storage ...................................................................................................................................................................... 36
6 Installation and putting into operation for the first time .............................................................................................. 37
6.2 Assembly of travelling hoists ..................................................................................................................................... 38
6.2.1 Overview ................................................................................................................................................................... 38
6.2.2 Checking dimensional accuracy of the tracks ........................................................................................................... 39
6.2.2.1 Tolerance of the individual girder .............................................................................................................................. 39
6.2.2.2 Twisting ..................................................................................................................................................................... 39
6.2.2.3 Tolerance of the crab track gauge............................................................................................................................. 40
6.2.2.4 Gradient of the crab rails ........................................................................................................................................... 40
6.2.2.5 Difference in rail height.............................................................................................................................................. 41
6.2.2.6 Rail level difference ................................................................................................................................................... 41
6.2.3 Fitting the end stops/clamp-fitted buffers .................................................................................................................. 42
6.3 Assembly and alignment of the travelling hoists ....................................................................................................... 42
6.3.1 Assembly instructions................................................................................................................................................ 42
6.3.2 Aligning the travelling hoist on the crane................................................................................................................... 42
6.3.3 Assembly of adjusting jig A ....................................................................................................................................... 44
6.3.3.1 Assembly of the adjusting jig on the roller side (preparation of adjusting jig for assembly) ...................................... 44
6.3.4 Assembly of adjusting jig B ....................................................................................................................................... 45
6.3.4.1 Version a: Fixing with threaded pin guide for EZDR with one travel drive (inside).................................................... 45
6.3.4.2 Version b: Fixing with two clamps for EZDR with two travel drives (outside)............................................................ 47
6.3.5 Adjustment for horizontal alignment .......................................................................................................................... 49
6.3.6 Disassembly of adjusting jigs A and B ...................................................................................................................... 50
6.3.7 Assembly and adjustment of the guide rollers........................................................................................................... 52
6.3.8 Final adjustment of the thrust rocker ......................................................................................................................... 56
6.4.1 Wiring ........................................................................................................................................................................ 58
6.4.1.1 General...................................................................................................................................................................... 58
6.4.1.2 Frequency inverter .................................................................................................................................................... 58
6.4.1.3 Control cable and line voltage connection................................................................................................................. 59
6.4.2.1 Direct connection to the machine .............................................................................................................................. 59
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6.4.2.2 Connection to the KBK trailing cable trolley .............................................................................................................. 60

6.4.3 Checking the direction of movement ......................................................................................................................... 60
6.5 Rope reeving ............................................................................................................................................................. 61
4 6.5.1 Reeving methods ...................................................................................................................................................... 61
6.5.2 Reeving methods for the rope hoist .......................................................................................................................... 61
6.5.3 Fitting MGS/ZMS overload protection ....................................................................................................................... 62
6.5.3.1 MGS/ZMS overload protection, 2/1, 4/1 and 6/1 reeving .......................................................................................... 62
6.5.3.2 ZMS overload protection, 4/2 reeving ....................................................................................................................... 63
6.5.4 Fitting the rope .......................................................................................................................................................... 63
6.5.5 Bottom block reeving................................................................................................................................................. 64
6.5.5.1 2/1 reeving................................................................................................................................................................. 64
6.5.5.2 4/1 reeving................................................................................................................................................................. 66
6.5.5.3 4/2 reeving................................................................................................................................................................. 69
6.5.5.4 6/1 reeving, EZDR-Pro 10 ......................................................................................................................................... 72
6.6 Putting into operation for the first time....................................................................................................................... 75
6.6.1 Checks before putting the unit into operation for the first time .................................................................................. 75
6.6.2 Inspection regulations ............................................................................................................................................... 75
6.6.3 Geared limit switch ................................................................................................................................................... 75
6.6.3.1 Geared limit switch function ...................................................................................................................................... 75
6.6.3.2 Setting the cut-out points........................................................................................................................................... 77
6.6.3.3 Set the upper cut-out points ...................................................................................................................................... 77
6.6.3.4 Set the lower cut-out points....................................................................................................................................... 78
6.6.4 Overload test with 125% ........................................................................................................................................... 79
6.6.5 Travelling hoist travel characteristics and run-on paths when stopping .................................................................... 79
7 Operation .................................................................................................................................................................. 80
7.2 Switching on .............................................................................................................................................................. 81
7.2.1 Checks when starting work ....................................................................................................................................... 81
7.2.2 Visual check .............................................................................................................................................................. 81
7.2.3 Check the limit switches ............................................................................................................................................ 82
7.2.4 Check strain relief elements ...................................................................................................................................... 82
7.2.5 Check operation of the brake .................................................................................................................................... 83
7.2.6 Check hook safety catch ........................................................................................................................................... 83
7.3 Control pendant switch assignment .......................................................................................................................... 84
7.4 Switching off ............................................................................................................................................................. 84
7.5 Stopping operation in an emergency......................................................................................................................... 84
8 Maintenance ............................................................................................................................................................. 85
8.3 Maintenance schedule .............................................................................................................................................. 86
8.4 Wire ropes ................................................................................................................................................................. 88
8.5 Discarding the wire rope............................................................................................................................................ 89
8.6 Wear limits on rope sheaves ..................................................................................................................................... 90
8.7 Fitting the rope, single groove ................................................................................................................................... 91
8.7.1 Unwind rope .............................................................................................................................................................. 91
8.7.2 Fitting the rope .......................................................................................................................................................... 92
8.8 Fitting the rope, more than one groove ..................................................................................................................... 96
8.8.1 Unwind rope .............................................................................................................................................................. 96
8.8.2 Fitting the rope, more than one groove ..................................................................................................................... 96
8.9 Shortening the wire rope ........................................................................................................................................... 97
8.10 Lubricating the wire rope ........................................................................................................................................... 97
8.11 Regular inspections and monitoring measures for load hooks.................................................................................. 98
8.12 Travel wheel wear ..................................................................................................................................................... 99
8.13 Oil change ............................................................................................................................................................... 100
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8.14 General overhaul (GO) ........................................................................................................................................... 100

9 Malfunctions ............................................................................................................................................................ 101
9.1 Safety instructions ................................................................................................................................................... 101
5
9.2 Conduct when malfunctions occur .......................................................................................................................... 101
9.3 Conduct after malfunctions have been eliminated .................................................................................................. 101
9.4 Malfunctions, causes and remedy ........................................................................................................................... 102
10 Actual duration of service ........................................................................................................................................ 103
10.1 Calculating the actual duration of service................................................................................................................ 103
Declaration of conformity.......................................................................................................................................................... 104
.................................................................................................................................................................................................. 105
Declaration of incorporation ..................................................................................................................................................... 106
Index......................................................................................................................................................................................... 107
214 961 44/141212
6
1 General
1.1 EZDR-Pro 5 - 10 double-rail crab

You have purchased a Demag product.
This Demag rope hoist was manufactured in accordance with the relevant European standards and regulations.
The rope hoist complies with the statutory regulations of, for example, EC directive 2006/42/EC.
Demag rope hoists are of modular design. Their main assemblies include:
● Gearbox
● Hoist motor
● Integrated electrical equipment
● Rope reeving components
● Control pendant
● Travel unit
The following data always apply for all ranges. Any differences for individual ranges are specially marked.
1.2 Information on the operating instructions

These operating instructions are designed to provide the owner with appropriate instructions for safe and correct
operation and for maintenance. These operating instructions are an integral part of the rope hoist.
rope hoists and additional equipment must have read and understood the items listed in the following:
errors and to ensure smooth and trouble-free operation of our products. They must be kept available in the imme‐
diate vicinity at all times. The rope hoist may only be operated by personnel who are fully familiar with the operat‐
ing instructions.
If special designs or additional options are 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 questions, please contact the manufacturer.
Based on Machinery Directive 2006/42/EC, the rope hoist is also designated as a machine in the sense of a
complete machine in the following. This always refers to all possible DR rope hoist types.
For a Demag rope hoist delivered ready for operation in the sense of a complete machine, we confirm conformity
with the requirements of Directive 2006/42/EC by means of the attached EC declaration of conformity.
A declaration of incorporation is enclosed for partly completed Demag rope hoists which are assembled with addi‐
tional parts to create a machine ready for operation. The declaration of incorporation refers to the scope of deliv‐
ery of the partly completed or non-assembled machinery. Before the unit is put into operation, the user must take
additional measures to fulfil the safety requirements for the machine and issue the declaration of conformity for
the machine when it is ready for operation.

Important safety information and instructions in these operating instructions are marked by corresponding sym‐
bols and signal words.
Safety instructions and information must be followed. Follow these instructions with care to avoid any accidents,
injuries or damage.
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Any locally applicable accident prevention regulations and general safety regulations must also be followed.
The following symbols and instructions warn against possible injuries or damage and are intended to assist you in
your work.
7
DANGER
This warning symbol indicates an immediate danger that can result in severe injuries or death.
WARNING
This warning symbol indicates a possibly dangerous situation that might result in severe injuries or death.
CAUTION
This warning symbol indicates a possibly dangerous situation that might result in medium or slight injuries or ma‐
terial damage.
Operating hazard for the machine

● This symbol indicates information on the appropriate use of the machine.
● Failure to follow these instructions may result in malfunctions, damage or pollution of the environment.
1.4 Liability and warranty

All information included in these operating instructions has been compiled on the basis of the relevant regulations,
state-of-the-art engineering principles and our many years of experience.
These operating instructions must be read carefully before starting any work on and with the machine, especially
before the machine is put into service for the first time. We assume no liability for any damage which results
from the following:
● Non-compliance with the operating instructions
● Inappropriate use of the machine
● Operation by insufficiently trained personnel
● Unauthorised conversions
● Any technical modifications

We reserve the right to incorporate technical modifications within the scope of improving the operating character‐
istics and further development of the machine.
1.5 Copyright
These operating instructions must be treated confidentially. They are only intended to be used by people who
work with or on the machine.
Any and all content, texts, drawings, images and any other information are protected within the sense of copyright
law and are subject to further industrial rights. Any misuse is an offence.
No part of this documentation, in whole or in part, may be reproduced, distributed, shown in public or used in any
other way without specific prior consent. Infringements are an offence resulting in obligatory compensatory dam‐
ages. Further rights reserved.
214 961 44/141212
8
1.6 Spare parts
Only genuine Demag spare parts may be used.
CAUTION
Incorrect or defective spare parts may cause damage, malfunctions or complete failure of the machine.
Only use genuine spare parts or parts approved by Demag.
Only genuine Demag spare parts may be used for safety-relevant wear parts. Examples: brake, motor, ...
The use of unauthorised spare parts renders null and void any claims for warranty, service, damages or liability
against the manufacturer or his appointed personnel, dealers and representatives.
1.7 Terms and definitions

Manufacturer
The manufacturer is the person who:
1. manufactures machinery under his or her own name and places it on the market for the first time;
2. resells machinery made by other manufacturers under his or her own name, whereby the reseller is not con‐
sidered to be the manufacturer, provided the name of the manufacturer (as defined in 1.) appears on the
equipment;
3. imports machinery into Germany and places it on the market for the first time or
4. exports machinery to another member state of the European Union and hands it over direct to an owner in
that country
Owner
Owners (employer, company) are defined as persons who own a machine and who use it as intended or allow it
to be operated by suitable and trained persons.
Operating personnel/machine operator
Operating personnel or machine operators are defined as persons entrusted by the owner of a machine with oper‐
ation of the equipment. The operating personnel must be trained by the owner in accordance with the tasks to be
performed.
Trained person
Trained persons are defined as persons who, owing to their technical training, knowledge and experience of elec‐
trical machines as well as knowledge of the relevant valid standards, codes of practice and regulations, are able
to assess the tasks given to them and to identify and eliminate potential hazards.
Specialist personnel are defined as persons assigned by the owner of a machine to carry out special tasks such
as installation, setting-up, maintenance and fault elimination. Specialist personnel must be trained by the owner
before any work is carried out on or with the machine.
electrical machines as well as knowledge of the relevant valid standards, codes of practice and regulations, are
able to assess the tasks given to them and to identify and eliminate potential hazards. Qualified electricians must
be trained by the owner in accordance with the tasks to be performed.
Experienced technicians are defined as persons who, owing to their technical training and experience, have suffi‐
cient knowledge in the field of machines. They must be familiar with the relevant national industrial safety regula‐
tions, codes of practice, accident prevention regulations, directives and generally accepted engineering standards
enabling them to judge the safe operating condition of machines.
Assigned expert engineer (in the Federal Republic of Germany according to BGV D8, Section 23, for determining
214 961 44/141212
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 the machine (S.W.P. = safe working period) and to
carry out a general overhaul of the machine.
9
Authorised expert engineer (according to BGV D6, Section 28 in the Federal Republic of Germany)
In addition to the expert engineers of the Technical Supervisory and Inspection Board, an authorised expert engi‐
neer for the inspection of machines is defined as an expert engineer authorised by the Industrial Employers’ Mu‐
tual Insurance Association.
Design limit
For selection of the crane, the size is defined in accordance with the application and the customer specifications.
The design limits of the crane must not be exceeded.
Rope hoists
Rope hoists are systems used for lifting and moving loads, such as cranes, crabs and travelling hoist units, rail
systems.
Crabs and travelling hoists
A crab or travelling hoist is a mobile crane assembly for changing the situation of the lifting rope (on the load at‐
tachment side). Depending on the type, the crab/travelling hoist carries one or several return sheaves for the lift‐
ing rope or directly the hoist unit. The crab/travelling hoist travels along a girder.
1.8 Test and inspection booklet

A test and inspection booklet filled in with all details must be available for every rope hoist. The results of the reg‐
ular tests and inspections must be entered into the test and inspection booklet and must be certified by the in‐
spector. Test and inspection booklet order no.: Tab. 2, Page 2.
1.9 After-sales service

Our after-sales service will provide you with technical information on our machines, etc.
Please keep the serial or order number (see test and inspection booklet, 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.
The relevant Demag after-sales service centre is given, for example, on the back page of the rope hoist test and
inspection booklet.
Manufacturer’s address:
PO Box 67
Telephone +49 (0)2335 92-0
Fax +49 (0)2335 92-7676
www.demagcranes.com
1.10 Disposal of machine parts

Unless a return or disposal agreement has been concluded, recycle separated components after proper removal:
● Scrap any remaining metallic material
● Dispose of plastic elements for recycling
● Separate and dispose of any other components by material type
Electric scrap, electronic components, lubricants and other auxiliary materials are subject to special disposal
regulations and may only be disposed of by certified companies.
National disposal regulations must be considered regarding environmentally friendly disposal of the machine. Fur‐
ther information can be obtained from corresponding local authorities.
214 961 44/141212
10
2 Safety
2.1 General
The ‘Safety’ chapter provides an overview of all important safety aspects for optimum protection of personnel as
well as safe and trouble-free operation of the machine.
At the time of its development and manufacture, the machine was built according to generally accepted engineer‐
ing standards and is considered to be safe to operate. The machine may still be a cause of danger if it is not used
correctly or as intended by suitably trained personnel.
Knowledge of the contents of the operating instructions is one of the requirements necessary to protect personnel
from hazards and to avoid malfunctions and, therefore, to operate the machine safely and reliably.
Any conversions, modifications or additions to the machine are prohibited unless approved by Demag in writing.
These operating instructions describe operation with one travelling hoist; operation of several travelling hoists on
one crane girder or tandem operation of cranes are not included in these operating instructions.
2.2 Safety signs on the machines
2.2.1 Safety signs for fitting the rope socket

Any pictograms, signs or labels on the rope hoist must be obeyed and must not be removed. Pictograms, signs or
labels that are damaged or no longer legible must be replaced immediately.
Adhesive labels
Fig. 1
1 Rope clamp
Fitting the rope socket  "Fitting the rope socket for 2/1", Page 65
214 961 44/141212
11
2.2.2 Safety signs for adjusting the thrust rocker
43235844.eps
Fig. 2
Adjusting the thrust rocker  "Final adjustment of the thrust rocker", Page 56.
2.3 Intended use

The machine may only be used as intended and in compliance with the requirements for the owner and the fol‐
lowing limitations as specified in these operating instructions. Any other use may result in a danger to life and limb
and/or cause damage.
● EZDR rope hoists are only designed for lifting loads. The maximum safe working load is the load capacity
specified on the capacity plate. This must not be exceeded. The maximum safe working load includes the lifted
load and dead load (e.g. load handling attachments).
● Rope hoists may only be installed, operated, maintained and removed when in perfect working order by trained
personnel in accordance with the relevant safety and accident prevention regulations. Personnel must meet
the requirements according to  "Operating personnel requirements", Page 16.
● Intended use also includes compliance with the safety instructions as well as any other instructions on assem‐
bly/disassembly, commissioning, function/operation, maintenance/fault elimination as well as compliance with
the instructions on safety devices, protection against hazards and any possible remaining hazards.
● The rope hoist may only be used subject to the permissible technical data,  "Technical data", Page 18. In
particular, the maximum permitted load according to these operating instructions must not be exceeded.
● The rope hoist must be maintained regularly and appropriately by trained personnel in line with the specified
deadlines and checked according to  "Maintenance schedule", Page 86. Wearing parts must be replaced in
good time in accordance with the frequency and intensity of use.
● Loads must never be pulled at an angle, pulled or dragged and fixed loads must never be pulled free.
● Transporting people with or people riding on the machine is always prohibited, this does not apply to equip‐
ment specially designed for transporting people (see intended use of lifting equipment).
● Molten masses must not be lifted or transported with Demag hoist units as standard.
● As standard, Demag hoist units are not intended or rated for tandem operation.
● UVV/BGV D8, Section 23 (2) and BGV D6, Section (1) guidelines must be not be ignored.
No liability for inappropriate use
The manufacturer is exempt from any liability for use other than the purpose which is technically possible and ac‐
214 961 44/141212
ceptable according to these operating instructions. In particular, the manufacturer assumes no liability for damage
due to inappropriate or any other prohibited use of the machine in the sense of the "Intended use" section.
No liability for structural modifications
12
The manufacturer is not liable for any unauthorised structural modifications which have not been agreed with him.
This includes incorrect connection of the machine to devices or equipment that do not belong to our scope of de‐
livery, or the installation or use of third-party accessories, equipment, sub-assemblies or spare parts that are not
approved by the manufacturer.
Depending on the type and scope of the machine, it may be necessary to have an inspection carried out by an
expert engineer before it is handed over to the owner.
The machine is designed for operation indoors and at temperatures ranging from - 10° C to + 45° C. At extreme
temperatures and in aggressive atmospheres, the owner must implement special measures after consulting De‐
mag.
Use of the control pendant
Lifting and lowering and, if applicable, cross-travel and long-travel motions are controlled by means of the corre‐
sponding control elements on the control unit. The slow speeds are intended for attaching the load, lifting it free
and depositing it. Loads can be precisely positioned at slow speeds.
Short transport times can be achieved at higher speeds. They are suitable for travelling without a load or with a
safely suspended load if no hazard can be caused by the faster motion sequences.
Inching must be avoided at fast speeds, as it causes increased wear and load sway.
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13
2.4 Hazards that can be caused by the machine
The machine has been subjected to a risk analysis. The design and execution based on this analysis corresponds
to state-of-the-art engineering principles. However, residual risks remain.
The machine is operated with high electrical voltage.
DANGER
Live components
Electrical energy may cause very severe injuries. Danger to life caused by electrical current if the insulation or
individual components are damaged.
– Switch the machine off and secure it against restoration of the power supply before any maintenance,
cleaning or repair work is carried out.
– Switch the power supply off before any work is carried out on the electrical equipment. Check to ensure
that the components to be replaced are de-energised.
– Do not remove any safety equipment or render it inoperative by modifications.
WARNING
Crushing hazard
Body parts can be crushed when loads are lifted or lowered.
Ensure that nobody is present in the immediate danger zone when loads are lifted or lowered.
WARNING
Suspended load. Falling parts.
Danger to life and limb if lifted loads are dropped.
Keep out of the danger zone at all times.
– Keep a sufficient safety distance.
– Never step under a suspended load.
Certain work and practices are prohibited when using the machine as they may involve danger to life and limb
and result in lasting damage to the machine, e.g.:
● Unsafe load handling (e.g. swinging/throwing the load).
● Do not handle suspended loads above people.
● Do not pull or drag suspended loads at an angle.
● Do not pull free any fixed or obstructed loads.
● Do not exceed the maximum permitted load.
● Do not leave suspended loads unsupervised.
● Do not allow load-supporting means (ropes/chains) to run over edges.
● Do not use load-supporting means (ropes/chains) as a load bearing sling.
● Do not allow loads to drop when the load-supporting means (ropes/chains) are in a slack condition.
● Do not subject the control switch to inappropriate mechanical loads.
● Do not allow the control cable to wind around the rope.
● Do not allow motion of the load hook in the bottom block to be obstructed. No twisting (torsion) may be caused
in the rope.
Do not work with twisted ropes, especially with 2/1 reeving.
● Do not manipulate electrical equipment.
214 961 44/141212
● Transporting people is not permitted unless the machine is specifically approved for transporting people.
● Do not lift the load at full speed.
14
● Vibration from the load being transported (e.g. when the load is deposited on vibrating machinery) must not be
transmitted.
● Avoid any collisions with stationary equipment and structures; runways must be designed in such a way that
the entire travel path of the crane is always free of obstructions.
2.5 Responsibility of the owner

Information on safety at work refers to the regulations of the European Union that apply when the machine is
manufactured. The owner is obliged to ensure that the specified industrial safety measures comply with the latest
rules and regulations and to observe new regulations during the entire service life of the machine. Local industrial
safety legislation and regional regulations and codes of practice applicable at the site of operation of the machine
must be observed outside the European Union.
General safety, accident prevention and environmental protection regulations that apply where the machine is in
operation must be observed and complied with in addition to the safety instructions contained in these operating
instructions.
The owner and any personnel authorised by him are responsible for correct operation of the machine and for
clearly defining responsibilities for installation, operation, maintenance and cleaning. The operating instructions
must be followed in full and without any limitations.
Special local conditions or applications may lead to situations which are not considered in these operating instruc‐
tions. In such cases, the required safety measures must be defined and implemented by the owner. Necessary
measures may also relate, for example, to the handling of hazardous materials or tools and the provision/wearing
of personal protection equipment. The operating instructions must, if required, be supplemented by the owner with
instructions relating to the organisation of work, working procedures, authorised personnel, supervising and re‐
porting obligations, etc. For further information, see  "Safety instructions", Page 80.
Furthermore, the owner must ensure that
● any further working and safety instructions resulting from the risk assessment of the machine workplaces are
specified in operating procedures.
● personnel who work with or on the machine are provided with appropriate first-aid equipment. The personnel
must be trained in the use of the first-aid equipment.
● the operating instructions are always kept available in the immediate vicinity of the machine for installation, op‐
erating and maintenance personnel.
● the personnel are trained in accordance with the work to be performed.
● the machine is only operated when in safe and proper working order.
● the safety devices are always kept freely accessible and are checked regularly.
● the national regulations for use of the machine are observed.
● any specified regular checks and inspections are carried out on time and are documented.
● the operating/travel area is adequately illuminated.
● suitable and tested load handling attachments are provided and used.
The owner is urged to develop procedures and guidelines for any malfunctions, to instruct users and to affix these
instructions at a suitable place where they can be easily seen.
214 961 44/141212
15
2.6 Operating personnel requirements
Only authorised and trained personnel may work on the machine. The personnel must have received instruction
on the machine functions and any hazards that may occur.
Every individual given the task of working on or with the machine must have read and understood the operating
instructions before any work on the machine starts.
Persons under the influence of drugs, alcohol or medicines which affect their reactions must not work on or with
the machine.
Age and job-specific regulations relevant at the place where the machine is operated must be observed for the
selection of any personnel.
Personnel are obliged to report to the owner without delay any changes to the machine that impair safety.
For independent operation (machine operator) or maintenance (maintenance fitter) of the machine, 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 the machine and who have proven their qualifi‐
cation to the owner in this respect.
2.7 Personal protection equipment

When work is carried out on or with the machine, the following is recommended to be worn according to the own‐
er's risk assessment:
● Protective clothing, closely fitting working clothes (low tear strength, no loose sleeves, no rings or any other
jewellery, etc.).
● Safety shoes to protect against falling parts and against slipping.
● Gloves for handling the wire rope.
● Safety helmet to be worn by everybody in the danger zone.
2.8 Emergency stop device
DSE-10R
43249344.eps
Fig. 3
WARNING
Unauthorised, negligent or accidental switching-on.
Check to ensure that the reason for the emergency stop has been eliminated before the machine is switched on
again.
The emergency-stop device must not be used to switch the machine off in normal operation.
214 961 44/141212
The machine is fitted with an emergency-stop device (1) to prevent damage and injuries. This is located on the
control unit. The emergency-stop operating function must be checked regularly.
16
The owner of the machine may be obliged to carry out regular inspections by national industrial safety legislation
and regional regulations. In Germany, this is specified by the accident prevention regulations for winches and
hoists (BGV D8) and the accident prevention regulations for cranes (BGV D6), for example. These specify 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 tests and inspections must be kept.
The owner is obliged to ensure that the machine complies with the latest rules and regulations and to observe
new regulations at all times.
If no comparable inspection regulations or requirements apply at the place where the machine is operated, we
recommend compliance with the above-mentioned regulations.
2.10 Inspection regulations

Notes on inspections in accordance with:
● UVV accident prevention regulations for winches, lifting and towing devices, BGV D8
● UVV Cranes, BGV D6
● EN 14492-2 – Cranes; Power-driven winches and hoists; Part 2: Power-driven hoists
● prEN 15011 Cranes – Bridge and gantry cranes
The EC Machinery Directive requirements are therefore also fulfilled.
214 961 44/141212
17
3 Technical data
3.1 Explanation of size designations/type assignment

E Z DR-Pro 5- 3,2 4/1 6 Z 6/1 400 00 - 50 - 30 1400 45
Rail head width [mm]
Track gauge [mm]
Max. cross-travel speed [m/min]
Frequency [Hz]
Electrical equipment code  Tab. 4, Page 18
Operating voltage [V]
Lifting speed [m/min]
Motor type: Z = Cylindrical rotor
Hook path [m]
Reeving
Load capacity [t]
Range
Demag rope hoist
F = Foot-mounted hoist
K = Low-headroom monorail hoist
U = Standard-headroom monorail hoist
Z = Double-rail crab
E = Electric travel trolley
Tab. 3
Electrical equipment Use

code
00 Prepared for electrical equipment provided by the customer.
01 EZDR with internal electrical equipment for operation on a crane. Crane bridge enclosure and DSE-10R control pendant
with control cable included.
02 EZDR with solo electrical equipment for use as a solo travelling hoist. DSE-10R control pendant with control cable inclu‐
ded.
05 EZDR with fitted ‘DPC’ parallel interface.
Tab. 4 Electrical equipment code list
214 961 44/141212
18
3.2 Selection criteria
3.2.1 Specification of the rope hoist
The size of the hoist is determined by the load spectrum, average operating time per working day, load capacity
and reeving.
1. What are the operating conditions?
2. What is the specified safe working load?
3. To what height must the load be lifted?
4. What is the required lifting speed?
5. Do the loads need to be lifted and lowered with great accuracy?
6. Is horizontal load travel necessary?
7. How is the hoist to be controlled?
The group is determined by the load spectrum and operating time.
Load spectrum Average operating time per working day in hours

1 Light 4-8 8-16 more than 16
2 Medium 2-4 4-8 8-16
3 Heavy 1-2 2-4 4-8
4 Very heavy 0.5-1 1-2 2-4
FEM 2m 3m 4m
Group of mechanisms to
ISO M5 M6 M7
Tab. 5
The load spectrum (in most cases estimated) can be evaluated in accordance with the definitions (see below):
1. Light
Hoist units which are usually subject to very small loads and in exceptional cases only to maximum loads.
2. Medium
Hoist units which are usually subject to small loads but rather often to maximum loads.
3. Heavy
Hoist units which are usually subject to medium loads but frequently to maximum loads.
4. Very heavy
Hoist units which are usually subject to maximum or almost maximum loads.
Load spectra
1. 2. 3. 4.
43241444.eps
Fig. 4
L Load d Small dead load

LZ Operating time e Small to medium dead load
a Full load f Heavy dead load
b Medium partial load g Very heavy dead load
214 961 44/141212
c Small to medium partial load
19
Selection table
Group of mechanisms to FEM/ISO 2m/M5 3m/M6 4m/M7 2m/M5 3m/M6 4m/M7 2m/M5 3m/M6 4m/M7
2)
Reeving arrangement 2/1, 4/2 4/1 6/13)

Range Load capacity [t]
DR 5 2.5 2 1.6 5 4 3.2 - - -
DR 10 5 4 3.2 10 8 6.3 16 12.5 -
Tab. 6
Calculation example
Load capacity 5t
Load spectrum ‘Medium’ from table
Lifting speed 6 m/min
Creep lifting speed 1 m/min
Reeving 4/1
Average hook path 3m
No. of cycles/hour 20
Working time/day 8 hours
Tab. 7
The average operating time per working day is estimated or calculated as follows:
Operating 2 x average hook path x no. of cycles/hour x working time/day

=
time/day = 60 x lifting speed
Operating 2 x 3 x 20 x 8
= 2.66 hours
time/day = 60 x 6
Tab. 8
For the medium load spectrum and an average daily operating time of 2.66 hours, the table above shows group
2m. For a load capacity of 5 t and 4/1 rope reeving, the following table indicates hoist size DR 5 - 5.
3.3 Selection table

2/1
2m M5 2.5
3m M6 2 12; 20 12/2 18/3 1-25
4m M7 1.6
4/1
2m M5 5
DR 5
3m M6 4 6; 10 6/1 9/1.5 0.5-12.5
4m M7 3.2
4/2
2m M5 2.5
3m M6 2 9.9 12/2 18/3 1-25
4m M7 1.6
214 961 44/141212
3) 6/1reeving only on DR 10
20 5) The Prohub function enables loads weighing up to one third of the rated capacity to be lifted at 1.5 times the rated speed.
2/1
2m M5 5
3m M6 4 12; 20 10/1.7 1-18 5) 1-25
4m M7 3.2
4/1
2m M5 10
3m M6 8 6; 10; 20 5/0.8 0.5-9 5) 0.5-12.5
4m M7 6.3
DR 10
6/1
2m M5 16
3m M6 12.5 6; 7; 13.3 2.7/0.4 0.4-6 5) -
4m M7 10
4/2
2m M5 5
3m M6 4 5.8; 11.35; 25.2 10/1.7 1-18 5) 1-25
4m M7 3.2
Tab. 9
3.4 Hoist motor technical data

50 Hz 400 V
ZBR 100 D 12/2 - 12 12/2 0.8 20 410 240 5.7 9 0.55 0.75
B050 2 6/1 5.3 40 2780 120 11 55 0.88 0.85
ZBR 132 D 12/2 - 12 18/3; 1.4 20 400 240 9.6 15.0 0.54 0.68
B140 2 9/1.5 8.9 40 2870 120 18.0 120.0 0.89 0.85
50 Hz 400 V 50 Hz 400 V (∆U 20 V)
Motor size A mm 2 m
ZBR 100 D 12/2 25 1.5 19
ZBR 132 D 12/2 50 2.5 15
Tab. 11

214 961 44/141212
5) The Prohub function enables loads weighing up to one third of the rated capacity to be lifted at 1.5 times the rated speed.
50 Hz 400 V
12 10/1.7; 1.4 20 400 240 9.6 15.0 0.54 0.68
ZBR 132 D 12/2 -
2.7/0.4;
B140 2 8.9 40 2870 120 18.0 120.0 0.89 0.85
5/0.8
50 Hz 400 V 50 Hz 400 V (∆U 20 V)
Motor size A mm² m
ZBR 132 D 12/2 50 2.5 15
Tab. 13
3.4.3 DR 5 - DR 10 motor key data for inverter operation

electric hoists.
Inverter-fed hoist motor acceleration current = 1.2 x rated current I(A).
Inverter-fed hoist motor rated cos phi = 1.0
Range Reeving Lifting Group of Motor key data Hoist out‐ Inverter
speed mecha‐ put
nisms
[m/min] FEM/ISO Type Brake No. of % CDF n for P hoist Type Rated cur‐
poles 87 Hz [kW] rent at
[rpm] 2 kHz [A]
2m/M5 ZBR 132 B4 2530 11.4 DIC-4-025 25
2/1, 4/2 1-25 3m/M6 B140 4 60 9.1 DIC-4-025 25
ZBR 112 A4 2540
4m/M7 7.3 DIC-4-017 16.5
DR 5
2m/M5 ZBR 132 B4 2530 11.4 DIC-4-025 25
4/1 0.5-12.5 3m/M6 B140 4 60 9.1 DIC-4-025 25
ZBR 112 A4 2540
4m/M7 7.3 DIC-4-017 16.5
2m/M5 ZBR 132 C4 16.3 DIC-4-040 40
1-18 3m/M6 B140 4 60 2530 13.1 DIC-4-032 32
ZBR 132 B4
4m/M7 10.4 DIC-4-025 25
2/1, 4/2
2m/M5 50 2520 21.3 DIC-4-040 40
1-25 3m/M6 ZBR 132 C4 B140 4 17.9 DIC-4-040 40
60 2530
4m/M7 13.8 DIC-4-032 32
DR 10
2m/M5 ZBR 132 C4 15.9 DIC-4-040 40
0.5-9 3m/M6 4 60 2530 12.8 DIC-4-032 32
ZBR 132 B4
4m/M7 10.1 DIC-4-025 25
4/1 B140
2m/M5 50 2520 21.1 DIC-4-040 40
0.5-12.5 3m/M6 ZBR 132 C4 4 17.0 DIC-4-040 40
60 2530
4m/M7 13.4 DIC-4-032 32
Tab. 14
The inverter housing is not attached to the hoist unit and is included in the delivery as a separate item.
● The inverter housing has to be attached by the customer.
● The standard cable measures approx. 3 m in length.
● The inverter housing measures (H x W x D) 600 x 880 x 300 mm.
● When the inverter housing is installed, a minimum distance of 100 mm must be maintained from the top edge
of the hoist unit.
214 961 44/141212
22
Calculation of cross sections/fuse links for other cable lengths
DR 5/10 range Fuse (time delay) 8) Supply lines 9)

for 50 Hz 400 V for 5% voltage drop ∆U 400 V (∆U 20 V)
Inverter type [A] [mm²] [m]
DIC-4-040 50 6.0 97
DIC-4-032 35 4.0 80
DIC-4-025 35 2.5 65
DIC-4-017 16 1.5 58
Tab. 15
3.5 Motor key data for inverter-controlled cross-travel drive
3.5.1 DR 5, DR 10 cross-travel drives, 2/1 - 4/1 - 4/2 reeving

Rated cos phi = 1.0
DR 5 - 10 range No. of poles CDF n Inverter Inverter

kHz
ZBA 71 B 4 DR B003 4 60 3430 DIC-4-002-C 2.4
Tab. 16
3.5.2 DR 10 cross-travel drives, 6/1 reeving

Rated cos phi = 1.0
DR 10 range No. of poles CDF n Inverter Inverter

kHz
2 x ZBA 80 A 4 DR B007 4 60 2270 DIC-4-007-C 7.3
Tab. 17
3.5.3 Calculation example

Example for calculating the cross-sections Q of the conductors of cables exceeding the length indicated in the
table:
ZBR 100 D2/12, 400 V required length 25 m
Known cross-section x required length

Q= =
Known cable length
1.5 mm2 x 25 m
Q= = 2 mm2
19 m
Tab. 18
214 961 44/141212

3.6 Hook dimension C
C
43248744.eps
Fig. 5
The hook dimensions C specified in the following apply to the top emergency-stop cut-out point.
The emergency limit switch for the top hook position must be set so that dimension C (see table below) is reached
when the switch cuts off the lifting motion.
Range Group of mechanisms Reeving

FEM/ISO 2/1 4/1 4/2 6/1
2m/M5
EZDR-Pro 5 3m/M6 530 440 430 -
4m/M7
2m/M5
660 520
EZDR-Pro 10 3m/M6 530 740
4m/M7 760 630
Tab. 19 Hook dimension C from girder running surface
In connection with an operating limit switch, hook dimension C is increased with reference to the operating switch-
off point.
3.7 Gearbox oil filling

The quantity of oil needed in the gearbox depends on the EZDR 5, 10 range. Before it is delivered, the gearbox is
filled according to the order.
Under normal operating conditions, the oil does not have to be changed until a general overhaul is carried out.
Under exceptional conditions, e.g. increased ambient temperatures, we recommend that oil changes be adapted
to suit these conditions.
Oil change
First clean the gearbox parts and gearbox casing thoroughly with commercially available cleaning agents, then
the gear oil can be drained. Then fill with the new gearbox oil. The required quantity and grade of oil can be seen
in the table below.
Range EZDR 5 EZDR 10

HG hoist gearbox [litres] 4.7 7.2
FG travel gearbox [litres] 0.65 1.1
Tab. 20
At ambient temperatures of -10 °C to +45 °C, CLP 220 EP gear oil should be used, e.g. Esso SPARTAN EP.
Order no.: 472 902 44 = 1.0 kg
214 961 44/141212
24
3.8 Operating conditions
Ambient temperature range -10 to +45 °C
Max. air humidity 80 %
Max. altitude/air pressure 1000 m above sea level
Tab. 21
CAUTION
Safe operation is only possible under the conditions specified above.
Please contact the manufacturer for any other operating conditions.
CAUTION
The rope hoist may be damaged if it is operated outdoors in poor weather.
If it is operated outdoors, provide the rope hoist with a cover to protect it from the weather and keep travelling
hoists under shelter when they are not in use.
214 961 44/141212
25
3.9 Noise emission
Noise emission measurement according to DIN 45635
-3 dB(A)
-6 dB(A)
1m
2m
4m
43311444.eps
Fig. 6 Sound pressure reduction in relation to the distance from the sound source
A Measuring point
B Sound source
The sound pressure level of a rope hoist can be seen in the following table.
Sound pressure level LpAF in relation to the load capacity and size of the rope hoist at a distance of 1 m:
Type Hoist unit

EZDR Pro Max. noise emission level LpAF in dB(A), measured at a distance of 1 m10)
No load Under load
Main lifting speed Main lowering speed Main lifting speed Main lowering speed
5 70 dB 70 dB 73 dB 77 dB
10 77 dB 78 dB 77 dB 79 dB
Tab. 22
Type Cross travel

EZDR Pro Max. noise emission level LpAF in dB(A), measured at a distance of 1 m 10)
No load Under load
Left V2 Right V2 Left V2 Right V2
5 68 dB 68 dB 71 dB 72 dB
10 67 dB 66 dB 67 dB 67 dB
Tab. 23
The specified values (emission values) were measured under maximum load.
214 961 44/141212
26 10) All noise level data are subject to a tolerance of ± 2 dB (A).

The following structural influences were not considered in the measurements:
● transmission of noise via steel structures
● reflection of noise from walls, etc.
The sound pressure level is reduced by approx. 3 dB(A) each time the distance is doubled.
3.10 Paint finish

The machine is supplied in the following standard colours:
RAL 5009 azure blue

Hoist unit
RAL 1007 chrome yellow
Bottom block
RAL 9005 jet black
Hook RAL 9005 jet black
RAL 5009 azure blue
Travel unit
Tab. 24
3.11 Weight
Reeving 2/1 4/1 4/2

Hoist motor 12/2 4 12/2 4 12/2 4 12/2 4 12/2 4
Deadweight 490 510 510 530 510 530 530 560 -
Deadweight 530 550 550 570 550 570 600 550 550 570
Deadweight 560 580 580 600 580 600 600 630 580 600
Reeving 2/1 4/1 4/2

Hoist motor 12/2 4 12/2 4 12/2 4 12/2 4 12/2 4
Deadweight 608 646 632 669 647 684 674 717 -
Deadweight 648 686 672 709 687 724 714 757 807 850
Deadweight 678 716 702 739 730 767 757 800 850 893
Reeving 4/2
Deadweight 647 684 - -
214 961 44/141212

13) With frequency inverter 27
Reeving 4/2
Deadweight 687 724 714 757 807 850
Deadweight 717 754 744 787 837 880
3.12 Track girder requirements
3.12.1 Runway
32138533-dor
Fig. 7 Runway paint finish
The running surfaces must only be given a primer coat.
Minimum requirements for runways:

● Do not use beams with profile sections and cross-sections that are smaller than the minimum dimensions
specified in our brochures for track girders of double-rail crabs as otherwise deformation of the girders might
occur. Permissible deviations in dimension and shape of the track girder according to DIN EN 10034.
The special travel unit requirements are listed in accordance with the ranges in the following chapter  "Travel
unit", Page 29:
- Dimensional accuracy of the tracks
- Tolerance of the individual girder, of the crab track gauge
- Difference in rail height
- Gradient of the crab rails
● Hoist travel on track beams must in no way be obstructed by protruding suspension bolts, screw heads, butt
straps, clamping plates, etc.
● Track gradients should not exceed 2%.
● Appropriately dimensioned end stops must be fitted at both ends of the runway.
● Track joints must be clean and smooth. Bolted joints must be outside the travel area of the travel wheels (ob‐
serve maximum web thickness).
214 961 44/141212
● Fitting the cross-travel unit  "Checking dimensional accuracy of the tracks", Page 39.
28 13) With frequency inverter

● The running surfaces of rails and track beams must only be given a primer coat of 40 µ in the area of the
wheels and guide rollers. Travel characteristics would be impaired by a top coat ( Fig. 7, Page 28).
● Rails and track beams should be kept clean; oil, grease, ice and dirt on the running surfaces will cause travel
wheels to skid.
3.12.2 Travel unit

The travel units have a fixed width.
Available track gauges for EZDR 5 and 10 units are 1400 mm, 2240 mm and 2800 mm.
Before installing the travel unit on the track, it must be checked for dimensional accuracy,  "Checking dimen‐
sional accuracy of the tracks", Page 39.
Do not use the double-rail crab to pull free, pull or drag loads on the ground.
It must never run against the buffer stops at full speed, as otherwise damage or accidents may occur.
3.13 Control system

Crane and crab control using CANopen Safety CAN-bus technology:
● Redundant control system with two controllers that monitor each other
● Transmission of all safety-relevant signals acc. to CANopen Safety
● Permanent or cyclic monitoring of all safety functions
● Safety concept uses crane contactor as second entity for switching off
● On-board analysis and service system permits crane monitoring (optional)
● Minimum cabling required, therefore reduced weight and space
● Flexible adaptation due to modular PCB concept
● Cross-travel inverter and braking resistor integrated in the lower electrical enclosure
● Alternative control units can be plugged in
● Programmable functions:
- Load spectrum recorder to determine the remaining safe working period
- MGS/ZMS overload protection (ZMS optional)
- Load summation for two crabs
- Slack rope cut-off (optional)
- Load display with selectable unit (t, kg, lbs, T)
- SGDM / BER function
- Co-ordinated and safe operation of two crabs or two hoist units
- Synchronous operation of two hoist units with frequency inverter
- Area-related load and speed reduction (optional)
- Various by-pass control/pass-through control types (optional)
- Operating limit switch, rope limit switch, limit switch for phase-sequence error (optional)
- Holding and catching brake (optional)
● Integrated monitoring features
- Phase sequence
- Brake application
- Brake wear
- Speed
- Overheating
- Contactor switching statuses
214 961 44/141212
- Limit switch sequence
29
4 Design and function
4.1 Design
1 2
10 3
43245644.eps
Fig. 8
1 EZDR double-rail crab 7 4/1 bottom block

2 Travel motor 8 Hoist motor
3 Travel unit 9 Rope drum
4 Thrust rocker 10 Electrical equipment cover with integrated elec‐
5 Hoist gearbox trical equipment and geared limit switch
6 4/1 top block
Demag EZDR-Pro double-rail crabs are manufactured in two ranges, each with three groups of mechanisms.
4.2 Arrangement of assemblies

The design is characterised by parallel arrangement of the rope drum and the hoist motor. The gearbox and the
electrical equipment housings constitute the two central assemblies of the rope hoist. These two components are
bolted together to form the hoist unit frame by means of three connecting rods.
The crab frame consists of a welded steel structure for accommodating the hoist unit and the rope reeving com‐
ponents as well as the travel wheels and the cross-travel drive.
214 961 44/141212
30
4.3 Drives
4.3.1 Hoist and travel drive
Demag ZBR cylindrical-rotor motors with separately controlled DC brakes are used as hoist drives. They are de‐
signed in accordance with the design rules of the FEM, to meet the high demands made on electric hoists. ZBR
hoist motors feature IP 55 type of enclosure (for motor and brake).
A creep lifting speed of 1/6 of the main lifting speed is obtained by using a 2/12-pole motor.
Demag ZBA brake motors with separately controlled brakes are used as travel motors. Type of enclosure of the
ZBA travel motors is IP55.
4-pole travel motors which are controlled by a frequency inverter are used. The speed is infinitely variable.
4.3.2 Gearbox/rope reeving components

The torque of the motor is transmitted direct to the helical gearbox . The hoist gearbox (5) accommodates all gear
stages of the three-stage gearing. It is also the basis of the rope hoist.
The drum, rope sheaves and rope comply with the following design rules:
● FEM 9.661
● ISO 4308-1
● prEN 13001-3.2
4.4 Geared limit switch

Motions are limited at the upper and lower hook positions by the geared limit switch. In general, the geared limit
switch is provided with 4 contacts. The contacts are assigned in the factory as stated in the order of the rope
hoist.
The geared limit switch is fitted inside electrical equipment cover (10) of the Demag rope hoist. It switches off the
rope hoist when the top or bottom hook position is reached. The direction of movement can be reversed.
The emergency limit switch must not be approached in normal operation.
Operating limit switches are required where the end positions are approached regularly during normal operation.
In such cases, the switches must be adjusted so that the operating limit switch is actuated first and then, i.e. if this
fails to operate, the emergency limit switch is actuated.
work. This can be done by using a solution with a geared limit switch and a 2-stage button on the control pendant.
The 2-stage button must be pressed to move the hook back out of the end position (lowering).
214 961 44/141212
31
4.5 Integrated controls
43245744.eps
Fig. 9
The electrical equipment cover (1) accommodates the control system for the required connections, powerfeed
and further sensors. The connections are of plug-and-socket design throughout. The cover is locked by means of
twist locks and fitted on hinges.
4.6 Control pendant operating element
4.6.1 Overview
Available control pendants
The rope hoist is controlled by a Demag DSE-10R control pendant of

DSE-10R
plug-in design. The control pendant features an integrated mechatron‐
ics solution for infinitely variable motions in the individual axes.
The control system provides step or variable control according to the
selected drive.
The control pendant housings are made of high-quality thermoplastic
which is highly resistant to impacts. They are resistant to fuels, salt wa‐
ter, grease, oils and lyes.
WARNING
43249444.eps Danger from acids
Fig. 10 Strong mineral (e.g. hydrochloric or sulphuric) acids may
corrode pendant housings.
Avoid contact with these substances.
214 961 44/141212
32
4.6.2 DSE-10R
The rope hoist is controlled by a Demag DSE-10R control pendant.

Demag rope hoists are generally fitted with emergency limit switches
and a test button (2-stage) in the DSE-10R control pendant. The test
button can be used to by-pass the ‘lifting’ operating limit switch to check
4
the emergency limit switch. The control pendant is fitted according to
2  "Connecting the control cable", Page 59.
The control pendant should be suspended so that the bottom edge is
approx. 1 m above floor level. Suspend the control pendant in such a
1 way that the arrow symbols on the buttons indicate the correct direc‐
tions of movement.
3 The control pendant is generally of plug-in design for service and main‐
tenance-friendly installation.
43237044.eps
Item Function
Fig. 11 1 Emergency-stop button
2 Test button
3 Buttons to control the motion axes
4 Display
Tab. 28
● The two-stage test button (2) can be used to by-pass the ‘lifting’ op‐
erating limit switch to check the emergency limit switch.
● Service data or the load can be shown in the display (4).
● Only a general load value trend is displayed when standard equip‐
ment is fitted (MGS overload protection and load detection by means
of slip calculation).
● The load value is shown with an accuracy of ± 5 % when special
equipment is installed (ZMS strain gauge carrier link as overload pro‐
tection).
● An additional bumper protects the housing against particularly harsh
ambient conditions.
4.6.3 Principle
The DSE-10R consists of an integrated mechatronics solution, i.e. the mechanical actuating system acts on a
magnet sensor system that evaluates the control commands via an electronic system.
This makes stepless actuation possible in all three motion axes. The integrated DR control system provides step
or variable control in accordance with the optionally selected drives.
4.6.4 Wiring
The integrated DR control system features transmission of the control signals from the DSE-10R control unit to
the DR control system or to the crane control system via a CAN-bus for the first time. This makes it possible to
reduce wiring requirements to a minimum. The number of connection diagrams is reduced to one diagram.
4.6.5 Display
Information on the load value and the service data (min. quantity) is available via the standard display (4)
 Fig. 11, Page 33.
The load value trend is displayed when standard MGS overload protection is used and the load is detected by
means of slip calculation. The load is displayed with an accuracy deviation of a percentage when the optional
ZMS strain gauge carrier link is installed as overload protection.
214 961 44/141212
4.6.6 IrDA infrared interface

The DSE-10R control pendant is provided with an integrated infra-red interface (IrDA) to read and transmit the DR
rope hoist service data (see control pendant operating instructions,  Further documents, page 2).
33
The control pendant and the mains connection cable must be fitted by the customer in such a way that the con‐
nectors are not subjected to any tensile or transverse forces.
The control cable of the control pendant is provided with vulcanised strain relief wire cords which must be attach‐
ed by the customer.
4.7 Overload protection
MGS ZMS
43237144.eps
Fig. 12
MGS mechanical or ZMS electronic overload protection (option) can be used to protect Demag rope hoists and
supporting structures against overloads.
A summation measuring device, slack rope relay and load display can also be fitted in combination with ZMS
overload protection.
214 961 44/141212
34
4.8 Type plate (example)
2 Baujahr: 20xx Fabrik-Nr.: 96751031 9

3 Gruppe: xx Tragfaehigkeit: xxxx kg 10
4 Baugroesse: xxxx x Hakenweg: xx m 11
5 Getr.i.: xx Haupthub: xx m/min 12
6 Einscherung: xx Feinhub: xx m/min 13
7 Seildurchmesser: xx mm rechn. Seilbruchkraft: xx kN 14
8 Auftrags-Nr.: 000000 - 00000000 - 00 ASN: xx
43237244.eps
Fig. 13
The type plate contains the following information 8 Order number

1 Manufacturer 9 Serial no.
2 Year of manufacture 10 Load capacity [kg]
3 Group of mechanisms to FEM/ISO 11 Hook path [m]
4 Size 12 Main lifting speed [m/min]
5 Gearbox transmission ratio i 13 Creep lifting speed [m/min]
6 Reeving 14 Calculated rope breaking force [kN]
7 Rope diameter [mm]
The type plate of the rope hoist is located on the side of the gearbox housing of the travel motor.
214 961 44/141212
35
5 Transport, packing, storage
WARNING
Risk of injury from falling parts
Secure components during transport. Do not step under the suspended load.
CAUTION
Inappropriate transport
The machine may be damaged.
Lift loads only at the marked lifting points. Only use suitable hoisting equipment which has sufficient load capaci‐
ty.
5.2 Transport inspection

● Check that the delivery is complete and for transport damage immediately upon receipt.
● If any transport damage is visible from the outside, only conditionally accept the delivery. Note the scope of
damage in the shipping documents/delivery note of the forwarding company and lodge a claim.
● Lodge a claim for any defects that are not immediately detected as soon as they are discovered, since claims
for damages may only be asserted within the relevant claim notification periods.
5.3 Packing
If no agreement has been made on the return of the packing material, separate the materials according to type
and size and make it available for further use or recycling.
Environmental protection:
● Always dispose of packing materials in an environmentally compatible way and according to locally applicable
disposal regulations.
● If required, utilise the services of a recycling company.
5.4 Storage
Until they are installed, the machine and accessories must be kept closed and may only be stored under the fol‐
lowing conditions:
● Do not store outdoors.
● Store in dry and dust-free places, relative air humidity: max. 60%.
● Do not expose to aggressive media.
● Protect against direct sunlight.
● Avoid mechanical vibrations.
● Storage temperature: -25 °C to +55 °C.
● Avoid strong temperature fluctuations (condensation).
● Oil all bare machine parts (rust protection).
● Check the general condition of all parts of the packing at regular intervals. If required, refresh or renew rust
protection.
● If stored in a damp location, the machine must be packed tight and protected against corrosion (desiccant).
214 961 44/141212
36
6 Installation and putting into operation for the first time
WARNING
Dangerous electric current
Work on electrical equipment may only be carried out by qualified specialist personnel in compliance with the
safety regulations.
– Before starting work, switch off the electrical supply and secure against restoration.
Special information for assembly
a) b)
43311344.eps
Fig. 14 Example of safe assembly
a) Protection for the working area

b) Example of a suitable working platform
WARNING
Risk of injury if incorrectly assembled
Incorrect installation can lead to severe injury and/or damage to property.
Therefore, this work may only be carried out by authorised, instructed personnel who are familiar with the princi‐
ple of operation of the machine in compliance with all safety regulations:
– If a lifting appliance is used for assembly, only use appropriate attachments for the lifting of persons which
ensure that work is carried out in a safe and stable position ( Fig. 14, Page 37).
– In the course of putting the unit into operation, it may be necessary to render safety devices or features
temporarily inoperative.
214 961 44/141212
– First check that the voltage and frequency specified on the data plates match the owner's mains power sup‐
ply.
– All clearance dimensions and safety distances (see approval drawing) must be checked before putting the
unit into operation.
37
– Work may need to be carried out in the danger zone when the unit is put into operation.
– Be careful when working on open components that have sharp edges. Risk of injury.
– Keep the working area clean and tidy. Store any unneeded machine or installation parts and tools in such a
way that there is no risk of them falling.
– Fit components appropriately. Comply with specified bolt tightening torques. Incorrectly fitted components
may fall and cause severe injuries.
– The electrode holder and earth must always be connected to the same assembly when welding work is car‐
ried out as otherwise serious damage may be caused to the machine.
– Attach the rope hoist only at the appropriate connecting points.
– Only carry out installation work when all requirements regarding the installation location are met  "Operat‐
ing conditions", Page 25.
6.2 Assembly of travelling hoists
6.2.1 Overview
b
a
d
c
43245844.eps
Fig. 15
214 961 44/141212
a Single-groove design, 4/1 reeving c Double-groove design, 4/2 reeving

b Single-groove design, 2/1 reeving d Single-groove design, 6/1 reeving
Check that the machine is complete and in perfect technical condition before installation.
38
6.2.2 Checking dimensional accuracy of the tracks
6.2.2.1 Tolerance of the individual girder
The steel girders must be aligned properly before fitting the cross-travel units, therefore, the dimensional accuracy
of the tracks must be checked before fitting.
Lateral deviation
n s
L
2 L
2
L
L
2 L
L
2
43245944.eps
Fig. 16
n = ± 2 mm, maximum lateral deviation

s = ± 2 mm, maximum lateral rail deviation
– Measure lateral girder/rail deviation ‘n’ or ‘s’ by means of a cord, laser or theodolite at half of the girder
length.
6.2.2.2 Twisting
Any twist must be compensated when the connecting plates are fitted.
● Max. permissible twist ‘y’ is 0.5 mm/m
y Calculation based on formula: ymax = 0.5 x LTr
Example for calculating permissible twist ‘y’ for a girder length of 10 m

● ymax = 0.5 x LTr
● y max. = 0.5 mm/m x 10 m = 5 mm
43246144.eps
Fig. 17
214 961 44/141212
39
6.2.2.3 Tolerance of the crab track gauge
b
L + 4 mm
a KA - +2 mm
-2 mm
43246244.eps
Fig. 18
a Track gauge: LKA ± 4 mm

b Centre of web plate
– Check track gauge over the entire travel path.
6.2.2.4 Gradient of the crab rails

a
43246344.eps
Fig. 19
a Max. gradient dimension 1 mm
– Gradient of the crab rails to be measured at points spaced 1 m apart over the entire track gauge.
214 961 44/141212
40
6.2.2.5 Difference in rail height
43246444.eps
Fig. 20
a Max. permissible difference in height 5 mm
The maximum permissible difference in rail height is 5 mm.
6.2.2.6 Rail level difference

5 mm
4 mm
43246544.eps
Fig. 21
∆H = max. 1.5 mm
The maximum permissible difference in height between two measuring points arranged next to each other along
one rail is 1.5 mm.
214 961 44/141212
41
6.2.3 Fitting the end stops/clamp-fitted buffers
Fitting the end stops/clamp-fitted buffers is described in detail in the separate fitting instructions  (203 652 44).
Further details  "Assembly and alignment of the travelling hoists", Page 42.
The double-rail crab must never run against the buffer stops at full speed, as otherwise damage to the hoist unit
or even accidents may occur.
The monorail hoist is counter-balanced by the thrust rocker which presses against the track from below.
6.3 Assembly and alignment of the travelling hoists
6.3.1 Assembly instructions
WARNING
Crushing hazard and risk of injury from falling parts.
Safely support the travel unit on the track girder while it is being installed to avoid any risk of crushing or falling.
Refer to section  "Checking dimensional accuracy of the tracks", Page 39 for special data regarding inspection
of tracks and girders.
Before installing the travel unit on the track, it must be checked for dimensional accuracy, see section  "Check‐
ing dimensional accuracy of the tracks", Page 39.
6.3.2 Aligning the travelling hoist on the crane
They must be aligned using adjusting jigs, .
214 961 44/141212
42
Adjusting jigs
A B
1 2
A B
a)
b)
43449344.eps
Fig. 22
A View of roller-side travel unit 2 Adjusting jig on wheel block side

214 961 44/141212
1 Adjusting jig on roller side a) Version with threaded pin

B View of wheel block-side travel unit b) Version with clamps
43
6.3.3 Assembly of adjusting jig A
6.3.3.1 Assembly of the adjusting jig on the roller side (preparation of adjusting jig for assembly)
– Loosen the star grips (5) and open the clamping device.
3
4
5
43449444.eps
Fig. 23
– Loosen the bolted connection of the profile section (3).
4
43449544.eps
Fig. 24
– Position the adjusting jig in such a way that the plate of the travel unit (6) is located between the clamping
jaws (4) of the adjusting jig.
214 961 44/141212
– Slide the profile sections together until the clamping jaws grip.
– Tighten the bolted connection of the profile section.
44
– Shift the adjusting jig in height until the lower side of the profile sections (3) is slightly above the outer rings
of the travel rollers (7).
3 5
7
43449644.eps
Fig. 25
– Shift the clamping jaws with the star grips.

– Retighten the bolted connections.
6.3.4 Assembly of adjusting jig B
6.3.4.1 Version a: Fixing with threaded pin guide for EZDR with one travel drive (inside)
– Remove nuts (1) and washers (2) of the adjusting jig.
1 2
3
4
43449444.eps
Fig. 26
214 961 44/141212
45
7 7
8 9 9
5 6
43449844.eps
Fig. 27
– Insert the threaded pints(9) in the wheel block bores.
– Align the wheel blocks to the adjusting jig, as required.
214 961 44/141212
46
2
1 2 10
43449944.eps
Fig. 28
– Tighten nuts (1) with washers (2) to align the wheel blocks (10) with each other.
6.3.4.2 Version b: Fixing with two clamps for EZDR with two travel drives (outside).
– For alignment, use the adjusting jig with clamp (1).
1
2
3
1
43450044.eps
214 961 44/141212
Fig. 29
– Remove the travel drives incl. torque brackets.

47
6 6
9
10
11
8 7 8
4 5
43450144.eps
Fig. 30
– Align the adjusting jig in parallel to the wheel block front side.
– Fix the adjusting jig with the two clamps (8) on the threaded pins of the travel drive fastening arrangement.
– Tighten nuts (9) with washers (10).
In this way, the wheel blocks (11) are aligned flush to each other.
214 961 44/141212
48
6.3.5 Adjustment for horizontal alignment
The following steps apply for both versions (a and b) of view B (assembly on the wheel block side)
– Align both sides of the adjusting jigs A and B parallel (=, see fig.) to each other.
=
A B
43450244.eps
Fig. 31
– Align the wheel blocks centrally on the travel rails (2). Pay attention to the mark (3) on the housing.
3
= = 2
43450344.eps
Fig. 32
– Set the wheel blocks down onto the rail.

– Re-tighten the wheel block screws (1), 4 on each wheel block.
214 961 44/141212
49
CAUTION
Loose connections
– Wheel block screws (1)
DRS 125: 130 Nm
DRS 160: 330 Nm
6.3.6 Disassembly of adjusting jigs A and B

Completion version a
– Loosen the nuts (1) and remove the adjusting jig B on the wheel block side.
43450444.eps
Fig. 33
214 961 44/141212
50
1
43451044.eps
Fig. 34
Completion version b
– Loosen the nuts (1) and washers (2) on both clamps (3).
– Remove the clamps and the adjusting jig B.
– Fit the two travel drives.
214 961 44/141212
51
6.3.7 Assembly and adjustment of the guide rollers
Fit the guide rollers
43450544.eps
Fig. 35
– Insert the screws (1) and tighten them by hand.

– Check the horizontal alignment of the mounting plate and correct it, if necessary.
– Tighten the bolts.
CAUTION
Loose connections
DRS 125: 130 Nm
DRS 160: 330 Nm
– Fit the buffers (2).

214 961 44/141212
52
Adjust the guide rollers
3
2
43450644.eps
Fig. 36
– Loosen screws (1).

– Adjust the guide rollers (2) to a maximum of 1 mm (0.5 mm per side) play.
To do this, use a feeler gauge, for example.
– Tighten screws (1).
CAUTION
Loose connections
DRS 125: 130 Nm
DRS 160: 330 Nm
– Fit the pressure rollers (3) and adjust them, (see hoist unit operating instructions).
214 961 44/141212
53
Test run along the entire runway
43450744.eps
Fig. 37
– Carry out a test run.

The rollers must not come into contact with the weld seams under any circumstances. Minimum distance to the
weld seams 2.5 mm.
– Check gap between thrust rocker (2) and web plate (3), which must be a minimum of 5 mm.
If the gap is not large enough, the parallel position of the crab must be changed by adjusting the guide roll‐
ers.
214 961 44/141212
54
Final adjustment of the horizontal guide rollers
4 3
x x
2 2 2 1
43247944.eps
Fig. 38 DRS wheel block (shown without buffer)
Adjusting the horizontal guide rollers:

1. Align travel wheel (4) with the centre of rail (3) and then adjust horizontal guide rollers (2).
2. To do this, loosen locking screws (1) and align guide rollers (2) with rail (3) taking ‘dimension x’ into account.
3. Tighten locking screws (1) (pay attention to the tightening torque in the table)  Tab. 29, Page 55.
4. Then check the distance of guide rollers (2) to rail (3).
Size Locking screw tightening torque [Nm] Dimensions in mm

x
DRS 125 130 0.5
DRS 160 330 0.5
Tab. 29
214 961 44/141212
55
6.3.8 Final adjustment of the thrust rocker
S
C
A
6 1 1
5
3
X
43248044.eps
Fig. 39
1 Thrust rocker S Overall height = overall height of rail and upper

2 Lock nut flange
3 Pressure spring x Tensioning dimension
4 Rail A, B, Mounting bore holes
C
5 Girder section/upper flange
6 Bolt
Setting the thrust rocker

1. Determine upper flange and rail dimension (S).
2. Refer to the table for the corresponding mounting bore holes (A, B or C).
214 961 44/141212
3. Fit thrust rocker on crab frame by means of screws (6) via the relevant threaded bore holes (tightening tor‐
que 130 Nm).
4. Adjust pre-tension dimension (x) using locknut (2) to apply the contact pressure of the thrust rocker to the
upper flange.
56
Pre-tensioning of pressure spring and fitting
Mounting for bore hole A Mounting for bore hole B Mounting for bore hole C
Installation Pre-tension dimension X [mm] Installation di‐ Pre-tension dimension X [mm] Installation di‐ Pre-tension dimension X [mm]
dimension DR 5 and 10 DR 10 6/1 mension DR 5 and 10 DR 10 6/1 mension DR 5 and 10 DR 10 6/1
‘S’ [mm] ‘S’ [mm] ‘S’ [mm]
34 3.4 5.3 51 3.8 5.7 71 2.7 4.1
38 4.1 6.2 54 4.3 6.5 75 3.6 5.4
42 4.8 6.8 58 5.0 7.5 79 4.3 6.5
46 5.5 8.3 62 5.7 8.6 83 5.0 7.5
50 6.2 9.3 66 6.4 9.6 87 5.7 8.6
70 7.2 10.8 91 6.4 9.6
95 7.2 10.8
Tab. 30
214 961 44/141212
57
6.4.1 Wiring
6.4.1.1 General
DANGER
Live components
All wiring and connection work may only be carried out by an instructed and qualified electrician according to the
specifications of the electrical connection diagram included in the supply.
Each machine is provided with a wiring diagram showing details of the controls.
The wiring of the Demag machine complies in all respects with current DIN VDE and accident prevention regula‐
tions. Unauthorised intervention and modifications may result in infringement of these regulations.
The switchgear is designed for extreme conditions. However, its service life depends on usage. Advise operators
that
● inching (i.e. giving short pulses to the motor to obtain small movements) should be avoided as far as possible,
e.g. when attaching a load. It may cause excessive wear and premature failure of the switchgear.
● corrosion on plastic (identifiable by dull, sooty or brittle surfaces) and metal components in enclosed switch‐
gear housings can be caused by too frequent inching.
● corroded parts must be replaced in good time.
6.4.1.2 Frequency inverter

Since the machine is fitted with a frequency inverter, the following additional connection requirements must be
observed:
● Check connection to the public supply network without further measures in accordance with the provisions of
standard EN 61000-3-2.
● Frequency inverters fulfil the emission limit value requirements of product standard EN 61800-3. Increased re‐
quirements resulting from the application environment of the frequency inverter must be met by the use of op‐
tional components.
● Operation in a non-earthed system (IT system) is allowed after the Y capacitors inside the inverter have been
disconnected.
● Fault-free operation with a current-operated e.l.c.b. (earth-leakage circuit-breaker) is ensured with a tripping
current > 30 mA if the following is considered:
- Residual-current-operated circuit-breakers sensitive to all types of currents (type B acc. to EN 50178), when
connecting frequency inverters with two (L1/L2) or three-phase (L1/L2/L3) connection to the power supply.
- The residual-current-operated circuit breaker protects a frequency inverter with a leakage-current reduced
filter or without a radio interference suppression filter.
- The Y capacitors in the inverter must be disconnected. This increases cable-bound emitted interference
(EMC).
214 961 44/141212
58
6.4.1.3 Control cable and line voltage connection
CAUTION
Electrical connection with incorrect voltage.
A
The electronic equipment may be destroyed if the control
voltage is too high.
If the measured value exceeds or drops below the voltage
specified on the machines by more than 10%, a control
transformer must be connected on the primary side ac‐
B
cording to the table in the circuit diagram (see electrical
43238844.eps
connection diagram).
Fig. 40
– Before starting any connection work, use a voltmeter
to check whether the voltage and frequency specified
on the data plate match the mains supply.
Voltage-changing motors are wired in our works for the operating volt‐
age stated in the order of the Demag rope hoist. The standard control
voltage is 48 V 50/60 Hz.
The diagram shows the mains connection and control voltage sockets
on the rope hoist:
● 4-pole plug-in mains connection, connector A,
● 48 V control voltage and CAN-bus control signal plug connection,
connector B.
Plug in the relevant connectors and tighten the locking screws by hand
to make the connections.
6.4.2.1 Direct connection to the machine
340 875 44
M6
504 419 44
43238944.eps
Fig. 41
Connect the control cable with vulcanised strain relief cords as shown in the diagram. (see separate DSE-10R
control pendant operating instructions and electrical connection diagram).
214 961 44/141212
59
6.4.2.2 Connection to the KBK trailing cable trolley
DSE-10R control pendant adjustment

DSE-10R control pendants are supplied with cable lengths of 6 m or 10 m as standard. The suspension height
can be adjusted by means of a self-locking clamping mechanism to suit individual requirements. Adjust as descri‐
bed below  Fig. 42, Page 60.
1. Loosen clamping mechanism (1).
2. Adjust the required suspension height. Bundle any control cable that is not needed and store it in cable col‐
lector (2).
43239144.eps
Fig. 42
6.4.3 Checking the direction of movement
CAUTION
Error in assembly
Failure to carry out this check may result in severe damage or injury.
The direction in which the rope hoist moves depends on the phase sequence in the power supply. The load hook
must move upwards when the control pendant ‘lifting’ switch is actuated. If this is not the case, two of the supply
cable leads should be swapped over to ensure that the emergency limit switches operate correctly.
If the phases are incorrectly connected, the control system will automatically switch the hoist motor motion off af‐
ter it briefly starts up. Error code 38 appears on the display of the DSE-10R control pendant or on the radio con‐
trol (optional).
Check the top and bottom hook positions and adjust accordingly  "Geared limit switch ", Page 75.
214 961 44/141212
60
6.5 Rope reeving
6.5.1 Reeving methods
2/1 4/1 4/2 6/1
43248144.eps
Fig. 43 EZDR reeving arrangements, 2/1, 4/1, 4/2 and 6/1 reevings
6.5.2 Reeving methods for the rope hoist
General
Demag DR-Pro rope hoists are supplied with the rope separate from the bottom block.
Reeving of the ropes for Demag EZDR-Pro rope hoists with 2/1, 4/1, 4/2 and 6/1 reeving arrangements is shown
in the following sections.
Rope routing for the various reeving arrangements is shown in the following diagrams, in section  "Bottom block
reeving", Page 64.
CAUTION
Cutting hazard
Care must be taken to keep the rope tight and not to twist it while reeving. Rope routing must always be complied
with.
For single-groove rope drums, the rope is retained by a wedge and a rope socket anchorage that is incorporated
in the rope-retaining crosshead.
Please ensure that the load-bearing end of the rope enters the vertical part of the socket ( Fig. 47, Page 65).
The rope is properly secured if the wedge remains visible above the anchorage and the dead end protrudes by
approx. 10 cm when under load.
The rope can be replaced by Demag service engineers or an authorised specialist company.
The method of securing the rope end by means of this anchorage is absolutely reliable and conforms to the rele‐
vant regulations. An additional safety feature to prevent the dead end of the rope from slipping must be fitted in
214 961 44/141212
accordance with ISO 4309. Fit the required rope clamp as shown in  Fig. 47, Page 65.
61
CAUTION
The rope must not be secured with a rope clamp fitted over both rope ends. This would cause bruising and un‐
even stress in the carrying fall of the rope and thus lead to its destruction.
Check suspension of the rope socket.
Ensure that the double spring clip is correctly seated when the rope socket is fitted  Fig. 47, Page 65.
Check fitting of the MGS/ZMS overload protection.
Ensure that the retaining ring clicks into the groove of the pin when the retaining ring is fitted  Fig. 47,
Page 65. It must be possible to turn the retaining ring easily after it is fitted. Grease the bearing points with a
suitable adhesive lubricant. Order no.: 472 933 44.
6.5.3 Fitting MGS/ZMS overload protection
6.5.3.1 MGS/ZMS overload protection, 2/1, 4/1 and 6/1 reeving
MGS ZMS
5 5
1
2 1
3
MGS ZMS
3 2
2 4
4
43303444.eps
Fig. 44
1 Pin 4 Spring ring

2 Washer 5 Lever
3 Collar sleeve
Install MGS or ZMS overload protection in the crosshead and the lever as shown in the drawing.
214 961 44/141212
62
6.5.3.2 ZMS overload protection, 4/2 reeving
ZMS
ZMS
2
3
43430844.eps
Fig. 45
1 Pin 2 Washer
3 Spring ring
Install ZMS overload protection in the crosshead and the lever as shown in the drawing.
See section  "Fitting the rope", Page 92

214 961 44/141212
63
6.5.5 Bottom block reeving
6.5.5.1 2/1 reeving
43248244.eps
Fig. 46
1 Rope drum 4 Rope socket

2 Bottom block 5 Double spring clip
3 Rope clamp
1. Slide the loose rope end on rope drum (1) through the rope sheave in bottom block (2).
214 961 44/141212
64
9
8
3 4 5 5 6
3
1
6
4
7
7
2 2 10
43238344.eps
Fig. 47
1 Rope wedge 6 Pin

CAUTION
CAUTION

DR 5 6
DR 10 33
Tab. 31
214 961 44/141212
65
CAUTION
diagram.
– Fit washer (4) and secure pin (6) with double spring clip (3).
6.5.5.2 4/1 reeving
1 2
4
5
6
43248344.eps
Fig. 48
1 Double spring clip 5 Rope sheave in bottom block

3 Rope clamp 7 Compensating sheave/return sheave
4 Rope drum
1. Slide the loose rope end on rope drum (4) through a rope sheave in bottom block (6).
2. Then lay the rope end over compensating sheave (7).
3. Slide the rope end through the second rope sheave of bottom block (5).
214 961 44/141212
66
Rope arrangement in bottom block
43297444.eps
Fig. 49
– The rope is led into and out of the protective cover through the bore holes (arrows). Push the plastic protec‐
tive covers fully down (shown on the left) when the rope is fitted.
9
8
3 4 5 5 6
3
1
6
4
7
7
2 2 10
43238344.eps
Fig. 50
1 Rope wedge 6 Pin

214 961 44/141212
67
CAUTION
CAUTION

DR 5 6
DR 10 33
Tab. 32
CAUTION
diagram.
– Fit washer (4) and secure the pin with double spring clip (3). 214 961 44/141212
68
6.5.5.3 4/2 reeving
4
3
43248444.eps
Fig. 51
1 Rope drum 4 Bottom block sheave

2 Wire rope 5 Compensating sheave
3 Bottom block sheave
Installing the rope requires utmost care and a lot of experience. We recommend that this work be carried out by
214 961 44/141212
69
Fitting the bottom block for 4/2 reeving
● Fitting the bottom block with cable grip for assembly (1) (part no.:
8 mm - 15 mm dia. 713 990 45)
● Introduce cable grip (1) into bottom block (3).
43238044.eps
Fig. 52
214 961 44/141212
70
● Insert wire rope (2) into the cable grip.
2
● Push the wire rope through one side of the bottom block together
with the cable grip.
Do not pull the cable grip.
● Guide the wire rope through compensating sheave (5,  Fig. 51,
Page 69) and into the second sheave of bottom block (4,  Fig. 51,
3
Page 69).
● Remove the cable grip from the end of the rope.
● Secure the end of the rope to the other end of rope drum (1) with
rope clamps  "Securing the end of the rope, more than one
groove", Page 71.
43238144.eps
Fig. 53
Securing the end of the rope, more than one groove
See section  "Fitting the rope, more than one groove", Page 96
214 961 44/141212
71
6.5.5.4 6/1 reeving, EZDR-Pro 10
1 2
3
4
6 5
43248544.eps
Fig. 54
1 Double spring clip 4 Wire rope

3 Rope drum 6 Rope clamp
Follow the steps described below with the loose end of the rope to reeve the rope for 6/1 reeving (see diagram for
rope routing arrangement):
1. Guide the end of the rope through outer sheave (1) of the bottom block (without removing the bottom block
cover).
6
2
4
1 5
3
214 961 44/141212
43248644.eps
Fig. 55
72
2. Guide the end of the rope over first sheave (2) of the top block.
3. Guide the end of the rope over centre sheave (3) of the bottom block.
4. Guide the end of the rope over second sheave (4) of the top block.
5. Guide the end of the rope over third sheave (5) of the bottom block.
6. Secure the end of the rope in rope socket (6) of the anchorage on the frame,  "Fitting the rope socket for
6/1", Page 73.
7. Wind up the rest of the rope by turning the drum in the lifting direction.
8. Check the setting of the limit switch for the lifting motion and adjust, if necessary,  "Set the upper cut-out
points", Page 77, see hook dimension ‘C’.
9
8
3 4 5 5 6
3
1
6
4
7
7
2 2 10
43238344.eps
Fig. 56
1 Rope wedge 6 Pin

5 Collar sleeve 10 Rope
CAUTION
214 961 44/141212
73
CAUTION
– Rope clamp tightening torque: 33 Nm

DR 10 33
Tab. 33
CAUTION
diagram.
– Fit washer (4) and secure the pin with double spring clip (3).
214 961 44/141212
74
6.6 Putting into operation for the first time
6.6.1 Checks before putting the unit into operation for the first time
The owner is obliged to carry out the following checks before putting the unit into operation for the first time,
 "Regular inspections", Page 17.
Activity See section Check

Check oil level in the hoist gearbox of the rope hoist  "Gearbox oil filling", Page 24 x
Check rope securing devices and rope guide KD14) x
Check strain relieving elements, control cable and control pendant housing for  "Connecting the control cable", Page 59 x
damage
Check spring tension of supporting roller and plastic coat of supporting roller  "Assembly and alignment of the travel‐ x
bearing ling hoists", Page 42
Check electrical switchgear and wiring  "Wiring", Page 58 x
Check operation of the limit switch  "Switching on", Page 81 x
Check operation of the brake  "Check operation of the brake", x
Page 83
Check operation of overload protection device KD14) x
Check lubrication of rope  "Wire ropes", Page 88 x
Check hook and hook safety catch  "Regular inspections and monitoring x
measures for load hooks", Page 98
Check with an overload of 125%  "Overload test with 125%", Page 79 x
Tab. 34
6.6.2 Inspection regulations

Inspection before putting the product into operation for the first time:
● If hoist units are used as cranes, an inspection must be carried out by an expert engineer in accordance with
relevant accident prevention regulations (BGV D6, Section 25) for cranes.
● Hoist units used in accordance with relevant accident prevention regulations for winches, hoists and towing
devices (BGV D8) must be inspected by an experienced technician.
The inspection in accordance with BGV D8 mainly consists of a visual inspection and a function check. It is de‐
signed to ensure that the equipment is in a safe condition and that any defects and damage, e.g. caused by inap‐
propriate handling during transport, are identified and repaired.
In addition, regulations specific to cranes must also be taken into consideration during acceptance and other in‐
spections in accordance with relevant accident prevention regulations for cranes (BGV D6).
6.6.3 Geared limit switch
6.6.3.1 Geared limit switch function

The geared limit switch is fitted in the electrical equipment enclosure of the Demag DR rope hoist. It switches off
the rope hoist when the top or bottom hook position is reached. The direction of movement can be reversed. The
emergency limit switch must not be approached in normal operation. The emergency limit switches trigger the
emergency stop function.
Operating limit switches (optional) are required if the end positions are approached regularly during normal opera‐
tion. In such cases, the switches must be adjusted so that the operating limit switch is actuated first and then, i.e.
if this fails to operate, the emergency limit switch is actuated. The operating limit switch only switches the hoist
unit off.
work. This can be done by using the 2-stage button of the DSE-10R control pendant.
214 961 44/141212
The key-operated button must be pressed to move the hook back out of the end position (lowering).
14) KD = After-sales service 75

Geared limit switch adjustment
1 2
43239444.eps
Fig. 57
1 "Block" adjusting screw

2 "Individual" adjusting screw
A 4 mm hexagon socket key is needed to adjust the geared limit switch.
WARNING
Live components
Before setting the switching points, make sure that live contacts are provided with a guard to protect against ac‐
cidental contact. Allow for run-on.
Operating principle
Each contact is allocated to a cam disk which is infinitely adjustable. The cam disks can be adjusted independent‐
ly by means of "individual" adjusting screws (2).
Adjustment
When ‘individual’ adjusting screw (2) is turned clockwise, the cam disk is also turned clockwise. The switching
point is shifted upwards in accordance with the hook path.
When the screw is turned anti-clockwise, the switching point is shifted downwards. Standard cam disks are de‐
signed in such a way that a maximum useful path and a run-on path are available.
Adjusting individual contacts (2)
The geared limit switch is already permanently connected with the control system via the system connector cable.
Move the load hook of the rope hoist into the specified cut-off position (see section 8.1.1, table 1 for cut-off
points). Turn the "individual" adjusting screw until the contact maker opens the contact to adjust the contacts.
If the run-on path is exceeded, the contact either opens or closes.
Adjusting blocks of contacts (1)
The contacts are adjusted in blocks by means of "block" adjusting screw (1). All cam disks are adjusted together,
while the relative adjustment of the individual contacts remains unchanged. When the "block" adjusting screw is
turned clockwise, the cam disks are also turned clockwise.
For adjustment, please note:
● The geared limit switch is adjusted before leaving the factory to avoid complete unwinding of the rope, only.
214 961 44/141212
● Approach cut-out points several times to check the limit switch functions are operating correctly.
76
6.6.3.2 Setting the cut-out points
The emergency limit switches must be properly adjusted to ensure that accidents are prevented and to avoid
damage to the rope hoist. The emergency limit switches are adjusted before leaving the factory to avoid complete
unwinding of the rope, only. Following installation of the rope hoist, they must be readjusted and checked for the
particular operating conditions.
If you want to set the maximum possible lifting height for your specific operating conditions, the following must be
observed:
● The emergency limit switch for the top hook position must be set so that dimension C is reached when the
switch cuts off the lifting motion, see  "Hook dimension C", Page 24.
● The emergency limit switch for the bottom hook position must be set so that the load hook does not touch the
floor.
The cut-out points of the geared limit switch have already been set to default values when the machine leaves our
factory.
If non-default values are to be set for the cut-out points, proceed in the sequence described in the following.
6.6.3.3 Set the upper cut-out points
WARNING
Incorrect setting
Commissioning work may only be carried out by qualified specialist personnel in compliance with the safety reg‐
ulations. Safety devices must not be rendered inoperative when the unit is put into service. When the unit is first
put into operation, the following must be observed:
– Secure and fence off the working and danger zone.
– Determine the cut-out points for the emergency and operating limit switches (optional)  Tab. 19, Page 24.
– Adjust the cut-out points on the geared limit switch (emergency limit switch and operating limit switch).
CAUTION
Note function of the cut-out positions
The cut-out points must be adjusted so that the operating limit switch (optional) is actuated first and then, i.e. if
this fails to operate, the emergency limit switch is actuated.
– Emergency limit switches must not be approached in normal operation.
– For standard equipment (without operating limit switch):

Adjust dimension C setting for the top hook position. Determine the distance based on the tables  "Hook
dimension C", Page 24.
C
214 961 44/141212
43248744.eps
Fig. 58
77
– For units fitted with emergency and operating limit switches (optional):
The upper emergency-stop cut-off point (emergency limit switch) must be adjusted in such a way that the
permissible cut-off point setting is maintained when the lifting motion has been switched off by the emergen‐
cy limit switch. Determine hook dimension C based on the tables  "Hook dimension C", Page 24.
– Adjust dimension C setting for the top hook position (operating limit switch). Determine the distance based
on the tables  "Hook dimension C", Page 24.
43248744.eps
Fig. 59
6.6.3.4 Set the lower cut-out points
CAUTION
Incorrect adjustment
Ensure that the minimum number of retaining windings are wound on the drum when setting the bottom hook
position.
Range Required rope windings on the drum

2/1, 4/1, 6/1 reeving 4/2 reeving
EZDR-Pro 5
3 3.5
EZDR-Pro 10
Tab. 35
– Use the control pendant to set the bottom hook position for the emergency limit switch so that the load hook
does not touch the floor.
– Set the cut-out points (see above).
214 961 44/141212
78
6.6.4 Overload test with 125%
The switch setting for the overload test is located under the equipment
cover.
789 ● After DIP switch 6 has been switched from OFF to ON, the overload
protection device is de-activated for 15 minutes and limited to 146%
456
AB
CDE so that the crane acceptance test can be carried out at 125%.
23
F0 1
● After 15 minutes or every time the hoist unit is switched off and on
(start-up of the control system) or after switch 6 is reset to OFF, the
789 overload protection device (110%) becomes active again.
456
AB

CDE
23
F0 1
789
456
AB
CDE
23
F0 1
1
8
7
6
5
4
3
2
ON
43239544.eps
Fig. 60
6.6.5 Travelling hoist travel characteristics and run-on paths when stopping
Small cross-travel movements that can occur when the travelling hoist is braked are caused by load sway. How‐
ever, this results in a reduction of load sway.
This effect is referred to as passive load-sway reduction and is not critical for the travelling hoist or crane.
214 961 44/141212
79
7 Operation
WARNING
Inappropriate operation
Incorrect operation may result in severe injury or damage to property.
The machine may only be operated by authorised and instructed personnel in compliance with all accident-pre‐
vention and safety regulations.
– National regulations for the use of cranes and lifting appliances must be observed and followed.
WARNING
Danger if care obligations are neglected
Danger to life and limb if the machine is operated with little care.
Requirements for operating the machine include:
– All installation/assembly work has been carried out according to the operating instructions.
– The rope must be adequately lubricated.
– The rope must be in good condition. Operation with defective or damaged ropes results in a high risk of
accidents with personal injuries and is therefore prohibited. Risk of damage to the machine.
– Any changes or modifications which prejudice safety must be reported to the nearest person responsible
immediately.
– Repairs may only be carried out by experienced technicians.
WARNING
Falling loads
Any person remaining in this danger zone may suffer serious injury or death.
Only use suitable and tested load handling attachments.
– Observe the operating instructions for the load handling attachment.
– Do not exceed the maximum permissible load capacity of the load handling attachment.
– Do not transport loads above people when using load handling attachments that retain the load by means
of magnet, friction or suction forces without an additional load securing device.
Before starting work:

● Put on protective clothing.
● Ensure that nobody is present in the danger zone of the machine.
● Check operation of the brakes, emergency limit stop devices and emergency stop devices.
During operation:
● Do not approach emergency limit stop devices (e.g. emergency limit switch) in normal operation.
● Do not render safety devices inoperative.
● Adopt a position that ensures a clear view of the danger zone for lifting and travel motions.
● Never touch the ropes while the machine is in operation.
WARNING
Damaged components/malfunctions on the machine
In the event of obvious defects or malfunctions, stop the machine without delay and secure it against switching
on again.
214 961 44/141212
80
CAUTION
Danger due to premature wear/corrosion
Corrosion on plastic (identifiable by dull, sooty or brittle surfaces) and metal components in enclosed switchgear
housings can be caused by too frequent inching. Corroded parts must be replaced in good time.
Advise operators to avoid inching (i.e. giving short pulses to the motor to obtain small movements) as far as pos‐
sible, e.g. when attaching a load. It may cause excessive wear and premature failure of the switchgear.
7.2 Switching on
7.2.1 Checks when starting work
The operator is obliged to carry out the following checks before starting work ( "Regular inspections", Page 17):
Activity Section Check

Visual check  "Visual check", x
Page 81
Check operation of the limit switch  "Check the limit x
switches", Page 82
Check strain relieving elements, control cable and control pendant housing for damage  "Check strain relief el‐ x
ements", Page 82
Check operation of the brake  "Check operation of x
the brake", Page 83
Check hook and hook safety catch  "Check hook safety x
catch", Page 83
Check rope for damage and broken wires  "Discarding the wire x
rope", Page 89
Tab. 36
7.2.2 Visual check

– Check the machine to ensure it is complete. Do not operate the machine if parts have been removed (cov‐
ers, limit stop buffers, ...).
– Check the machine for any visible external damage.
214 961 44/141212
81
7.2.3 Check the limit switches
1. By-pass the operating limit switch by pressing test button (4).
2. Approach the emergency limit switch using motion axis control buttons (3).
3. Simultaneously actuate test button (4) and motion axis control buttons (3) to back away from the emergency
limit switch.
43239744.eps
Fig. 61
7.2.4 Check strain relief elements

– Carry out a visual inspection of the strain relief elements:
The strain relief cords must be firmly attached. No forces must act on the connector when the control pend‐
ant is moved.
43241844.eps
Fig. 62
214 961 44/141212
82
7.2.5 Check operation of the brake
– Raise the load hook and lower it again. The load hook must only run on a short distance when the button is
released.
The load hook must stay at the same height (i.e. it must not lower without a button being actuated) when a
load is attached to it.
Significant run-on or lowering when in the idle position indicates that the brake is worn.
– Make the unit travel to the right/left. Braking of the travelling hoist must be clearly noticeable when the button
is released.
It must not be possible to move the travelling hoist by pulling the ropes to the side.
Significant run-on or the possibility of moving it when in the idle position indicates that the brake is worn.
– Brake linings must be inspected once a year, ⇒ also assembly instructions 214 228 44.
WARNING
Only operate the machine when it is in safe operating condition.
If inspection reveals that a brake slips, the brake must be adjusted or repaired. Do not operate the machine if the
brake slips.
7.2.6 Check hook safety catch
Check the hook safety catch  "Regular inspections and monitoring measures for load hooks", Page 98.
214 961 44/141212
83
7.3 Control pendant switch assignment
The motion directions of the crane/load hook are clearly identified with
fixed symbols regardless of the control pendant type:
Lower load
Lift load
Cross travel to the left
Cross travel to the right
Crane travel backwards
Crane travel forwards

F1/F2: Refer to the control pendant operating instructions for switch as‐
signment
43297844.eps
Fig. 63
7.4 Switching off

1. When work has been completed, position the unloaded bottom block outside the travel area.
2. Press emergency-stop button (1). The emergency-stop button is unlocked by turning it.
3. Switch off the power supply at the mains connection or isolating switch.
43249844.eps
Fig. 64
7.5 Stopping operation in an emergency

1. Press emergency-stop button (1).
214 961 44/141212
43249844.eps
Fig. 65
84
8 Maintenance

The following sections contain a description of maintenance work that is necessary for optimum and uninterrupted
operation of the machine.
WARNING
Risk of injury.
Incorrect maintenance work may result in severe injury or damage to property.
Maintenance work may only be carried out by authorised and instructed specialist personnel in compliance with
all safety regulations.
DANGER
Live components
lations.
Always:
1. Wear personal protection equipment.
2. Fence off the working area.
3. Before starting work, switch off the machine and secure it against switching on again.
4. Switch off the power supply at the mains connection or isolating switch. Check that the system is de-ener‐
gised.
5. Ensure that there is sufficient freedom of movement.
6. Parts of the body can be crushed when working on the machine. Secure the machine/machine parts against
unintended movement and work with the utmost care and caution.
7. Keep the working area clean and tidy. Loose parts or tools left lying around may cause accidents.
8. Reinstall safety devices as required by relevant regulations and check them for correct operation after finish‐
ing maintenance work.
9. Only use genuine Demag spare parts.
CAUTION
Lubricants/oils
Risk of injury resulting from contact with the body/skin. Oils and lubricants are a health hazard.
Contact with these media may result in serious damage to health (poisoning, allergies, skin irritation, etc.)
– Pay attention to the manufacturer's safety data sheets and instructions.
CAUTION
Risk of injury. Risk of slipping.
Leaking oils and lubricants are hazards due to the increased risk of slipping.
Spilt oils and lubricants must be absorbed immediately by means of sawdust or oil absorbent and disposed of in
an environmentally compatible way.
214 961 44/141212
85
Hoists and cranes must be inspected by an experienced technician at least once a year. Regular inspections
mainly consist of a visual inspection and a function check which should include a check to determine the condition
of components and equipment regarding damage, wear, corrosion or other alterations and a check to determine
the integrity and efficiency of safety devices.
It may be necessary to remove parts in order to inspect wearing parts.
Load-bearing media and suspensions must be inspected along their entire length, including those parts which
cannot normally be seen. A function and brake test with a load (test load that is close to the maximum permissible
load capacity) must be carried out.
Updating the test and inspection booklet
● The owner must arrange for all inspections to be carried out and documented in the hoist or crane test and
inspection booklet.

The specified inspection and maintenance intervals apply to normal operating conditions. If routine maintenance
reveals that the intervals are too long, they should be shortened according to the specific operating conditions.
Check before putting into operation, before starting work and during operation
put into oper‐
ation
Check rope securing devices and rope guide  "Fitting the rope, single
X X X
groove", Page 91
X X
Check electrical switchgear and wiring  "Connecting the electrical
X X
equipment", Page 58
Check operation of the limit switch  "Check the limit switches",
X X X
Page 82
Check strain relief elements, control cable and  "Check strain relief ele‐
X X X
control pendant housing for damage ments", Page 82
Check operation of the brake  "Check operation of the
X X X
brake", Page 83KD15)
Check operation of overload protection device KD 15) X X
Check condition of the brake lining KD 15) X
Check lubrication of rope  "Lubricating the wire rope",
X X
Page 97
Check hook and hook safety catch  "Regular inspections and
monitoring measures for load X X X
hooks", Page 98
X X
Page 89
Tab. 37
214 961 44/141212
86 15) The inspection may only be carried out by Demag Customer Service or by authorised specialist personnel.
Check during operation
put into oper‐
ation
Check adhesive lubricant in bearing points of
return sheaves, crossheads, compensating  "Reeving methods for the
X
sheaves and pins of rope anchorage, re-grease rope hoist", Page 61
as required
Check suspension of the rope anchorage,
check play of the setbolt/pin in counter bore  "Reeving methods for the
X
hole for the retaining plate. rope hoist", Page 61
Check spring clip for correct fit.
Check brake displacement, adjust as required KD 15) X X
X
Check all connections (bolts, weld seams etc.) KD 15) X
Check rope securing devices and play of rope  "Reeving methods for the
X
guide on drum rope hoist", Page 61
X X
Page 89
Lubricate rope  "Lubricating the wire rope",
X
Page 97
Check load hooks for cracks, deformation and  "Regular inspections and
wear monitoring measures for load X
hooks", Page 98
Check hook safety catch for deformation  "Regular inspections and
monitoring measures for load X
hooks", Page 98
Check wear of the travel wheels  "Travel wheel wear",
x
Page 99
Check bottom block KD 15) X
Check securing elements (clips, bolts, etc.) for
KD 15) X
tight fit and corrosion
Check and apply or supplement corrosion pro‐
KD 15) X
tection, as required
Change oil in main hoist gearbox/cross-travel
Every 8 - 10 years
gearbox
Check plastic components of the limit switch for
KD 15) X
corrosion
Check electrical enclosure seals KD 15) X
Check condition of all buffers KD 15) X
Check power supply lines (main and crab pow‐
er supply). For current collectors: Check sliding
KD 15) X
contacts and travel rollers for wear and sliding
contacts for contact pressure
DRS wheel block: Check travel wheel wear and
 214 276 44 X
bolted connections
Tab. 38
WARNING
Danger due to incomplete maintenance.
Danger to life and limb since safe operation of the machine is not ensured.
– Carry out all specified maintenance work appropriately and in time.
– Please contact Demag Customer Service for any work that you cannot carry out yourself.
– Make sure that the entries in the test and inspection booklet of the crane installation are complete.
General overhaul (GO)

214 961 44/141212
The general overhaul should coincide with the annual inspection On reaching the theoretical duration of service
Fit rope hoist-specific Demag GO set X
Tab. 39
87
8.4 Wire ropes
Construction, application and reeving of wire ropes
Range DR-Pro 5
Reeving arrangement 2/1 4/1 4/2
Hook path [m] 12 20 6 10 9.9
Rope structure 16) 17) 16) 17) 16) 17) 16) 17) 16)
Group of 2m/M5 X X X X X
mechanisms to 3m/M6 X X X X X
Wire rope di‐
[mm] 9 9 9 9 7
ameter
Theoretical approx.
76.67 91.70 76.67 91.70 76.67 91.70 76.67 91.70 45.8
breaking force [kN]
Minimum
[kN] 63 79.30 63 79.30 63 79.30 63 79.30 39.8
breaking force
[N/
Rope grade 1960 2160 1960 2160 1960 2160 1960 2160 1960
mm²]
Rope length [m] 27.3 43.45 28.1 44.3 46.8
Tab. 40
Range DR-Pro 10
Hook path [m] 12 20 40 6 10 20
Rope structure 16) 18) 16) 18) 19) 16) 18) 16) 18) 16) 18)
Group of 2m/M5 X X X X X X
mechanisms to 3m/M6 X X X X X X
Wire rope di‐
[mm] 13 13 13 13 13 13
ameter
Theoretical approx.
164.93 197.9 164.93 197.9 170.3 164.93 197.9 164.93 197.9 164.93 197.9
breaking force [kN]
Minimum
[kN] 132 166.2 132 166.2 129.8 132 166.2 132 166.2 132 166.2
breaking force
[N/
Rope grade 1960 2160 1960 2160 1960 1960 2160 1960 2160 1960 2160
mm²]
Rope length [m] 28.25 44.25 84.5 29.3 45.25 85.25
Tab. 41
Range DR-Pro 10
Hook path [m] 6.7 13.3 6.7 13.3 5.8 11.35 25.2
Rope structure 16) 16) 18) 18) 16)
Group of 2m/M5 X X X
mechanisms 3m/M6 X X X
to FEM/ISO 4m/M7 X X X
Wire rope di‐
[mm] 13 13 9
ameter
Theoretical approx.
164.93 197.9 76.67
breaking force [kN]
Minimum
[kN] 132 166.2 63
breaking force
Rope grade [N/mm²] 1960 2160 1960
Rope length [m] 48.7 88.5 48.7 88.5 31.6 53.8 109.2
Tab. 42
214 961 44/141212
8.5 Discarding the wire rope
The following information on the assessment and maintenance of wire ropes has been compiled on the basis of
German, European and international standards as well as relevant trade literature and is to be regarded only as
the most significant information that is not intended to be complete, but to help the owner of a Demag rope hoist
to become familiar with the subject of ‘Discarding wire ropes’. Furthermore, all national standards, regulations or
any legislation of other countries must be fulfilled and considered together with the above information or they take
priority, as applicable.
Assessment of the discard criteria of wire ropes requires many years of experience and expert knowledge. An
assessment may only be carried out by a Demag service engineer or by a corresponding specialist.
A visual check must always be carried out over the entire length of the rope, including points which cannot nor‐
mally be seen, critical points must be inspected with particular care and attention.
CAUTION
Risk of injury
Risk of injury due to possibly broken wires.
Always wear protective gloves when checking wire ropes.
In order to discover broken strands more easily, the load must be removed from the unit and the rope bent man‐
ually along its entire working length. Run the rope through your hand, which must be protected by a thick glove.
The bending radius should be approximately that of the rope sheaves,
A wire rope must be discarded when its condition is no longer considered to be safe for further operation:
● If there are any structural changes, such as swelling, loosening.
The installation must be stopped immediately if this type of damage occurs.
● When the number of visible broken load-carrying wires in the external strands at the worst spot has reached
the following figures, counted over a reference length of rope of 6 times or 30 times the rope diameter, which‐
ever gives the worst result  Tab. 43, Page 90.
Critical points, for example, include:
1. Rope zones subject to the highest number of alternating bending cycles and in particular to alternative de‐
flection. This also applies to rope zones on compensating sheaves which are subject to a very high number
of reversed bending cycles due to rope swing or uneven winding on rope drums. These rope sections show
increased abrasion and a higher number of broken wires.
2. The zones in which loads are picked up, i.e. rope zones which are on a rope sheave at a preferred load pick-
up point or rope zones which are wound onto or off a rope drum.
3. Rope anchorages that subject the wire rope to a load in addition to normal tensile load. Vibrations in the tran‐
sition area and moisture penetrating into the rope anchorage result in corrosion and broken wires.
4. Rope zones on rope drums. The load pick-up point on the rope drum is subject to increased wear (abrasion,
broken wires and/or structural changes).
5. Rope zones exposed to aggressive media, general weather conditions or high temperatures. Observe the
specifications of the manufacturer of the wire rope and the lubricant used.
The rope may be replaced by Demag service engineers or an authorised specialist company.
214 961 44/141212
89
Wire rope used Group of mechanisms to FEM/ISO
2m/M5, 3m/M6, 4m/M7 2m/M5, 3m/M6, 4m/M7
Rope dia. [mm] Rope structure Number of broken wires over a rope length of Number of broken wires over a rope length of
6 x rope diameter 30 x rope diameter
No. of Rope length No. of Rope length
broken wires [mm] broken wires [mm]
7 42 210
9 20) 13 54 26 270
13 78 390
7 42 210
21) 14 28
9 54 270
13 22) 21 78 42 390
13 23) 10 78 20 390
Tab. 43
8.6 Wear limits on rope sheaves
43240444.eps
Fig. 66
Size Reeving Groove root dia. Rope dia. Min. flange plate thickness Max. depth of strand im‐
[mm] [mm] tmin pressions
[mm]
2/1, 4/1 182 9 5.6 0.5
DR 5
4/2 225 11 5.3 0.4
230 5.6
2/1, 4/1
13 6.3 0.7
DR 10 280
6/1 3.5
4/2 225 11 4.6 0.5
Tab. 44
The cross section of the rope groove must not be less than the specified minimum dimension tmin at any position.
Negative impressions in the rope groove must not exceed the specified maximum dimension.
214 961 44/141212
8.7 Fitting the rope, single groove
8.7.1 Unwind rope
43297544.eps
Fig. 67
CAUTION
Cutting hazard
DANGER
– Shearing hazard
214 961 44/141212
91
Securing the end of the rope
1. 2. 3.
4. 5. 6.
7. 8.
43336444.eps
Fig. 68
1. Attach the retaining clip

2. Insert the rope anchorage
3. Attach the rope
4. Close the retaining clip
5. Press the retaining clip into the guide slot of the rope anchorage
214 961 44/141212
6. Fit the hose clamp

7. Tighten the hose clamp
92 8. Check the tight fit of the retainer.

Wind approx. 4 turns of the rope tightly round the drum. To do this, switch on the hoist motor lifting motion and run
the rope through your hand, which must be protected by a thick glove.
Then fit the rope guide.
Preparing the rope guide
7
8
9
X 5
6
4
9
43240944.eps
Fig. 69
4 Section with inserted lock nuts 8 Hexagon nut with flange

5 Segment with rope guide rollers 9 Socket head bolt
6 Segment X Rope guide on the connecting rod  Fig. 70,
7 Hexagon bolt Page 93 (11)
– Disassemble rope guide
Fitting the rope guide
4 5
4 11
6
5
214 961 44/141212
43241044.eps
Fig. 70
93
– Fit the guide of side section (4) on connecting rod (11) – side section (4) rests on the wire rope – see dia‐
gram.
– Place the two segments (5+6) over the rope drum from above. Fit segment with rope guide rollers (5) with
the rollers pointing towards the wire rope on the drum.
– Slide the rope guide sideways until it rests in the empty groove next to the rope on the drum.
The rope guide rollers must now lie over the wire rope.
Fastening the rope guide on the drum
8 7 6 Nm
43241144.eps
Fig. 71
CAUTION
Loose connections
– Fasten the rope guide with hexagon bolt (7) and hexagon nut with flange (8).
– Check:
It must be possible to move the fitted rope guide on the drum by hand.
214 961 44/141212
94
Attaching the rope guide to the connecting rod
6 Nm
4 9
10
43241244.eps
Fig. 72
– Slide the rope guide until the bore holes in the segment with guide rollers (5) coincide with the bore holes in
side section (4).
CAUTION
Loose connections
– Insert the two socket head bolts (9) and secure using side section (4).
– Lift the rope guide rollers with a screwdriver to press them against the rope.
– Remove split pin (10).
214 961 44/141212
95
8.8 Fitting the rope, more than one groove
8.8.1 Unwind rope
43297544.eps
Fig. 73
CAUTION
Cutting hazard
DANGER
– Shearing hazard
8.8.2 Fitting the rope, more than one groove
Fitting the rope anchorage
Attaching the rope,  "Securing the end of the rope", Page 92 .

Introducing the rope
– Slide the other end of the rope through a rope sheave in the bottom block using the cable grip,  "Fitting the
bottom block for 4/2 reeving", Page 70.
– Then guide the wire rope through the compensating sheave and through the second sheave of the bottom
block.
214 961 44/141212
96
Fastening the rope on the drum
A B
40 Nm
43334844.eps
Fig. 74
A Rope anchorage on the gearbox side

B Rope anchorage on the switchgear-box side
CAUTION
Loose connections
Secure the end of the rope to the rope drum with rope clamps (B).
– Remove the cable grip from the end of the rope and fasten the end of the rope to the other end of the rope
drum with rope clamps (1).
– Wind approx. 4 turns of the rope tightly round the drum. To do this, switch on the hoist motor lifting motion
and run the rope through your hand, which must be protected by a thick glove.
– Then fit the rope guide  "Fitting the rope guide", Page 93
8.9 Shortening the wire rope

The rope must not be cut or shortened at or separated from aluminium end sleeve (2) or the twisted rope end. If,
in exceptional cases, it is necessary to shorten the wire rope, this must be done in compliance with engineering
standards.
8.10 Lubricating the wire rope

Grease the rope with a suitable lubricant and preservative, e.g. Cedracon. Ensure that the agent reaches the inte‐
rior of the rope structure, part no. 665 013 44.
Grease the bearing points of the top block, crosshead, compensating sheave, the pin of the rope anchorage and
the guide rod of the rope guide with a suitable adhesive lubricant, part no. 472 933 44.
214 961 44/141212
97
8.11 Regular inspections and monitoring measures for load hooks
If a check or inspection reveals that these components are worn beyond the dimensions shown in  Fig. 75,
Page 98 and the table, or if deformations and cracks can be seen in these parts, the affected parts must be
replaced at once with genuine spare parts.
Load hook inspection
Range DR 5 DR 10
Reeving 2/1, 4/2 4/1, 6/1 2/1, 4/2 4/1, 6/1
a2 Group of mecha‐ 1Am/M4 ... 2m/M5 ... 1Am/M4 ... 4m/M7
a nisms to FEM/ISO 4m/M7 4m/M7 3m/M6
Hook size 1.6 2.5 2.5 4 5
a Hook opening 40 41 41 49 55
a1 56 63 63 71 80
a2 Nominal dimen‐ 45 50 50 56 63
a1
sion 24)
a2 Maximum dimen‐ 49.5 55 55 61.6 69.3
sion
h2
h2 Nominal dimen‐ 48 58 58 67 75
sion25)
43240044.eps
h2 Minimum dimen‐ 45.6 55.1 55.1 63.6 71.2
Fig. 75 sion
Tab. 45
Check the hook safety catch for correct operation and for any damage.
214 961 44/141212
24) Permissible variation: +10%

98 25) Permissible variation:-5%
8.12 Travel wheel wear
DRS 125, 160
s s
d1
43312644.eps
Fig. 76
➨ Wear indicators
The wear indicator on the flange facilitates preventive inspections of the installation.
The travel wheel must already be replaced even if only one segment of the wear indicator is open, as shown in
the lower part of the diagram.
Tread wear
Travel wheels must be replaced when the following limit values are reached:
Travel wheel rated diameter Remaining smallest flange width s Smallest travel wheel diameter Maximum difference in travel
d1 wheel diameters for coupled
wheels
[mm] Dimensions in [mm]
125 6.0 18.4 0.1
160 7.0 153.4 0.15
Tab. 46
The new wheel blocks have to aligned horizontally when wheel blocks are replaced. They must be aligned using
214 961 44/141212
adjusting tools/jigs,  "Aligning the travelling hoist on the crane", Page 42.
99
8.13 Oil change
The hoist and travel gearboxes are filled with the required quantity of lubricant before leaving the factory. In nor‐
mal cases, it is not necessary to change or supplement it.
Gearbox filling quantities  "Gearbox oil filling", Page 24.
CAUTION
Oil leaks are an operating hazard.
Oil leaks/loss of oil in the course of operation may cause damage to or total failure of the machine. If this occurs,
stop the machine and notify Service.
8.14 General overhaul (GO)

The owner is obliged to carry out a general overhaul when the theoretical duration of service is reached ( "Reg‐
ular inspections", Page 17):
WARNING
Operating safety at risk
Specified general overhaul intervals must be strictly complied with.
When 90% of the theoretical duration of service has elapsed – after 8 to 10 years if the hoist is correctly classified
– the owner must arrange for a GO general overhaul to be carried out. A general overhaul must be carried out by
the end of the theoretical duration of service.
During the general overhaul, the following parts must be replaced in addition to the checks and work specified in
the inspection and maintenance schedule:
● Gear wheels of the gearbox
● Gearbox bearings
● Motor
● Rope drum
● Gear oil
● Connecting elements
● Switchgear in the control system
The small parts (screws, washers ...) to be replaced when maintenance and assembly work is carried out are not
listed separately.
Therefore, the provisions of the relevant UVV accident prevention regulations and BGV D8 are satisfied.
The installation may continue to be used when an expert engineer has entered the conditions for further utilisation
into the test and inspection booklet. Completion of the general overhaul must be confirmed in the test and inspec‐
tion booklet and a further period of utilisation in accordance with FEM 9.755 must be entered.
The general overhaul may be carried out by Demag expert engineers or an authorised specialist company.
● The general overhaul carried out by the manufacturer or a specialist company authorised by him satisfies the
requirement to be met for continued operation of the machine.
214 961 44/141212
100
9 Malfunctions
WARNING
Risk of injury.
Incorrect elimination of malfunctions may result in severe injury or damage to property.
Malfunctions may only be eliminated by authorised and instructed specialist personnel in compliance with all
safety regulations.
DANGER
Live components
lations.
9.2 Conduct when malfunctions occur

Always:
1. Bring 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. Disconnect the machine from the power supply and secure the machine against reconnection.
3. Inform the person responsible at the location about the malfunction.
4. Have the malfunction and the cause of the malfunction identified and eliminated by authorised specialist per‐
sonnel.
9.3 Conduct after malfunctions have been eliminated
WARNING
Putting into operation again
Before switching on again, check that:
– Malfunction and cause of malfunction have been eliminated.
– All safety devices have been fitted properly and are in perfect condition and working order.
– Nobody is present in the danger zone of the machine.
214 961 44/141212
101
9.4 Malfunctions, causes and remedy
The control system of the DR rope hoist is provided with an intelligent self-diagnosis and fault-finding system.
Warning and error messages are shown direct in the display of the DSE-10R control pendant and/or by means of
acoustic signals.
If a fault occurs, the following instructions for finding faults apply:
Fault Cause Remedy

A Rope hoist and crane travel not functioning. 1 System switched off Check whether unit is switched on
2 Emergency stop actuated Release emergency stop
3 400 V voltage missing Check voltage
4 48 V control voltage missing Check voltage
5 Crane switch contactor has tripped Inform Service
B Rope hoist does not lift or lower, long and 1 Phases swapped Swap phase sequence of powerfeed, in‐
cross travel functioning form Service
2 Brake worn, brake distance too long, lift‐ Inform Service
ing is stopped
3 Brake release signal missing Inform Service
4 Phase missing Check voltage
C Rope hoist only lifts or lowers at low lifting Incorrect geared limit switch setting Set according to the operating instruc‐
speed tions
D1 Rope hoist only lowers and an intermittent 1 Overload lifted Remove overload
acoustic signal is emitted
D2 Rope hoist only lowers, long and cross travel 2 Thermal contact of hoist motor active Allow hoist motor to cool down
possible
E Lifting motion does not reach "top" or "bot‐ Incorrect geared limit switch setting Set according to the operating instruc‐
tom" position, but lifts and lowers tions
F Cross travel not functioning 1 Thermal contact of cross-travel motor ac‐ Allow cross-travel motor to cool down
tive
2 Check cross-travel inverter for ‘Ready’ Open cover of electrical equipment and
status check green operation LED on inverter:
Green = ready,
otherwise inform Service
3 Brake of cross-travel motor does not re‐ Brake or control defective,
lease inform Service
G Crab only travels at slow speed 1 Crab/crane in blocked area (by-pass Leave the blocked area
control) 26)
2 Incorrect fast-to-slow limit switch/area Adjust appropriately
switch setting
3 Incorrect parameter settings Inform Service
H Lifting and cross travel not possible, long 1 Crab circuit breaker has tripped Open cover of electrical equipment and
travel is possible, switching noises of the switch circuit breaker on again
crab electrical equipment main contactor can 2 400 V voltage missing Measure voltage
be heard.
3 Connector loose Check 400 V plug-in connections for tight
fit
lines
I Long travel is not possible, lifting and cross Crane circuit breaker has tripped Open cover of crane electrical equipment
travel are possible, switching noises of the and switch circuit breaker on again
crane electrical equipment main contactor
can be heard.
J Only long travel is not possible but no Thermal contact 26) Allow long-travel motor to cool down
switching noises of the crane electrical of long-travel motor active
equipment main contactor can be heard.
K Crane only travels at slow speed 1 Crab/crane in blocked area (by-pass Leave the blocked area
control) 26)
2 Check connector of ‘fast-to-slow switch’ Inform Service
L Display in control pendant shows nothing 1 48 V control voltage missing Measure voltage
2 A control voltage fuse has tripped Open cover of crane electrical equipment
and switch fuse on again
214 961 44/141212
lines
Tab. 47
102 26) Optional

10 Actual duration of service
10.1 Calculating the actual duration of service
43249744.eps
Fig. 77
When powered hoist units are used, the owner must determine and record the used share of the theoretical dura‐
tion of service for the hoist, see BGV D8. ( "Regular inspections", Page 17)
The load spectrum is recorded and calculated by means of the control system integrated in the DR unit. The
elapsed duration of service is shown on display (4) of the DSE-10R control pendant. Read the value and enter it
into the test and inspection booklet when the annual inspection is carried out. The value displayed is indicated in
%.
A general overhaul must be arranged to be carried out when 90% of the service life has elapsed (when 10% is
shown on the display).
Safe working period (S.W.P.)

The theoretical duration of service (to ISO 4301/FEM 9.755) in connection with the actual mode of operation
( "Selection criteria", Page 19) results in the safe working period (S.W.P.).
See control pendant operating instructions,  Tab. 2, Page 2, for further information.
214 961 44/141212
103
0110 1/ 2
Hereby we,


ready for service - as a series product or manufactured to order - after completion of
assembly/being put into service including function check and load test prior to being put
into service to be confirmed on page 2 complies with all relevant requirementsof
The safety objectives of Low Voltage Directive 2006/95/EC are achieved.

e
Applied harmonised standards and/or C standard drafts, in particular:

pl Part 2: Power driven hoists
m
The relevant technical documentation according to Annex VII Part A of Directive 2006/42/EC has
Sa

Authorised representative for technical documentation:
Wetter, 25.01.2013


U02180
0110 2/ 2

-----------------------------------------------------------------------------------------------------------
For assembly / first putting into service including function check
...................................., date ................................................
Name: ................................................
Signature: ................................................
e
------------------------------------------------------------------------------------------------------------
For the load test in the scope of the acceptance test

pl
...................................., date ................................................

m
Name: ................................................
Signature: ................................................
Sa

U02180
0110 1/ 1
Hereby we,


supplied as partly completed machinery is intended to be incorporated into machinery and its
initial bringing into service is prohibited until the machinery* into which this partly completed
machinery is to be incorporated has been declared in conformity with all relevant provisions of

(* insofar as this machinery is subject to the scope of application)
e
delivery, are met by application of the following harmonised standards or C standard drafts:
Part 2: Power driven hoists
EN 61000-6-2
pl
Electro-magnetic compatibility (EMC), Part 6-2:
m
The safety objectives of Low Voltage Directive 2006/95/EC are achieved

Sa
The special technical documentation according to Annex VII Part B of Directive 2006/42/EC has
Wetter, 25.01.2013


U02180
Index
A Specialist personnel 9
Switching off 84
After-sales service address 10
Symbols 7
Assigned expert engineer 9
S.W.P. 103
B
T
Block adjustment 76
Trained person 9
C Travelling hoist 10
Cylindrical-rotor motor 31
D
DC brake 31
Design 30
Design limit 10
Drives 31
E
Emergency limit switch 75
Experienced technician 9
Expert engineer 10
G
Geared limit switch 75
General overhaul (GO) 100
H
Helical gearbox 31
I
Individual adjustment 76
M
Machine operator 9
Maintenance 85
Manufacturer 9
Manufacturer’s address: 2
Minimum requirements for runways 28
Model code 18
O
Operating limit switch 75
Operating personnel 9
Operation 80
Owner 9
Q
Qualified electrician 9
214 961 44/141212
S
Signal words 7
Size designations 18 107
The current addresses of our sales offices, subsidiaries and agencies worldwide can be
found on the Demag Cranes & Components GmbH homepage at

PO Box 67 · 58286 Wetter (Germany)
Phone +49 (0 )2335 92-0
Fax +49 (0 )2335 92-7676
Printed in Germany
www.demagcranes.com
ZNA – ZBA – ZBF motor range
41807744.eps
0300 EN/US /PDF 229 203 49 720 IS 919

Contents 0 Foreword 3
0.1 Copyright 3
0.2 After-sales service 3
0.3 Guarantee 3
0.4 Limitations of liability 4
0.5 Definitions 4
1 Safety 5
1.1 Symbols 5
1.2 Intended use 5
1.3 Prohibited practises, improper use 5
1.4 Safety instructions 6
2 Receiving, transport and storage 7
2.1 Receiving 7
2.2 Transport 7
2.3 Storage 7
3 Product description 8
3.1 Motor 8
3.2 Brake 11
4 Installation 12
4.1 Checking the condition of the motor 12
4.2 Checking the installation site 12
4.3 Motor mounting position 12
4.4 Special instructions for installing the motor 12
4.5 Requirements for connecting the motor 12
5 Commissioning 13
5.1 Requirements 13
5.2 Check when commissioning 13
6 Maintenance 13
6.1 Checking before and during operation 13
6.2 Maintenance schedule 13
6.3 B004-B680 brakes 14
6.3.1 Measuring the brake displacement 14
6.3.2 Adjusting the brake air gap 14
6.3.3 Replacing the brake disk 16
6.4 “Brake settings” tables 20
6.4.1 For ZBA motors 20
6.4.2 For ZBF motors 20
6.5 Tightening torques 21
7 Motor/brake connection diagrams 22
7.1 Brake control 22
7.2 Brake operating times 26
7.2.1 ZBA range brake operating times 26
7.2.2 ZBF range brake operating times 27
7.3 Selection criteria 27
7.4 Connecting diagram selection for USA 240/480 V 60 Hz 28
7.5 Connecting diagram selection for Canada 330/575 V 60 Hz 30
7.6 Inverter operation 33
7.7 Connection/circuit diagrams 34
7.8 Connecting temperature and brake monitoring devices 64
8 Technical data 65
229203k1.p65/1099
9 Troubleshooting 66
10 Forms for documenting the installation, rating plate 67
2
0 Foreword
You have purchased a Mannesmann Dematic product. This equipment was manu-
factured in accordance with state-of-the-art engineering principles.
These operating instructions are designed to provide the operator with appropriate

maintaining and repairing our motors and additional equipment must have read and
understood
• the operating instructions
The operating instructions must be available to the operating personnel at all times in
our products.
0.1 Copyright These operating 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 Mannesmann Dematic. All documents are
protected within the sense of copyright law.

specific prior consent. Infringements are an offence resulting in obligatory compensa-
tory damages. All industrial rights reserved.
0.2 After-sales service For technical information on Mannesmann Dematic products and their systematic
application, please refer to one of our after-sales service stations, the relevant repre-
sentative or to our main office in Cleveland, Ohio.
0.3 Guarantee These operating instructions must be read carefully before installing and putting the
product into operation.
We assume no liability for damage and malfunctions resulting from failure to comply
with the operating instructions.
Wearing parts are not subject to the guarantee, guarantee claims must be made by
quoting the order number to Mannesmann Dematic immediately on detecting the
defect.
The guarantee is cancelled, for example, in the event of:

• inappropriate use,
• faulty devices or equipment connected or attached to the product which are not
part of our scope of supplies and services,
• refurbishment or modification of the product unless approved in writing by
Mannesmann Dematic.
229203k1.p65/1099
3
0.4 Liability All technical information, data and instructions for operation contained in these oper-
ating 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 geared motors which are the subject of these operating
instructions. Therefore, no claims can be derived from the information, illustrations
and descriptions contained in these operating instructions.
The descriptions and illustrations contained in this documentation do not necessarily
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, noncompliance with these operating instructions or inappropriate repairs and
maintenance. We expressly point out that only Mannesmann Dematic spare parts
and accessories approved by us may be used. Accordingly, this also applies to
other manufacturers’ parts used. 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 Mannesmann Dematic
from any liability for damages resulting therefrom.
With the exclusion of any further claims, Mannesmann Dematic is liable for any faults
or omissions on our part within the scope of the warranty obligations entered into in
the original contract. Claims for damages – except for legal claims resulting from
product liability legislation – are excluded, irrespective of the legal reason from which
such claims are derived.
0.5 Definitions Owner

Owners (employer, company) are defined as persons who own the product and who
use it appropriately or allow it to be operated by suitable persons.
Operating personnel
Operating personnel are defined as persons assigned by the owner of the product
to carry out special tasks such as installation, operation, setting-up, maintenance
including cleaning, fault elimination and transportation of the product.
Specialist personnel are defined as persons assigned by the owner to carry out
specific tasks.
• Qualified personnel
Qualified personnel are defined as persons, who, owing to their technical training,
knowledge and experience as well as knowledge of the relevant standards, are
able to assess the tasks given to them and identify 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 the product and are familiar
229203k1.p65/1099
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 the motors.
4
1 Safety
1.1 Symbols The following symbols and recommendations indicate potential safety hazards or
causes of damage or provide useful information.
Hazard warning
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 careful and cautious.
Pass on safety instructions to all persons entrusted with working on motors includ-
ing the power supply.
In addition to the safety instructions, observe all general safety regulations and
codes of practise at all times.

and enclosures) may only be opened by qualified electricians. Before opening, all
relevant operating, control, feed or other voltages must be disconnected.

This symbol in the operating instructions indicates all warnings which, if not com-
plied with, may result in damage to motors.
1.2 Intended use These motors may be used for all travel, lifting and turning motions in industrial ap-
plications. Compliance with the permitted operating conditions must be ensured for
operation of these drives (e.g. enclosure type, ambient temperature, installation
height).
1.3 Prohibited practises, Under certain conditions, operation of standard motors is prohibited as this could
result in malfunctions, faults in the equipment or hazard to life and limb, e.g.:
improper use
• Acidic, corrosive air as coolant
• Operation outside the permitted temperature range
• Operation beyond the normal air pressure. Otherwise, power adjustments are
necessary
• Operation under conditions of high humidity or splashwater
• Manipulation of electrical modules
Safety devices must not be rendered inoperable or modified or used in any way
other than that for which they have been designed.
229203k1.p65/1099
5
1.4 Safety The relevant national accident prevention regulations and the general safety condi-
tions must always be observed when our products are operated in order to avoid
instructions accidents and damage to machinery. If the safety instructions given in these operat-
ing instructions are not observed in any way, personal injury or even death can result.
Dangerous voltage!
Motors are connected to a mains power supply. Any contact with live parts can lead
to very serious injury or even death.
Putting motors into operation Do this only

• if you have read the operating instructions and the owner has instructed you in all
details,
• if the operating instructions are available for reference at the place of operation,
• if you are qualified personnel (electrician),
• if you are not under the influence of drugs, alcohol or medication that can ad-
versely affect your ability to react,
• if the general accident prevention, operating and installation regulations have
been observed.
Additional safety instructions Only carry out maintenance and installation work
• if you are qualified personnel (electrician),
• if the motors are at zero voltage,
• if no hazard exists (e.g. crushing hazard, slipping hazard, etc.),
• if the motors are secured against restoration of the power supply,
• if all cables and motor terminals are at zero potential (establish with a voltmeter),
• with insulated tools,
• using genuine spare parts.
229203k1.p65/1099
6
2 Receiving, transport and storage
2.1 Receiving The scope of delivery is specified in the shipping papers. Check the delivery imme-
diately on receipt to ensure that it is complete and examine it for damage caused in
transit. If necessary, a damage report must be made out in the presence of the
transport contractor’s representative as otherwise it will not be possible to rectify
the damage at no cost to you.
2.2 Transport The drive is supplied made up into one unit. Additional equipment may be supplied
in separate packaging.
The drive is packed depending on the transport method and its weight. Unless oth-
erwise agreed in the purchase contract, the packaging corresponds to the packag-
ing guidelines of Mannesmann Dematic.
Symbols used on the packing
This way up Fragile Keep dry Protect from heat
Top-heavy No hooks Attach sling here Centre of gravity

41283944 - 41284644.eps
Handle motors with utmost care to avoid damage caused by careless loading and
unloading, for example.
2.3 Storage Motors must be stored as follows:

• in dry places with low temperature fluctuations
• in the same position as for operation
• protected against dust and moisture
• on a wooden support
• free from vibration (no impacts)
Drives must not be stacked on top of each other.
Unless otherwise agreed in the purchase contract, standard conservation is guaran-

teed for a period of 6 months. The guarantee period begins on the day the unit is
delivered.
Contact Mannesmann Dematic in Cleveland, Ohio, if the motors are to be stored for
periods of longer than 6 months.
Important! Motors may otherwise be damaged.

229203k1.p65/1099
7
3 Product description
3.1 Motor Demag type Z cylindrical rotor motors can be supplied with or without brake (ZB
and ZN motors). The ZBA and ZNA motor range includes frame sizes Z..63 to
Z..225. The motor range includes pole-changing designs and motors with integrat-
ed fly wheels for particularly smooth load movement.
• The housings of motor frame sizes Z..63 to Z..132 are of a high quality aluminium
alloy with an integrated terminal box base. The terminal box cover and fan cover
are made of plastic.
• Motor frame sizes Z..160 to Z..225 have a grey cast iron housing with a fitted
terminal box. The fan cover is made up of sheet metal.
All motors can also be supplied with gearbox or flange and foot design with shafts
largely corresponding to IEC shaft dimensions.
Rating plate for Z.. 63 A to Z.. 71 B motors with/without brake

The rating plate is fitted on the drive-side motor end shield to the right or left of the
terminal box, e.g.
1
2
3
4
5
6
7
8
42241144.eps
1 Manufacturer
2 Type designation, number of phases, enclosure, temperature class, model
3 Serial number, duty factor, power
4 Motor weight, inertia factor, frequency, power factor
5 Speed, switching frequency, ambient temperature > 104°F
6 Connection, voltage, current
7 Brake: brake torque, supply voltage, coil voltage, coil current
8 Order number, entry number

229203k1.p65/1099
8
Rating plate for Z.. 80A to Z.. 132C motors with/without brake
The rating plate is attached to the right or left of the terminal box base, e.g.
2
3
4
5
6
8
9
10
42241244.eps
1 Manufacturer
2 Type designation, no. of phases
3 Serial number, temperature class, enclosure
4 Duty factor
5 Power, power factor, frequency
6 Speed, switching frequency, ambient temperature > 104°F
9 Model, motor weight, inertia factor

229203k1.p65/1099
9
Rating plate for Z.. 160 A to Z.. 225 B motors with/wihout brake, e.g.
1
2
3
4
5
7
8
42241344.eps
1 Manufacturer
2 Type designation, no. of phases, enclosure, temperature class, model
3 Serial number, duty factor, power
4 Motor weight, inertia factor, frequency, power factor
5 Speed, switching frequency, ambient temperature
229203k1.p65/1099
10
3.2 Brake ZB.-Motors Demag B004 to B680 disk brakes are spring-actuated brakes featuring electromag-
netic brake release. The brake fitted under the fan cover can be controlled independ-
ently of the motor and causes no axial movement of the rotor shaft or forces on the
bearings.
The diagram shows the function elements of the disk brake, which is spring-actuated
with electromagnetic release. When the power supply to the brake coil is interrupted,
the brake is applied. This operating principle is also known as a fail-safe brake.
Brakes B004 to B680 can be released by a rectifier integrated in the terminal box of
the motor or by applying DC voltage direct to the brake coil.
Two brake sizes are available for each motor frame size to cover a large brake torque
range for various applications.
B004 – B680 DC brakes
1 Brake spring
2 Pressure plate
3 Brake disk
4 Carrier
5 Motor end cap, brake side
6 Friction plate
7 Electromagnet
8 Adjusting nut
9 Radial shaft sealing ring
10 Stop plate
41687356.eps
229203k1.p65/1099
11
4 Installation
4.1 Checking the condition Before installing the motor, check whether it has suffered any damage during trans-
portation or while in storage, such as corrosion, leaks, deformation or breakage.
of the motor
Do not clean drives with compressed air!
4.2 Checking the The standard drive is suitable for operation in normal industrial conditions. If the ambi-
ent temperature, atmosphere or humidity are other than indicated on the rating plate,
installation site the motors must only be operated with special equipment or features (see rating
plate).
Ambient temperature: from –10°C to + 40°C (+18°F to +104 °F)
Installation height: up to 1000 m (3300 ft) above sea level
The site at which motors are installed must be designed in such a way that
• air may circulate to allow heat to be exchanged and that warm air is not induct-
ed again immediately,
• no residue from operating processes can accumulate on the motor, fall between
the drive elements or damage the sealing ring,
• the rating plate is accessible.
4.3 Motor mounting Before installing the motor, check that it will be operated in the mounting position
specified on the rating plate.
position
4.4 Special instructions for If the motor is operated outdoors in vertical mounting position IM V1 or in an inclined
mounting position with the shaft facing downwards, it should be protected by a cano-
installing the motor py provided by the customer.
For motors with condensation water openings which can be closed with a threaded
plug, the drain holes must be arranged at the lowest point of the motor as otherwise
water may enter. If the mounting position of the motor is changed and the drain holes
are no longer required, the openings must be closed.
4.5 Requirements for • You must be a trained electrician and familiar with the relevant accident prevention
regulations and codes of practise.
connecting the motor
• The motor and connecting cable must be disconnected from the supply.
• The frequency and voltage specified on the rating plate must correspond to the line
frequency and voltage.
The motor must be connected as described in section 7 “Motor/brake connection

diagrams”.
To change the direction of rotation of the motor, two of the three phase conductors
must be interchanged.
The instructions contained in section 5 “Commissioning” must be followed!

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12
5 Commissioning
5.1 Requirements Before the drive unit is put into service:

• the terminal box be must be closed,
• the fan cover must be fitted,
• the line voltage and frequency specified on the rating plate must match the given
power supply,
• the motor must be checked for correct connection (check direction of rotation),
• heat must be able to dissipate (e.g. air vent slits must be free),
• it must be ensured that the drive unit does not constitute a hazard (e.g. no hazards
caused by rotating or live parts),
• it must be ensured that there are no other hazard sources.
5.2 Check when Check that:

commissioning • the motor runs correctly (e.g. no speed fluctuations or excessive noise),
• there is no extreme vibration.
6 Maintenance
6.1 Checking before and If defects or damage are detected, the motor must not be put into operation or taken
out of service. It may only be put back into service when the defect has been elimi-
during operation nated.
Check the motor for: Check Action

• External damage ® Inform person responsible
• Unusual noises during operation ® Inform person responsible
• Dirt accumulation ® Remove dirt

Maintenance schedule
Interval Part Maintenance See section
In accordance with the Brake Check brake of motors fitted with brake 6.3 or 6.4
operating conditions, at least
every 3000 hours of
operation.
Every 10 000 hours of Motor Inspect the motor and clean the cooling air channels
operation.
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13
6.3 B004-B680 brakes
The following work may only be carried out by qualified personnel.
Observe relevant safety regulations and codes of practise and the instructions con-
tained in section 1.4 “Safety instructions”.
6.3.1 Measuring the brake Apart from wear, the brake is virtually maintenance-free. The organic/mineral brake
displacement lining is designed in such a way that worn surface particles are only given off as mini-
mal abrasion. This built-in regeneration of the brake lining surface ensures constant
braking characteristics. It is advisable to check the brake air gap at certain intervals
and to adjust it as necessary to ensure the brake releases reliably. When the brake is
released (power applied to brake coil), the brake disk can be freely turned.
Guide values for the air gap and bbraking work until adjustment are contained in the
“Brake settings” tables in section 6.4.
Note: It is only possible to give guide values for braking work until adjustment as they
depend on the given operating conditions.
When the brake has been adjusted several times, the remaining thickness bmin of the
brake disk must be checked. The guide pins feature an easily visible marking which
clearly indicates the minimum dimension. The brake rotor must be replaced when this
mark is exceeded. For this purpose, a maintenance and spare part set is available
which not only contains the brake rotor, but also the required small parts and installa-
tion instructions.
6.3.2 Adjusting the brake air gap The air gap must be adjusted when the max. permissible value given in the “Brake
settings” tables in section 6.4 has been reached, (however, immediately if the brake
no longer releases).
The time to adjust the brake can be determined using the “Adjustment monitoring”
option, estimated from the work done by the brake according to the “Brake settings”
tables in section 6.4, or established by regular inspections.
If the brake is not adjusted, it will no longer release after further wear. If the
motor then operates against the applied brake, the brake and motor may be
damaged and fail.
Condition: Brake and fan cover fully fitted
Tools required: • Open wrench, feeler gauges, pliers for retaining rings
• Long hexagon socket key
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14
Undo the four screws and remove the fan cover.
41431944.eps 41432044.eps
If the adjusting nuts are not accessible, remove the fan.

[For “Sealing arrangement” option, remove the covering tape.]
Remove or suck the loose brake abrasion from the inside of the brake enclosure.
Beware of the dust if the abrasion is blown out of the enclosure.
41432144.eps 41432244.eps
New
3
Remaining b
thickness
2
Check the remaining thickness of the brake disk with friction linings (1). The guide pins (2)
feature a mark (3) which the armature disk edge (4) must not cover. If the armature disk
edge (4) has reached the mark (3), the brake disk (1) must be replaced.
(For instructions refer to section 6.3.3 “Replacing the brake disk”.) 41437955.eps
s1
If the remaining thickness of the brake disk (1) is sufficient, adjust the brake as follows:
Tighten the three self-locking nuts uniformly until the air gap is zero. Loosen the nuts by angle
a1 given in the “Brake settings” tables in section 6.4 to set the air gap to s1min.
Check air gap s1 using a feeler gauge at three points around the circumference (adjust again if
necessary).
Note: The rotor shaft must be able to turn freely when the brake is released.
Check the brake for correct functioning.
229203k2.p65/1099
α1
41444245.eps
15
[For “Sealing arrangement” option, replace the covering tape.] Align the fan cover as appropriate for the model.
If the fan has been removed: fit the fan and, if applicable, the key. Secure the fan cover with the four screws.
Secure the fan with the retaining ring. Ensure the retaining ring clicks
correctly into place (see diagram).
41433244.eps 41432044.eps 41431944.eps
6.3.3 Replacing the brake disk Note: Damaged brakes may only be repaired by a Mannesmann Dematic
authorised workshop.
To ensure reliable functioning of the brake, the lining must be of a thickness defined
as the minimum remaining thickness in the “Brake settings” tables in section 6.4.
The brake disk is a wearing part and must therefore be replaced on reaching its mini-
mum thickness. The friction plate and armature disk must be checked and replaced, if
necessary.
Condition: Fan cover and covering tape (IP 55) removed

(see section 6.3.2 “Adjusting the brake air gap”).
Tools required: • Open wrench, feeler gauges, pliers for retaining rings to DIN 5254
• Long hexagon socket key
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Remove the retaining ring and fan.
41432144.eps 41432244.eps
16
1
Disconnect the cable for brake coil and microswitch (1), if applicable. Pull the cable out of the terminal box far enough to do the following.
Undo the three self-locking nuts (2) used for adjustment (pay attention to tension of brake and distance springs). The collared pins must
not be unscrewed, tighten them to the tightening torque specified in section 6.4 if necessary.
Carefully pull the magnet assembly off the three collared pins and the motor shaft.
For vertical mounting arrangement (brake at the top): fix the brake springs and, if applicable, the plunger (microswitch option) in place with
strips of adhesive tape or a rubber band.
41432344.eps 41432444.eps
a
2
3
1
a ® aperture mark
Remove stop plate (1). Pay attention to the distance springs, these can remain on the collared pins. (Replace the brake springs when changing the
brake disk.)
Remove armature disk (2) (both disks for the “Reduced noise level” and “Manual brake release” options) and brake disk (3).
Remove or suck the loose brake abrasion from the inside of the brake enclosure. Beware of the dust if the abrasion is blown out of the enclo-
sure.
Check the armature disk and the friction plate for damage, excessive scoring or similar, also check the friction plate for deformation and the collared
pins for extreme differences in diameter.
Replace worn or damaged parts.
When fitting new collared pins, ensure that the outside diameter is not damaged (use a counter-nut). Also pay attention to the tightening torques
given in the tables in section 6.4.
41432544.eps 41432844.eps
„I”
1 2
Place brake disk (1) centrally on the carrier. Pay attention to correct alignment and do not use force. Keep the friction surfaces clean (no
229203k2.p65/1099
grease on the friction surfaces) as the initial friction coefficient will otherwise be changed.
Align armature disk (2) (the thicker disk first for the “Reduced noise level” and “Manual brake release” options) with marker “I” facing the
terminal box and then fit the armature disk on the collared pins.
(The motor end shield must first be fitted with the marker in the right position)
41432744.eps 41432655.eps
17
a
2
1
Align stop plate (1) and place it on the collared pins in such a way that aperture mark a is facing towards the marker on the end shield. Place the three
distance springs on the threaded ends of the collared pins. Fit brake springs symmetrically into the magnet as before or as specified in the “Brake settings”
tables in section 6.4. For the vertical mounting arrangement with the brake at the top, prevent the springs from falling out using rubber bands or similar
(rubber band grips the outside of the brake springs). Align magnet (2) (with the opening for the operating lever facing towards the marker on the end shield
for the Manual brake release option) and push it into place. Fit the self-locking nuts on the collared pins. Ensure the stop plate is guided by the three col-
lared pins and does not get caught in the distance springs before the collared pins engage the magnet.
41432544.eps 41433144.eps
Pull the cable back into the terminal box.

Pull the cable back into the terminal box. Connect the cable for the
brake coil and, if applicable, microswitch (1).
41432344.eps
Adjust the brake as follows:

Tighten the three self-locking nuts uniformly until the air gap is zero. Loosen the
s1
nuts by angle a1 given in the “Brake settings” tables in section 6.4 to set the air
gap to s1min.
Check air gap s1 using a feeler gauge at three points around the circumference
(adjust again if necessary).
Note: The rotor shaft must be able to turn freely when the brake is released.
Check the brake for correct functioning after reconnecting the brake coil.
α1
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41444245.eps
18
For “Sealing arrangement” option, replace the
covering tape.
Fit the fan and, if applicable, the key.
Secure the fan with the retaining ring. Ensure the
retaining ring clicks correctly into place (see dia-
gram).
41433244.eps
Align the fan cover as appropriate for the model. Secure the fan cover with the four screws.
41432044.eps 41431944.eps
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19
6.4 “Brake settings” tables
6.4.1 For ZBA motors
Brake size B004 B007 B020 B050 B140 B280 B680

Quantity of springs 1) Brake torque M B in Nm (lb ft)
white red blue
6 0 0 – 7.6 (5.60) 20 (15) 50 (37) 140 (105) 280 (210) 680 (500)
4 2 0 – 5.9 (4.40) 16 (12) 39 (29) 109 (80) 218 (160) 529 (390)
3 3 0 – 5.1 (3.80) 13 (9.60) 33 (24) 94 (69) 187 (140) 454 (330)
3 0 0 – 3.8 (2.80) 10 (7.40) 25 (18.5) 70 (52) 140 (105) 340 (250)
2 2 0 – 3.4 (2.50) 9.0 (6.60) 22 (16.0) 62 (46) 124 (91) 302 (220)
0 6 0 – 2.5 (1.85) 6.6 (4.90) 17 (12.50) 47 (35) 93 (69) 226 (165)
0 4 0 1.7 (1.25) 1.7 (1.25) 4.4 (3.20) 11 (8.10) 31 (23) 62 (46) 151 (110)
0 3 0 1.3 (0.95) 1.3 (0.95) 3.3 (2.40) 8,3 (6.10) 23 (17) 46 (34) 113 (83)
0 4 2 2.3 (1.70) – – – – – –
0 0 6 1.8 (1.35) – – – – – –
0 0 4 1.2 (0.90) – – – – – –
0 0 3 0.9 (0.65) – – – – – –
Minimum brake air gap s 1 min in mm (in) 0.3 (0.0118) 0.3 (0.0118) 0.3 (0.0118)) 0.3 (0.0118) 0.35 (0.0138) 0.4 (0.0157) 0.4 (0.0157)
Maximum brake air gap s 1 max in mm (in) 0.65 (0.0256) 0.65 (0.0256 0.65 (0.0256) 0.65 (0.0256) 1.3 (0.0512) 1.3 (0.0512) 1.3 (0.0512)
Air gap adjusting angle a 1 in ° 120 120 120 90 80 70 60
Manual release axial play s 2 in mm (in) 1.5 (0.0591) 1.5 (0.0591) 1.5 (0.0591) 1.5 (0.0591) 2 (0.0787) 2 (0.0787) 2 (0.0787)
Manual release adjusting angle a 2 in ° 20 20 20 20 20 20 20
Brake disk remaining thickness b m in in mm (in) 5 (0.197) 5 (0.197) 6 (0.236) 7 (0.276) 8.5 (0.335) 10 (0.394) 11 (0.433)
Braking work until re-adjustment W N in Ws 100 · 10 6 100 · 10 6 120 · 10 6 200 · 10 6 1000 · 10 6 1500 · 10 6 2500 · 10 6
Collared pin pre-tension torques in Nm (lb ft) 2,3 (1.7) 2.3 (1.7) 4.0 (2.95) 9.0 (6.64) 30 (22.1) 70 (51.7) 140 (103)
1) Only applies for brakes without brake release device
6.4.2 For ZBF motors
Brake size B004 B020 B050 B140

Quantity of springs 1) Brake torque M B in Nm (lb ft)
white red blue

– 4 2 2.3 (1.70) 5.5 (4.10) 13.2 (9.60) 37.3 (27)
– 4 0 1.7 (1.25) 4.4 (3.20) 11 ( 8.10) 31 (23)
– 3 0 1.3 (0.95) 3.3 (2.40) 8.3 (6.10) 23 (17)
– 0 6 1.8 (1.35) 3.3 (2.40) 6.3 (4.60) 18 (13.5)
– 0 4 1.2 (0.90) 2.2 (1.60) 4.2 (3.1) 12 (8.90)
– 0 3 0.9 (0.65) 1.7 (1.25) 3.2 (2.40) 8.8 (6.50)
Minimum brake air gap s 1 min in mm (in) 0.35 (0.0138) 0.35 (0.0138) 0.35 (0.0138) 0.35 (0.0138)
Maximum brake air gap s 1 max in mm (in) 1.2 (0.0472) 1.2 (0.0472) 1.2 (0.0472) 1.2 (0.0472)
Air gap adjusting angle a 1 in ° 120 120 90 80
Manual release axial play s 2 in mm (in) 1.5 (0.0591) 1.5 (0.0591) 1.5 (0.0591) 2 (0.0787)
Manual release adjusting angle a 2 in ° 20 20 20 20
Brake disk remaining thickness b m in in mm (in) 5 (0.197) 6 (0.236) 7 (0.276) 8,5 (0.335)
229203k2.p65/1099
Braking work until re-adjustment W N in Ws 200 · 10 6 300 · 10 6 500 · 10 6 900 · 10 6
Collared pin pre-tension torques in Nm (lb ft) 2.3 (1.70) 4.0 (2.95) 9.0 (6.64) 30 (22.1)
1) Only applies for brakes without brake release device

20
6.5 Tightening torques The bolts on Demag Z.. range motors must be tightened with the torques given in the
table below. This also applies when high tensile bolts are used.
Bolt tightening torques
For hexagon socket bolts to DIN 912 and to DIN 6912 for IM B 14 flange mounting
Bolt size M5 M6 M8 M 10 M 12 M 16
Tightening torque 6.2 Nm (4.58 lb ft) 10.5 Nm (7.75 lb ft) 25 Nm (18.5 lb ft) 50 Nm (36.9 lb ft) 86 Nm (63.5 lb ft) 215 Nm (159 lb ft)
For VERBUS RIPP self-locking bolts for •IM B 3 foot mounting

•IM B 5 flange mounting
Bolt size M5 M6 M8 M 10 M 12 M 16
Tightening torque
for cast iron 7.5 Nm (5.54 lb ft) 14 Nm ( 10.3 lb ft) 30 Nm (22.1 lb ft) 65 Nm (48.0 lb ft) 100 Nm (73.8 lb ft) 270 Nm (199 lb ft)
Tightening torque
for cast aluminum 9 Nm (6.64 lb ft) 18 Nm (13.3 lb ft) 45 Nm (33.2 lb ft) 75 Nm (55.4 lb ft) – –
229203k2.p65/0300
21
7 Motor/brake connecting diagrams
7.1 Brake control Various control modules are available which are fitted in the brake motor terminal box
as standard for controlling Demag B004 to B680 disk brakes with DC magnets. Bra-
kes up to size
• B 050 for ZBA motors
• B 140 for ZBF motors
featuring 24 V DC coil voltage can be supplied and controlled by the installation
control system.
All rectifiers feature varistor protection against overvoltage at the AC input and on the
switching contact terminal as standard. GE, GS and GP brake rectifiers can be used
for voltages from 42 V AC to 500 V AC.
GE, GS and GP brake rectifiers can be fed separately with alternating current or con-
nected parallel to the motor winding. AC or DC brake control is possible with all brake
rectifiers depending on the connection.
The control system is of modular design. SE or VE modules for fast DC interruption of
the brake current can be added to brake motors fitted with GE, GS or GP brake
rectifiers, also at a later date, without the need for additional cables and switching
devices.
Operation with frequency inverters

If ZB cylindrical rotor brake motors are operated together with inverters, the
brake must be provided with a separate power supply and control.
Brake application times are highly dependent on the way in which the brake is con-
nected.
Supply and brake voltage

U line [AC] U brake [DC]
240 V and 240/480 V 108 V
480 V 216 V
330/575 V 150 V
Direct DC current supply to brake coil with 24V DC

Direct supply with 24V DC is possible for
• ZBA-motors up to brake size B 050
• ZBF-motors up to brake size B 140.
A brake control module is not necessary. The brake coil is protected with varistor
against overvoltage.
Brake control modules
• GE brake rectifier (normal excitation)

GE half-wave brake rectifiers are used for single-speed motors as standard, and
for pole-changing motors featuring separate power supply for brake size
– B050 for ZBA motors
– B140 for ZBF motors.
They mainly consist of a half-wave rectifier with integrated free-wheeling circuit.
Important: When used with a pole-changing motor, the GE module must be
provided with a separate power supply or in USA according to
diagram 037 980 84 (see section 7.7).
Note: When SE or VE units are used, no additional cables are necessary.
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22
• GS brake rectifier (high-speed excitation)
GS brake rectifiers are used for motors with brakes as of size B140 as standard.
They can be used for single-speed motors as well as for pole-changing motors
with a separate power supply. These rectifiers are used to temporally overexcited
the brake to relaease it and then to supply it with the appropriate holding voltage.
GS brake rectifiers can be used as an option for brake sizes B004 to B050. This
makes it possible to achieve shorter brake release times and higher motor starting
frequencies.
Up to brake size B050, two leads are sufficient for control (over-excitation factor
of 2), from brake size B140, on three leads are required (over-excitation factor
of 2,5).
GS modules include a reversible rectifier which overexcites the brake for approx.
0,3 seconds to release it and then supplies it with the appropriate holding voltage
from a half-wave rectifier.
Important: When used with a pole-changing motor, the GS module must
be provided with a separate power supply or according to
diagrams 037 981 84 and 038 025 84 (see section 7.7).
Note: When SE or VE units are used, no additional cables are
necessary.
• GP brake rectifiers (normal excitation for pole-changing motors)

GP brake rectifiers can be used as an option for simple control with pole-changing
motors together with switch-off in the DC circuit. In contrast to GE rectifiers, no
further supply line is required for voltage control.
The motor and brake control module are connected to the same power supply.
Note: When SE or VE units are used, no additional cables are
necessary.
• SE current relays (motor current-dependent high-speed trip relay)

SE current relays can be combined with GE, GS and GP brake rectifiers. They are
used for rapid demagnetization of the brake to achieve fast brake application times
without the need for additional wiring for brake switch-off in the DC circuit. SE
current relays are connected to one motor current phase. When the motor is swit-
ched off, the relay demagnetizes the brake by opeining the contact in the DC cir-
cuit.
When SE units are used, no additional cables are necessary to interrupt the power
supply for the brake.
Important: SE modules must not be used together with inverters.
We recommend the use of VE voltage relays for these
applications.
SE current relays can be used for rated motor currents up to 50 A.
• VE voltage relays (voltage-dependent high-speed trip relay)

VE voltage relays can be combined with GE, GS and GP brake rectifiers. In con-
trast to SE current relays, VE voltage relays must only be used for brakes with
a separate power supply. These modules may preferably be used for inverter-fed
motors. They are used for high-speed demagnetization of the brake to achieve fast
brake application times without the need for additional wiring for brake switch-off in
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the DC circuit. VE voltage relays are connected to the brake power supply. The
contact in the DC circuit is opened when the brake is switched off.
23
Brake control module technical data
Module Ident. no. Voltage range Max. continous brake Remarks

direct current
in V 1) A
260 892 84 110 ... 500 1,5
GE
260 890 84 42 ... 500 3
260 893 84 110 ... 500 1,5
GP
260 891 84 42 ... 500 3
GS 260 894 84 110 ... 500 1,5 2) Over-exitation factor: 2 oder 2,5
VE 260 897 84 42 ... 500 2
3) Control current range Motor sizes
(Single phase motor Z motors
current)
SE 260 864 84 0,25 ... 4 A 63 – 71
260 870 84 42 ... 500 2 0,8 ... 16 A 80 – 100
260 896 84 1,2 ... 50 A 112 – 225
1) Sinusoidal V o l t a g e s !
2) •2 leads ® Over-exitation factor of 2
•3 leads ® Over-exitation factor of 2.5 (required for ZBA-motor with brake size B140 and larger).
3) Standard: ® Motor rated current is less than or equal to the higher value for the SE current relay in "Control current range".
Note: If the motor rated current is greater than the higher value for the SE current relay in "Control current range":
® use next largest SE module.
Brake control module operating range:

• GE, GP, GS brake rectifiers
Brake voltage Brake size

U AC U DC B004 B007 B020 B050 B140 B280 B680
V V
42 – 109 19 – 49
GE 3 A
GP 3 A
GE 1,5 A
110 – 500 50 – 225 GP 1,5 A GS 1,5 A
GS 1,5 A
200 – 500 90 – 225 GS 1,5 A
U AC = Brake control module input voltage

U DC = Brake control module output voltage ® brake supply voltage
• SE current relay, VE voltage relay
Brake size
B004 B007 B020 B050 B140 B280 B680
Brake voltage Brake voltage Brake voltage

U AC U DC U AC U DC U AC U DC
V V V V V V
42 - 500 19 - 225 53 - 500 24 - 225 110 - 500 50 - 225
SE 2A
229203k3.p65/1099
VE 2A
U AC = Brake control module input voltage

U DC = Brake control module output voltage ® brake supply voltage
24
Brake selection table
Standard Brake Supply Allocated standard modules Remark

braking torque voltage
ZBA ZBF ZBA ZBF
single-speed or Part no. single- Part no. pole- Part no.
pole-changing speed changing
[ V AC]
42 - 109 GE [3,0 A] 260 890 84 GE [3,0 A] 260 890 84 a) Supply from a separate
DC voltage source is
+ SE 1)
possible without any
≤ 2,5 Nm ≤ 2,5 Nm B 003 limitations.
110 - 500 GE [1,5 A] 260 892 84 GE [1,5 A] 260 892 84
1) Voltage range:
+ SE
19 - 225 V DC
42 - 109 GE [3,0 A] 260 890 84 GE [3,0 A] 260 890 84
+ SE 1)
≤ 7,6 Nm – B 007
110 - 500 GE [1,5 A] 260 892 84 GE [1,5 A] 260 892 84 b) The GF module has a
limited
+ SE 1) voltage range:
GF [0,8 A] 260 943 84
42 - 109 GE [3,0 A] 260 890 84 GE [3,0 A] 260 890 84 220 - 500 V AC
+ SE 1)
≤ 20 Nm ≤ 5,5 Nm B 020
110 - 500 GE [1,5 A] 260 892 84 GE [1,5 A] 260 892 84
+ SE 1)
42 - 109 GE [3,0 A] 260 890 84 GE [3,0 A] 260 890 84
+ SE 1)
≤ 50 Nm ≤ 13,2 Nm B 050
110 - 500 GE [1,5 A] 260 892 84 GE [1,5 A] 260 892 84
+ SE 1)
42 - 109 – – GE [3,0 A] 260 890 84 GP [3,0 A] 260 891 84
+ SE 1) + SE 1) Supply from a separate DC

≤ 140 Nm ≤ 37,3 Nm B 140 voltage source is not possible
110 - 500 GS [1,0 A] 260 894 84 GE [1,5 A] 260 892 84 GP [1,5 A] 260 893 84
1)
Exception:
+ SE + SE 1) B 140 brake with braking
42 - 189 – – – – – – torque ≤ 37,3 Nm
≤ 280 Nm – B 280
190 - 500 GS [1,0 A] 260 894 84 – – – –
Voltage range:
42 - 259 – – – – – – 19 - 225 V DC
≤ 680 Nm – B 680
260 - 500 GS [1,0 A] 260 894 84 – – – –
1) The SE modules are allocated as follows depending on the rated motor current:
Rated motor current Module Part no.
≤ 4A 260 864 84
≤ 16 A SE 260 870 84
≤ 50 A 260 896 84
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25
7.2 Brake operating times Brake application times are highly dependent on the way in which the brake is con-
nected.
• Direct current connection

The coil circuit is interrupted when the brake module contact opens at the relevant
terminal. The magnetic field rapidly decreases and the brake torque rapidly rises.
Mannesmann Dematic rectifiers are protected against overvoltage at the switching
contact by varistors.
Interruption of the DC circuit between the module and the coil connections
is not permitted.
• Connection in the AC circuit

When the brake voltage is switched off, i.e. on the supply side before the rectifier,
an inductive coil current continues to flow through the rectifier diodes for a short
time. The magnet field decreases more slowly. The braking operation begins more
smoothly.
This connection type is not suitable for hoist drives.
• Connection in the motor circuit

The rectifier is connected directly to the motor terminals. When the motor is swit-
ched off, the residual motor voltage results in significantly longer switch-off times
compared to switch-off in the AC circuit.
Unless provided with switch-off in the DC circuit using a contact or the SE
current relay, this type of connection is not suitable for drives with overhaul-
ing loads, e.g. hoists, and may not be used in these applications.
Depending on the type of connection, the release and braking operation of B004 to
B 680 DC brakes can generally be characterized by the following values:
• t11 Brake release time with normal excitation (GE, GP) 1)

• t12 Brake release time with high-speed excitation (GS) 1)
• t21 Brake application time for switch-off in the AC circuit
• t22 Brake application time for switch-off in the DC circuit (contact)
• t23 Brake application time for switch-off in the DC circuit (SE, VE)
1) Definition: Release time is the time it takes to reach the full acceleration
torgue of the motor.
Brake release times may be reduced using high-speed excitation modules with which
a higher voltage is temporarily applied to the brake coil when the brake is turned on
and the magnetic field is built up more quickly.
7.2.1 ZBA range brake operating

times
Table 9 S i ze Release times in ms Application times in ms
t 11 t 12 t 21 t 22 t 23
B 004 60 35 250 55 85
B 007 120 60 90 30 60
B 020 130 90 40 20 30
B 050 120 100 90 30 80
B 140 – 110 60 30 60
B 280 – 140 300 90 160
B 680 – 140 300 150 225

229203k3.p65/1099
The brake release and application times given are guide values for the maximum
brake torque. In the case of lower brake torques, these values may change, particu-
larly t 21 for switch-off in the AC circuit.
26
7.2.2 ZBF range brake operating
times
Table 10 Size Release times in ms Application times in ms

t 11 t 12 t 21 t 22 t 23
B004 60 40 200 30 40
B020 60 40 300 50 60
B050 80 65 300 60 70
B140 110 90 350 100 100
The brake release and application times given are guide values for the maximum
brake torque (see table 10). In the case of lower brake torques, these values may
change, particularly t 21 for switch-off in the AC circuit.
7.3 Selection criteria The following criteria must be considered when selecting the connection diagram:
• Motor for use in USA or Canada
• Motor for inverter operation if applicable
• Brake motor or motor without brake
• Motor to be operated with
– one line voltage, e.g. 240, 480, 575 V, 60 Hz or
– two line voltages,e.g. - USA: YY/Y 240/480 V, 60 Hz
- Canada: D/Y 330/575 V, 60 Hz.
• Motor designed for one or two speeds
• Common or separate power supply to motor and brake
• Control module selected:
– GE for normal excitation
– GS for high-speed excitation
– GP for normal excitation for pole-changing motors
• Switch-off:
– in the DC circuit for short operating times (e.g. hoist drives, positioning drives
– in the AC circuit for medium operating times (e.g. travel drives, conveyor belts)
– in the motor circuit for stopping the motor in an uncritical time.
Refer to the following flow charts.
Notes: • The motor and brake of inverter-fed drives must have separate power
supplies.
• SE modules must not be used with inverter-fed drives.
• GE, GS or GP application for a maximum voltage of 500 V.
• Connection diagrams
– Connection diagram selection (flow chart) for line-fed drives in USA
and related tables ® section 7.4.
– Connection diagram selection (flow chart) for line-fed drives in Canada
and related tables ® section 7.5.
– Connection diagram selection (flow chart) for inverter-fed drives and
related tables ® section 7.6.
– Connection diagrams® section 7.7.
Diagrams shown in numerical order according to ident. no.
– Connection diagrams arranged in the motor terminal box.
• Condition when supplied for inverter operation:
When motors are supplied for INVERTER OPERATION, GE or GS
brake control modules are NOT connected with the motor winding as
229203k3.p65/1099
shown in the individual connection diagrams which document the motor

connection on delivery.
The brake control module must be provided with a separate
AC power supply.
27
7.4 Connecting diagram
selection for USA
240/480 V 60 Hz
Select connection diagram for

line operation
no
Motor with brake? Table 1
yes
Common power supply yes

B004 - B680 DC brake Table 2
to motor and brake?
no
yes
Separate AC power supply? Table 3
no
Separate DC power supply? Table 4
42002844.eps
229203k3.p65/1099
28
Table 1 Motors with no brake
1 Motor for one or two speeds Motor type

one speed two speeds
separate windings Dahlander winding
} /} } } /} { /}
020 338 84 020 333 84 031 849 84 023 331 84
Tables 2 – 4 Motors with a brake
2 Common motor and brake Motor type

power supply
one speed two speeds (separate windings)
(not suitable for inverter operation)
} /} } } /} { /}
Switch-off in Switching Brake size for Control module in terminal box
element
ZBA ZBF GE GS GP GE GS
DC circuit Contact £ B050 £ B140 037 986 84 037 987 84 037 978 84 037 980 84 037 981 84 –
³ B140 – – 038 028 84 – – 038 025 84 038 060 84
SE 1 ) 2 ) £ B050 £ B140 037 988 84 037 989 84 037 979 84 – – –
³ B140 – – 038 029 84 – – – –
AC circuit Contact £ B050 £ B140 037 986 84 037 987 84 037 978 84 037 980 84 037 981 84 –
³ B140 – – 038 028 84 – – 038 025 84 038 060 84
motor circuit – £ B050 £ B140 037 986 44 037 987 84 037 978 84 – – –
³ B140 – – 038 028 84 – – – –
1) Fitted in the terminal box
2) Not for inverter operation
3 Separate AC brake supply Motor type

} /} } } /} { /}
element
ZBA ZBF GE GS GE GS GE GS
DC circuit Contact £ B050 £ B140 037 986 84 037 987 84 037 980 84 037 981 84 – 037 992 84 037 993 84
³ B140 – – 038 028 84 – 038 025 84 038 060 84 – 038 031 84
SE 1 ) 2 ) £ B050 £ B140 037 988 84 037 989 84 037 982 84 037 983 84 – – –
³ B140 – – 038 029 84 – 038 026 84 038 061 84 – –
VE 1 ) £ B050 £ B140 037 990 84 037 991 84 037 984 84 037 985 84 – 037 994 84 037 995 84
³ B140 – – 038 030 84 – 038 027 84 038 062 84 – 038 032 84
AC circuit Contact £ B050 £ B140 037 986 84 037 987 84 037 980 84 037 981 84 – 037 992 84 037 993 84
³ B140 – – 038 028 84 – 038 025 84 038 060 84 – 038 031 84
4 Separate DC brake supply Motor connection

} /} } } /}
229203k3.p65/1099
Switch-off in Switching Brake size for No control module lin terminal box
element
ZBA ZBF
DC circuit Contact £ B050 £ B140 037 997 84 037 996 84 037 998 84
29
7.5 Connecting diagram
selection for Canada
330/575 V 60 Hz
Select
connection diagram
for line operation
yes
Motor without brake? Table 5
no
yes
Separate DC power supply? Table 6
no
yes Common power supply yes

1 line voltage? Table 7
to motor and brake?
no no
Separate power supply

Table 8
to motor and brake?
Common power supply yes

2 line voltages Table 9
to motor and brake?
no
Separate power supply

Table 10
229203k3.p65/1099
to motor and brake?
30 42048344.eps
Table 5 Motors with no brake
5 Motor for one or two speeds Motor type

{ /} } /} { /}
020 324 84 038 114 84 031 849 84 023 331 84
Tables 6 - 10 Motors with a brake
6 Separate DC brake supply Motor connection

{ /} } /}
Switch-off in Switching Brake size No control module in terminal box
element
ZBA ZBF
DC circuit Contact £ B050 £ B140 038 106 84 038 107 84 037 998 84
7 Common motor and brake Motor connection

power supply
(not suitable for inverter operation) two speeds – separate windings
} /}
element
ZBA ZBF GP
DC circuit Contact £ B050 £ B140 038 100 84
³ B140 – –
SE 1) 2) £ B050 £ B140 038 101 84
³ B140 – –
AC circuit Contact £ B050 £ B140 038 100 84
³ B140 – –
motor circuit – £ B050 £ B140 038 100 84

³ B140 – –
8 Separate AC brake supply Motor connection

two speeds
} /} { /}
element
ZBA ZBF GE GS GE GS
DC circuit Contact £ B050 £ B140 038 102 84 038 103 84 – 037 992 84 037 993 84
³ B140 – – 038 104 84 038 105 84 – 038 031 84
SE 1 ) 2 ) £ B050 £ B140 038 108 84 038 110 84 – – –
³ B140 – – 038 112 84 038 061 84 – –
VE 1 ) £ B050 £ B140 038 109 84 038 111 84 – 037 994 84 037 995 84
³ B140 – – 038 113 84 038 062 84 – 038 032 84
229203k3.p65/1099
AC circuit Contact £ B050 £ B140 038 102 84 038 103 84 – 037 992 84 037 993 84
³ B140 – – 038 104 84 038 105 84 – 038 031 84
2) Not for inverter operation 31
9 Common motor and brake Motor connection
power supply one speed
(not suitable for inverter operation) { /}
element
ZBA ZBF GE GS
DC circuit Contact £ B050 £ B140 038 092 84 038 094 84
³ B140 – – –
SE 1 ) 2 ) £ B050 £ B140 038 091 84 038 093 84
³ B140 – – –
AC circuit Contact £ B050 £ B140 038 092 84 038 094 84
³ B140 – – –
motor circuit – £ B050 £ B140 038 092 84 038 094 84
³ B140 – – –
10 Separate AC brake supply Motor connection

one speed
{ /}
element
ZBA ZBF GE GS
³ B140 – – 038 097 84
SE 1 ) 2 ) £ B050 £ B140 038 091 84 038 093 84
³ B140 – – 038 098 84
VE 1 ) £ B050 £ B140 038 095 84 038 096 84
³ B140 – – 038 099 84
AC circuit Contact £ B050 £ B140 038 092 84 038 094 84
³ B140 – – 038 097 84
229203k3.p65/1099
32
7.6 Inverter operation
Select connection diagram for

inverter operation
no
Motor with brake? Table 11
yes
B004 - B680 Separate AC yes

Table 12
DC brake voltage supply
no
Separate
Table 13
DC voltage supply
41808844.eps
Tables 11 - 13
11 Motor with no brake Motor connection

Canada USA
one speed one speed
{ /} } /} }
020 324 84 020 338 84
12 Separate AC brake supply Motor type

Canada USA
one speed one speed

{ /} } /} }
element
ZBA ZBF GE GS GE GS
DC circuit Contact £ B050 £ B140 038 092 84 038 094 84 037 986 84 037 987 84
³ B140 – – 038 097 84 – 038 028 84
VE 1) £ B050 £ B140 038 095 84 038 096 84 037 990 84 037 991 84
³ B140 – – 038 099 84 – 038 030 84
AC circuit Contact £ B050 £ B140 037 092 84 038 094 84 037 986 84 037 987 84
³ B140 – – 038 097 84 – 038 028 84

13 Separate DC brake supply Motor type

Canada USA
one speed one speed

{ /} } /} }
Switch-off in Switching Brake size for No control module in terminal box
229203k3.p65/1099
element
ZBA ZBF

33
7.7 Connection/circuit diagrams
Motor for one line voltage or

dual voltage motor ( 1: 3 )
Y high voltage
D low voltage
For inverter operation, connect motor with

Y or D connection according to inverter settings
Motor supplied with:

Jumper parts to connect the motor winding with
Y or D connection enclosed.
020 324 84 02032484.eps
Motor for one line voltage

Pole-changing, separate windings T1, T2, T3 for low speed
T11, T12, T13 for high speed
* = Supply to high speed winding via external

switch-over
020 333 84 02033384.eps
Dual voltage motor (1:2) YY low voltage

Y high voltage
For inverter operation, connect motor with YY or

Y connection according to inverter settings.

229203k4.p65/1099
• Motor winding connected with Y connection.

• Jumper parts to connect the motor winding
with YY connection enclosed.
34 020 338 84 02033884.eps

Pole-changing, Dahlander winding D for low speed
YY for high speed
Switch-over to high speed winding via external

supply switch-over and jumper.

Motor connection ends connected to terminal
board as shown.
023 331 84 02333184.eps

Pole-changing, separate windings T1, T2, T3 for low speed

switch-over
031 849 84 03184984.eps

229203k4.p65/1099
35
Motor for one line voltage, pole-changing, separate windings
Common power supply to motor and brake
switch-over.
T1, T2, T3 for low speed

Not suitable for inverter operation!
Switch-off in the DC circuit

• Remove jumper between terminals 3 and 4
• Connect contactor between terminals 3 and 4
Switch-off in the AC circuit

• Jumper between terminals 3 and 4
03797884.eps
• Contactor in the power line behind terminal 5
Motor current switch-off

Jumper between terminals 3 and 4
• Jumper parts to connect the motor winding enclosed.
• Brake connected to terminals 1 and 2 of the GP module.
• Jumper between terminals 3 and 4 of the GP module.
• GP module connected with the motor winding as in the connection diagram.
037 978 84

Common power supply to motor and brake * = Supply to high speed winding via external
switch-over.

Switch-off in the DC circuit dependent on motor

current
A = Intermediate terminal
03797984.eps

• Motor winding connected as in connection diagram (T1 and T11 connected to one terminal).
• SE module connected to terminals 3 and 4 of the GP module.
229203k4.p65/1099
• SE module connected with intermediate terminal A and the motor winding via terminal T1 T11.
• GP module connected with the motor winding and intermediate terminal A as in the connection diagram.
36 037 979 84
switch-over

A: Common power supply to motor and brake
Not suitable for inverter operation.
B: Separate power supply to brake
03798084.eps Switch-off in the DC circuit

Motor supplied with: • Remove jumper between terminals 3 and 4.
• Jumper parts to connect the motor winding enclosed. • Connect a contactor between terminals 3 and 4.
• Brake connected to terminals 1 and 2 of the GE module.
• Jumper between terminals 3 and 4 of the GE module.
• Jumper between terminals 3 and 4.
• Line-powered: GE module connected with the motor winding according to variant A
(T1 connected to terminal 6; terminal 5 free).
Important: The brake will not function without an external power supply to
terminal 5 of the GE module.
• Inverter operation: – GE module not connected to motor winding
– Power supply by customer thru variation B
037 980 84

switch-over

03798184.eps

• Jumper parts to connect the motor winding enclosed. Switch-off in the DC circuit
• Brake connected to terminals 1 and 2 of the GS module. • Remove jumper between terminals 3 and 4.
• Jumper between terminals 3 and 4 of the GS module. • Connect a contactor between terminals 3 and 4.
• Line-powered: GS module connected with the motor winding according to variant A
(T1 connected to terminal 6; terminal 5 free).
Important: The brake will not function without an external power supply to • Jumper between terminals 3 and 4.
229203k4.p65/1099
terminal 5 of the GS module. • Contactor in the power line behind terminal 5.
• Inverter operation: – GE module not connected to motor winding

037 981 84
37
Separate power supply to brake * = Supply to high speed winding via external switch-
over.


current
03798244.eps
• Motor winding connected as in connection diagram (T1 and T11 connected to
one terminal)
• SE module connected to terminals 3 and 4 of the GE module.
• SE module connected with the motor winding via intermediate terminal A and
terminal T1 T11
Important: The brake will not function without a separate power supply to
terminals 5 and 6 of the GE module.
037 982 84

Separate power supply to brake * = Supply to high speed winding via external
switch-over.


current
03798384.eps

• Brake connected to terminals 1 and 2 of the GS module.
• SE module connected to terminals 3 and 4 of the GS module.
• SE module connected with the motor winding via intermediate terminal A and terminal T1 T11.
229203k4.p65/1099
Important: The brake will not function without a separate power supply to terminals 5 and 6
of the GS module.
38 037 983 84
switch-over.

Voltage-dependent switch-off in the DC circuit
03798444.eps

• VE module connected to terminals 1, 3 and 4 of the GE module.
037 984 84

switch-over.

03798584.eps

• VE module connected to terminals 1, 3 and 4 of the GS module.
229203k4.p65/1099
terminals 5 and 6 of the GS module.
037 985 84
39
Dual voltage motor 1:2 A: Common power supply to motor and brake
Brake coil rated for the low vo
YY low voltage Y high voltage

For inverter operation, connect the motor with YY or
Y connection according to inverter settings

• Connect a contactor between terminals 3 and 4
03798644.eps
• Jumper parts to connect the motor winding with YY connection enclosed. Motor current switch-off
• Brake connected to terminals 1 and 2 of the GE module. • Jumper between terminals 3 and 4
• Jumper between terminals 3 and 4 of the GE module. ® not possible for separate power
supply to the brake
• Line powered: GE module connected with the motor winding according to variant A.
• Inverter operation: – GE• module not connected to motor winding
037 986 84
Dual voltage motor (1:2) A: Common power supply to motor and brake
YY low voltage Y high voltage Brake coil rated for the low voltage.

For inverter operation, connect the motor with YY or
Y connection according to inverter settings

• Remove jumper between terminals 3 and 4.
• Connect a contactor between terminals 3 and 4.
03798784.eps • Jumper between terminals 3 and 4
• Jumper parts to connect the motor winding with YY connection enclosed. Jumper between terminals 3 and 4
• Brake connected to terminals 1 and 2 of the GS module. ® not possible for separate power supply.
• Jumper between terminals 3 and 4 of the GS module.
229203k4.p65/1099
• Line-powered: GS module connected with the motor winding according to variant A.

• Inverter operation: – GS module not connected to motor winding
40 037 987 84
Y high voltage

Brake coil rated for the low voltage

current
03798884.eps
• Jumper parts to connect the motor winding with YY connection enclosed.
• SE module connected with intermediate terminal A and with the motor winding via T1.
• GE module connected with the motor winding according to variant A.
037 988 84
Dual voltage motor (1:2)

YY low voltage
Y high voltage


current
03798984.eps
229203k4.p65/1099
• SE module connected with intermediate terminal A and the motor winding via T1.
• GS module connected with the motor winding according to variant A.
037 989 84 41
Y high voltage
Separate power supply to brake

For inverter operation, connect motor with YY or
Y connection according to inverter settings.
03799084.eps

• Motor winding connected with Y connection
037 990 84

YY low voltage
Y high voltage

For inverter operation, connect the motor with YY or Y
connection according to inverter settings.
03799184.eps

229203k4.p65/1099
42 037 991 84
Motor for one line voltage,
YY for high speed
Switch-over to high speed winding via external supply

switch-over and jumper.
Separate power supply to brake.

Maximale Versorgungsspannung: 500 V AC.


03799284.eps

037 992 84

YY for high speed




03799384.eps
229203k4.p65/1099
037 993 84
43
YY for high speed


Voltage-dependent switch-off in the DC circuit.
03799484.eps
037 994 84

YY for high speed


03799584.eps

229203k4.p65/1099
terminals 5 and 6 of the GS module
44 037 995 84
Separate DC supply to brake * = Supply to high speed winding via exter-
nal switch-over.

0379964.eps

• Brake connected to Euro terminals.
Important: The brake will not function without a separate
DC supply to the brake
037 996 84
Motor umschaltbar für zwei Netzspannungen (1:2) YY low voltage

Y high voltage
Separate DC supply to brake

For inverter operation, connect motor with YY or Y
03799784.eps

229203k4.p65/1099
037 997 84 45
YY for high speed

03799884.eps

Brake connected to Euro terminals.
DC supply to the brake.
037 998 84

* = Supply to high speed winding via external switch-over


• Contactors in the power lines behind
terminals 5 and 6.
03802584.eps
• Line-powered: GS module connected with the motor winding according to variant A
(T1 connected to terminal 7; terminals 5 and 6 free).
229203k4.p65/1099
46 038 025 84
Separate power supply to brake * = Supply to high speed winding via exter-
nal switch-over.


current
03802684.eps
• Motor winding connected as in connection diagram (T1 and T11 connected
to one terminal).
terminal T1 T11.
terminals 5, 6 and 7 of the GS module.
038 026 84

switch-over.

03802784.eps

229203k4.p65/1099
038 027 84 47
Dual voltage motor (1:2) A: Common power supply to motor and brake
Brake coil rated for the low voltage.
YY low voltage Y high voltage

For inverter operation, connect the motor with YY
or Y connection according to inverter settings

03802884.eps • Contactors in the power lines behind
Motor supplied with: terminals 5 and 6.
• Brake connected to terminals 1 and 2 of the GS module. ® not possible for separate power
• Jumper between terminals 3 and 4 of the GS module. supply to the brake
• Netzbetrieb: GS module connected with the motor winding according to variant A.
• Umrichterbetrieb: – GS-Baustein nicht mit der Motorwicklung verbunden.
– Spannungsversorgung durch den Kunden nach Variante B.
038 028 84

YY low voltage
Y high voltage


current
03802984.eps

229203k4.p65/1099
• SE module connected with intermediate terminal A and the motor winding via T1.
48 038 029 84
YY low voltage
Y high voltage

For inverter operation, connect the motor with
YY or Y connection according to inverter settings.
03803084.eps

038 030 84

Pole-changing, Dahlander winding
D for low speed
YY for high speed




terminals 5 and 6
03803184.eps

229203k4.p65/1099
038 031 84 49
YY for high speed


03803284.eps

terminals 5, 6 and 7 of the GE module.
038 032 84

switch-over

03806084.eps
• Jumper parts to connect the motor winding enclosed. Switch-off in the DC circuit
• Brake connected to terminals 1 and 2 of the GS module. • Remove jumper between terminals 3 and 4.
• Jumper between terminals 3 and 4 of the GS module. • Connect a contactor between terminals 3 and 4.
• Line-powered: GS module connected with the motor winding according to variant A Switch-off in the AC circuit
(T1 connected to terminal 6; terminals 5 and 6 free). • Jumper between terminals 3 and 4.
229203k4.p65/1099
Important: The brake will not function without an external power supply to • Contactor in the power line behind terminals
terminals 5 and 6 of the GS module. 5 and 6.
038 060 84
50
* = Supply to high speed winding via external switch-
over.



current
03806184.eps
Motor supplied with: A = Intermediate terminal

038 061 84

* = Supply to high speed winding via external switch-over.


03806284.eps

229203k4.p65/1099
Important! The brake will not function without a separate power supply to
038 062 84 51
Dual voltage motor ( 1: 3 )
Y high voltage D low voltage Brake coil rated for the low voltage.

current
03809184.eps

• Jumper parts to connect the motor winding with Y or D connection enclosed.
• SE module connected with the motor winding according to variant Y.
• GE module connected with the motor winding according to variant A.
038 091 84
Dual voltage motor ( 1: 3 ) A: Common power supply to motor and brake

Y high voltage D low voltage Brake coil rated for the low voltage.

Y or D connection according to inverter settings.

03809284.eps • Remove jumper between terminals 3 and 4.

• Jumper parts to connect the motor winding with Y or D connection enclosed. • Contactor in the power line behind terminal 5.
229203k4.p65/1099

• Line-powered: GE module connected with the motor winding according to variant A.
• Inverter operation: – GE module not connected to motor winding ® not possible for separate power supply to the
– Power supply by customer thru variation B brake.
52 038 092 84
Dual voltage motor ( 1: 3 )

current
03809384.eps

038 093 84
Dual voltage motor ( 1: 3 ) A: Common power supply to motor and brake

Y high voltage D low voltage

Y or D connection according to inverter settings.

03809484.eps
• Contactor in the power line behind terminal 5.
229203k4.p65/1099

• Line-powered: GS module connected with the motor winding according to variant A.
® not possible for separate power supply to the
• Inverter operation: – GS module not connected to motor winding brake.
038 094 84
53
Motor for one line voltage or dual voltage motor ( 1: 3 ) Separate power supply to brake.
For inverter operation, connect motor with Y or D

03809544.eps

038 095 84

For inverter operation, connect motor with Y or

D connection according to inverter settings.
03809684.eps
229203k4.p65/1099
54 038 096 84
Motor for one line voltage or dual voltage motor ( 1: 3 )
For inverter operation, connect the motor with Y or



03809784.eps • Jumper between terminals 3 and 4.
Motor supplied with: terminals 5 and 6.
• Line-powered: GS module connected with the motor winding according to
variant A.
– Power supply by customer
038 097 84
Motor for one line voltage or dual voltage motor ( 1: 3 ) Separate power supply to brake


current
03809884.eps

229203k4.p65/1099

038 098 84 55
For inverter operation, connect the motor with Y or

03809984.eps
038 099 84

Common power supply to motor and brake * = Supply to high speed winding via external
switch-over.



• Schützkontakt in die Zuleitung zur Klemme 5

03810084.eps Jumper between terminals 3 and 4

• Jumper between terminals 3 and 4 of the GP module.
229203k4.p65/1099
• GP module connected with the motor winding as in the connection

diagram.
56 038 100 84
Common power supply to motor and brake
switch-over.


current
03810184.eps
• SE module connected to terminals 3 and 4 of the GP module.
• SE module connected with intermediate terminal A and the motor winding via terminal T1 T11.
• GP module connected with the motor winding and intermediate terminal A as in the connection diagram.
038 101 84

switch-over

Separate power supply to brake,

Spannung max. 500 V AC !


03810284.eps • Jumper between terminals 3 and 4.
Motor supplied with: • Schützkontakt in die Zuleitung zur Klemme 5
• Motorwicklung wie im Anschlußplan angeschlossen.
229203k4.p65/1099
038 102 84 57
Motor for one line voltage, pole-changing, separate windings * = Supply to high speed winding via external
switch-over


Spannung max. 500 V AC!


• Contactor in the power line behind terminal 5.
03810384.eps
038 103 84

switch-over


Spannung max. 500 V AC!


03810484.eps and 6.
229203k4.p65/1099
58 038 104 84
Motor for one line voltage, pole-changing, separate windings * = Supply to high speed winding via external
switch-over


Voltage max. 500 V AC!


03810584.eps
Motor supplied with: and 6.

Important: The brake will not function without an external power

supply to terminals 5, 6 and 7 of the GS module.
038 105 84
Motor for one line voltage or dual voltage motor ( 1: 3 )

For inverter operation, connect motor with Y or

03810684.eps

229203k4.p65/1099
Important: The brake will not function without a separate DC supply to the brake.
038 106 84 59
Separate DC supply to brake * = Supply to high speed winding via
external switch-over.

03810784.eps
• Motor winding connected as in connection diagram.
038 107 84

Separate power supply to brake switch-over.

T11,T12, T13 for high speed

current

03810884.eps
• Motor winding connected as in connection diagram (T1 and T11 connected to
one terminal).
229203k4.p65/1099
terminal T1 T11.
60 038 108 84
switch-over


Voltage max. 500 V AC !
03810984.eps
038 109 84

switch-over.


current

03811084.eps
229203k4.p65/1099
of the GS module.
038 110 84 61
switch-over.


03811184.eps

of the GS module.
038 111 84

switch-over.


current

03811284.eps A = Intermediate terminal

229203k4.p65/1099
Important: The brake will not function without a separate power supply to terminals 5, 6 and 7
of the GS module.
62 038 112 84
switch-over


03811384.eps

038 113 84

switch-over

03811484.eps

Motor winding connected as in connection diagram.
229203k4.p65/1099
038 114 84 63
7.8 Connecting temper- Depending on the motor features, the connections for temperature monitoring and/or
brake monitoring are brought out on Euro terminals in the terminal box.
ature and brake moni-
The following connection designations are used:
toring devices
• PTC thermistor
– Switch-off: P1 - P2 and P21 - P22
– Warning: P11 - P12
Important: PTC thermistors to DIN 44081 are suitable for tripping devices with
2.5 V DC output voltage and 4 kW tripping resistance.
PTC thermistors may only be continuity tested with max. 2.5 V DC.
Do not use a buzzer (voltage peaks) or similar devices. The resistance
of one PTC thermistor is 20 ... 250 W at temperatures of –20 °C to
JTNF – 20K. (TNF = rated operating temperature).
• Temperature detector (bimetallic switch): P1 – P2
• Brake monitoring
– Release monitoring: 801 – 802 – 803
Contact 2 (802 – 803) closed:
Brake not released, brake in applied position
Brake released
– Adjustment monitoring: 804 – 805 – 806
Brake must be adjusted
Normal operating condition
The diagrams below show the most important single connections.

When several monitoring devices are used (such as temperature detectors for the
motor and release monitoring for the brake), the individual circuits are combined in
one connection diagram which can be found inside the motor terminal box.
PTC thermistor PTC thermistor PTC thermistor PTC thermistorr
3x 3x 3x 6x
Switch-off Switch-off 1 Warning Switch-off
101 102 101 102 111 112 101 102

P1 P2 P1 P2 P11 P12 P1 P2
3x
Switch-off 2
201 202
P21 P22
03781944.eps 03782044.eps 03782144.eps 03782344.eps
PTC thermistor Brake monitoring Brake monitoring Temperature detector

Release monitoring Adjustment monitoring
6x
Warning
4 2 1 4 2 1
229203k5.p65/1099
wh gn bn wh gn bn
111 112 601 602
801 802 803 804 805 806
P11 P12
P1 P2
03782744.eps 03781644.eps 03781744.eps 03782244.eps
64
8 Technical data
Function conditions for standard design
Conditions Z range
Transport temperature – 20 ... + 40°C ( – 4 to + 104°F)
Storage temperature 0 ... + 40°C ( + 32 to + 104°F)
Storage conditions Dry, indoors
Ambient operating temperature – 20 ... + 40°C ( – 4 to + 104°F)
Environment Acid-free
Coolant Air
Coolant temperature max. + 40°C ( + 104°F)
Temperature rise limit of winding 105 K
Installation site height max. 1000 m ( 3300 ft ) above sea level
Air circuit Ensure by working clearance, unrestricted air intake
Enclosure IP 54
Mounting arrangement Low vibration
Working clearance at fan end 150 mm ( 5.91 in ) at rear
USA: 480 V 60 Hz (two speeds) 240 / 480 V 60 Hz (one speed)

Line voltage
Canada: 575 V 60 Hz (two speeds) 330 / 575 V 60 Hz (one speed)
Voltage tolerance ±10% of the line voltage
Max. speed 3600 rpm

229203k5.p65/1099
65
9 Troubleshooting
Pos. Problem Possible cause Solution
1 Motor does not start. Fuse has tripped. Replace fuse.
Power supply line interrupted Check connections.
Motor protection has tripped. Check motor protection for correct setting.
Control defective. Check motor connection.
Brake does not release. See section 9 "Brake does not release"
2 Motor does not start or USA: Motor for YY connection connected in star Correct motor connection.
starts slowly.
Canada: Motor for ∆ connection connected in star
Extreme voltage or frequency deviation from setpoint value. Improve quality of power supply; check power supply
line cross-section.
3 Motor runs in wrong direction. Motor incorrectly connected. Interchange two supply leads.
4 Motor hums and has high power Winding defective. Motor must be sent to specialist workshop for repair.
consumption.
5 Fuses trip or motor protection trips Short-circuit in the supply line. Eliminate short-circuit.
immediately.
Short-circuit in the motor. Motor must be sent to specialist workshop for repair.
Power supply cable incorrectly connected. Correct connection.
Short-circuit to ground in the motor. Motor must be sent to specialist workshop for repair.
6 Extreme loss of speed under load. Overload. Measure power, use larger motor or reduce load, if
necessary.
Voltage drop. Increase power supply line cross section.
7 Excessive motor Overload. Measure power, use larger motor or reduce load, if
temperature rise necessary.
(measure temperature). Insufficient cooling. Correct cooling air circulation or clear air circulation
channels, fit separate fan, if necessary.
Separate fan not running. Check connection, correct if necessary.
Ambient temperature too high. Reduce power, use larger motor, if necessary
USA: YY connection instead of star connection as specified. Correct connection.
Canada: ∆ connection instead of star connection as specified.

Temporary two-phase operation. Intermittent electrical contact in the power supply
line.
Fuse has tripped. Replace fuse.
Mains voltage differs from the rated motor voltage by more Match motor to power supply voltage.
than 10%. Higher voltages are particularly unfavourable for
low-speed motors as their no-load current is close to the
rated current even at normal voltage.
Duty type exceeded, e.g. starting frequency too high. Adapt operating conditions to corresponding motor
duty type.
8 Excessive noise. Friction bearing distorted, dirty or damaged. Realign motor, inspect friction bearings, replace if
necessary.
Rotating parts vibrating. Correct any imbalance.
Foreign bodies in cooling air circuit. Clean cooling air circuit.
9 Brake does not release Incorrect voltage applied to brake control unit. Apply correct voltage (see rating plate).
Brake control unit failure. Change brake control unit, check brake coil
(resistance), check switchgear.
Max. permissible air gap exceeded because the brake lining Adjust the brake (replace the complete brake lining
is worn out. carrier if the lining is worn out).
Voltage drop in the power supply line > 10 %. Ensure correct supply voltage is applied.
Brake coil short-circuit with the winding or housing. Change complete brake with control unit (specialist
workshop), check switchgear.
10 Motor does not brake. Brake lining worn out.
229203k5.p65/0300
Replace the complete brake lining carrier

Manual brake release device incorrectly adjusted. Set adjusting nuts to correct setting.
Manual brake release device locked. Release lock, remove lever.
Incorrect brake torque. Change brake torque.

66
10 Forms for documenting the installation,
rating plates
Z.. 63 A to Z.. 71 B motors, with/without brake

Installation designation:
42241444.eps
Z.. 80 A bis Z.. 132 C motors, with/without brake

42241544.eps
Z.. 160 A bis Z.. 225 B motors, with/without brake

229203k5.p65/1099
42241644.eps
67
British Columbia Ohio Quebec
19292 60th Ave., Suite 116 29201 Aurora Road 2700 Sabourin
Surrey, British Columbia V3S 8E5 Cleveland, Ohio 44139 Ville St-Laurent, Quebec H4S 1 M2
Telephone: (604) 530-5155 Telephone: (440) 248-2400 Telephone: (514) 336-5556
Telefax: (604) 530-5189 Telefax: (440) 248-3086 Telefax: (514) 336-4349
California Ontario Texas
5435 Industrial Parkway 1155 North Service Road West 16430 Aldine-Westfield Road
San Bernardino, California 92407 Oakville, Ontario L6M 3E3 Houston, Texas 77032
Georgia 584 Falconbridge Road, Unit #3 Washington
3625 Swiftwater Park Drive P.O. Box 2368, Station “A” 16771 N.E.80th Street, Suite 205
Suwanee, Georgia 30174 Sudbury, Ontario P3A 4S8 Redmond, Washington 98052
lllinois Pennsylvania
1800-E Howard Street 2148 Embassy Drive
Elk Grove Village, lllinois 60007 Lancaster. Pa 17603-2385
Telephone: (847) 593-3100 Telephone: (717) 396-9711
Printed in Germany DZS/0300/1T
Telefax: (847) 956-7621 Telefax: (717) 396-9719
Mannesmann Dematic Corp.

29201 Aurora Road
Telephone: (440) 248-2400
Telefax: (440) 248-3086
Internet: http://www.dematic-us.com Improvements will be incorporated without prior notice
Assembly instructions
A 10 - A 90 offset gearbox
41677855.eps
230810 enUS 229 200 49 719 IS 913.70

Original assembly instructions
Manufacturer Demag Cranes and Components GmbH

29201 Aurora Road
Telephone: (440) 248-2400
Fax: (440) 248-3086
Accompanying Also refer to the motor operating instructions for geared motors!
documents i
General documents Part no.:
EN EN FR ES
Brochures
Demag Drives brochure 208 732 44 208 734 44 208 735 44 208 736 44
Demag wheel range brochure 208 722 44 208 724 44 208 725 4 208 726 44
Catalogues / technical Data
Drive Designer Online www.demag-drivedesigner.com

Geared motors catalogue – DE / EN / FR 203 150 44 –
Geared motors catalogue – IT / EN / ES – 203 250 44 – 203 250 44
DRS wheel block system 203 350 44 203 352 44 203 353 44 203 354 44
Demag RAE/RNE wheel sets technical data 203 687 44 203 688 44 203 689 44 203 690 44
Geared travel motors catalogue – Volume 3 – Quick selection and gearbox limit torque – DE / EN / FR 203 013 44 –
Geared travel motors catalogue – Volume 3 – Quick selection and gearbox limit torque – IT / EN / ES – 203 014 44 – 203 014 44
D 11 - D 41 helical gearbox assembly instructions 214 719 44 214 720 44 214 721 44 214 722 44
D 50 - D 90 helical gearbox assembly instructions 214 150 44 214 151 44 214 152 44 214 153 44
W 10 – W 100 angular gearbox assembly instructions 214 057 44 214 058 44 214 059 44 214 060 44
A 10 - A 90 offset gearbox assembly instructions 214 205 44 214 206 44 214 207 44 214 208 44
Motor assembly instructions – Z motor range 214 227 44 214 228 44 214 229 44 214 230 44
KBA - KBF motor assembly instructions 214 317 44 214 318 44 214 319 44 214 320 44
Brake accessories for Z motor range, assembly instructions 214 040 44 214 041 44 214 042 44 214 043 44
Assembly instructions / Plug connection for KB and Z motor ranges 214 021 44 214 022 44 214 023 44 214 024 44
Encoders for Z motors, assembly instructions 214 371 44 214 372 44 214 373 44 214 374 44
DRS 112 – -200 wheel block system assembly instructions 214 275 44 214 276 44 214 277 44 214 278 44
DRS 250 – -500 wheel block system assembly instructions 214 326 44 214 327 44 214 328 44 214 329 44
RAE/RNE wheel set assembly and maintenance instructions 214 132 44 214 133 44 214 134 44 214 135 44
Spare parts lists
A010 222 820 44 222 821 44 222 822 44 222 823 44
A020 222 824 44 222 825 44 222 826 44 222 827 44
A030 222 828 44 222 829 44 222 830 44 222 831 44
A040 222 832 44 222 833 44 222 834 44 222 835 44
A050 222 836 44 222 837 44 222 838 44 222 839 44
A060 222 840 44 222 841 44 222 842 44 222 843 44
A070 222 844 44 222 845 44 222 846 44 222 847 44

22920049_enUS_230810
A080 222 848 44 222 849 44 222 850 44 222 851 44
A090 222 852 44 222 853 44 222 854 44 222 855 44
2
Contents 0
0.1
Foreword
Copyright
4
4
0.3 Liability for defects 4
0.5 Definitions 5
1 Safety 6
1.1 Symbols 6
1.2 Intended use 6
1.3 Prohibited practices, improper use 6
2 General 8
2.1 Storage 8
3 Gearbox product description 9
3.1 Motor – gearbox connection 9
3.2 Gearbox type designation 9
3.3 Gearbox rating plate 10
4 Assembling the drive 11
4.1 Transport 11
4.2 Checking the condition of the motor 11
4.3 Checking the installation site 11
4.4 Installing the offset gearbox 11
4.4.1 Quantity of lubricant dependent on size and
model code/mounting position 13
4.4.2 A10 - A90 model code/mounting position overview 15
4.4.4 Fitting offset gearboxes with hollow shaft, key or splined profile shaft 16
4.4.4 Fitting offset geared motors with hollow shaft, shrink disc connection 18
4.4.6 Torque bracket connection 19
4.4.6.1 D2 torque bracket for AM 10 19
4.4.6.2 D2 torque bracket for for A20 – A90 20
4.5 Assembling, disassembling motor and gearbox 21
4.5.1 Direct drive input A 10 to A 60 21
4.5.2 Direct drive input A 70 to A 90 21
4.5.3 Coupling connection 23
A 10 to A 60 23
4.5.4 Coupling connection 23
A 70 to A 90 23
4.6 Installing the offset geared motor 24
4.7 Direction of rotation of the offset geared motor 24
4.8 Special instructions for installing the offset geared motor 24
5 Commissioning 25
5.1 Requirements 25
5.2 Check when commissioning 25
5.3 Geared motors 25
6 Maintenance and repair 26
6.1 Inspection before starting work and during operation 26
6.2 Maintenance schedule 26
6.3 Gearbox/oil lubrication 27
7 Technical data 29
22920049_enUS_230810
Declaration of incorporation 30
3
0 Foreword
You have purchased a Demag product. This equipment was manufactured in accor-
dance with state-of-the-art engineering principles.
These assembly instructions are designed to provide the operator with useful instruc-
tions for safe and appropriate work on the product and to facilitate maintenance.

maintaining and repairing our geared motors and their additional equipment must
have read and understood
• the assembly instructions
• the safety regulations
gelesen und verstanden haben.
The assembly instructions must be available to the operating personnel at all times in
our products.
0.1 Copyright 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 par-
ties with the prior written consent of Demag.
All documents are protected within the sense of copyright law.

specific prior consent. Infringements are an offence resulting in obligatory compensa-
tory damages.
0.2 After-sales service If you have any questions on our products, please refer to the addesses on the last
page.
0.3 Liability for defects These assembly instructions must be read carefully before assembling and putting
the product into operation.
We assume no liability for any damage and malfunctions resulting from failure to com-
ply with the assembly instructions.
Any liability claims for defects must be made by quoting the order number immedi-
ately on detecting the defect.
• refurbishment or modification of the product unless approved in writing by Demag.
22920049_enUS_230810
4
0.4 Limitations of liability All technical information, data and instructions for operation contained in these as-
sembly 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 further
development of the gearboxes which are the subject of these assembly instructions.
The information, illustrations and descriptions contained in these assembly instruc-
tions are therefore only intended for information purposes.
The descriptions and illustrations contained in these assembly instructions do not
necessarily correspond to the scope of delivery or any subsequent spare part deliv-
ery, either; the drawings and illustrations are not to scale.
We assume no liability for defects, damage and malfunctions caused as a result of
operating errors, non-compliance with these assembly instructions or omitted and/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'
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 void any liability for damages resulting therefrom.
With the exclusion of any further claims, our liability for defects and liability obliga-
tions for any defects pertaining to the products supplied or faults in the documentation
delivered or any negligence on our part are exclusively based on the stipulations of
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.

Owners (employer, company) are defined as persons who own the product and who
use it appropriately or allow it to be operated by suitable persons.
Operating personnel
Operating personnel are defined as persons assigned by the owner of the product to
operate the product.
Specialist personnel are defined as persons assigned by the owner to carry out spe-
cific tasks, such as installation, setting-up, maintenance and fault elimination.
• Qualified personnel
Qualified personnel are defined as persons, who, owing to their technical training,
knowledge and experience as well as knowledge of the relevant standards, are
able to assess the tasks given to them and identify and prevent 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 incor-
rect handling and who have been informed about the required protective devices,
training and experience, have sufficient knowledge of the product and are familiar
22920049_enUS_230810
with the relevant national industrial safety regulations, codes of practice, accident
prevention regulations, directives and generally accepted engineering standards
(e.g. EC Directives, German VDE and BGV regulations) enabling them to judge
the safe operating condition of heared motors.
5
1 Safety
1.1 Symbols The following symbols and instructions warn against possible personal injuries or
damage to property and are intended to assist you in your work.
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 followed.
Pass on safety instructions to all persons entrusted with working on the geared motor
including the power supply.
In addition to the safety instructions, observe all general safety regulations and fac-
tory accident prevention regulations at all times.

Contact with live parts can result in immediate death. Protective covers (e. g. covers
and enclosures) marked with this sign may only be opened by qualified electricians.
Before opening, all relevant operating, control, feed or other voltages must be discon-
nected.
i Operating hazard for the installation

This symbol in the assembly instructions indicates all warnings which, if not complied
with, may result in damage to the geared motor.
1.2 Intended use These gearboxes are intended for all travel, lifting and turning motions in industrial
applications. Compliance with the permitted operating conditions must be ensured for
operation of these drives
(e.g. enclosure type, ambient temperature, installation height).
1.3 Prohibited practices, Under certain conditions, operation of the geared motors is prohibited as this could
improper use result in malfunctions, equipment failure or hazard to life and limb,
e.g. in the case of:
• Acidic, corrosive air as coolant.
• Operation outside the permitted temperature range.
• Operation outside the normal air pressure range. Otherwise, power adjustments
are necessary.
• Operation under conditions of high humidity or splashwater.
• Manipulation of electrical modules.
Safety devices must not be rendered inoperable or modified or used in any way other
than that for which they have been designed.
22920049_enUS_230810
6
1.4 Safety The relevant national accident prevention regulations and the general safety condi-
tions must always be observed when our products are operated in order to avoid ac-
instructions cidents and damage to machinery. If the safety instructions given in these assembly
instructions are not observed in any way, personal injury or even death can result.
Warning against dangerous electrical voltage

Geared motors are connected to a mains power supply. Any contact with live parts
can lead to very serious injury or even death.
Putting offset geared motors Do this only

into operation • if you have read the assembly instructions and the owner has instructed you in all
details.
• if the assembly instructions are available for reference at the place of operation.
• if you are qualified and specialist personnel.
• if you are not under the influence of drugs, alcohol or medication that can
adversely affect your ability to react,
• if the general accident prevention, operating and installation regulations-,
(e.g. DIN-VDE 0100/0113) have been observed.
Additional safety instructions Only carry out maintenance and installation work
• if you are qualified specialist personnel.
• if the motors are at zero voltage.
• if no hazard exists (e.g. crushing hazard, slipping hazard, etc.).
• if the motors are secured against restoration of the power supply.
• if all cables and motor terminals are at zero potential
(establish with a voltmeter),
• with insulated tools.
• using genuine spare parts.
Information on hazards spots Rotating fan wheel

When putting the motors into operation, it must be ensured that the area around the
fan is protected with a cover, in order to exclude injury of limbs (fingers).
Compliance with the required IP type of enclosure acc. to DIN EN 60034-5.
Rotating shaft end

When putting motors into operation there is a hazard on rotating shaft ends which
may draw in or catch e.g clothing or hair. In order to prevent injury caused by being
drawn in or caught, clothing should be closely fitting on the body and long hair be
protected by a cap or hair net.
Heat transfer on the motor enlocsure

During longer operating periods an increased temperature (90°C) can be expected
in the area of the stator housing! Contact with housing parts in this area should be
avoided in any case, in order to exclude burning! See burn threshold values acc. to
EN ISO 13732-1 standard
Abnormal noise
It is recommended to wear ear protection as soon as persons are exposed to noise
during operation in the direct vicinity of the motor for a longer period of time. The
noise limits as required by DIN EN 60034-9 must be complied with.
22920049_enUS_230810
7
2 General
2.1 Storage Gearboxes must be stored as follows:

• in dry places with only minor temperature fluctuations.
• in their service position.
• protected against dust and moisture.
• on a wooden support.
• free from vibration (no impacts).
Gearboxes must not be stacked on top of each other.
Unless agreed otherwise, liability for defects is granted for the standard preservation
in accordance with our terms and conditions of delivery. The period begins on the day
the unit is delivered.
Contact Demag in Wetter, Germany, if the gearboxes are to be stored for more than 6
months before they are put into operation.
i Gearboxes may otherwise be damaged.
22920049_enUS_230810
8
3 Gearbox product description
Demag offset gearboxes offer the optimum solution for space-saving requirements
owing to their compact design. The variety of drive shafts – hollow or solid shaft – and
the possible mounting variants as a hollow-shaft geared motor of torque bracket, foot
or flange-mounted design make it possible to implement cost-effective solutions for
the given drive requirement.
For these reasons, the offset geared motor design is used for travel drive applications
all over the world.
The range includes 9 gearbox sizes. Sizes A10 to A40 feature a dimensionally stable,
vertically split housing of high quality pressure die-cast aluminium. This guarantees
high stability for high performance and low dead weight.
Sizes A50 to A90 feature a grey cast iron housing, which is also split vertically.
Size A10 is of two-stage design, sizes A20 to A90 are two or three-stage
depending on the transmission ratio.
3.1 Motor – gearbox The motor either drives the gearbox via a “direct drive input” or “coupling”
connection connection.
• “Direct drive input” means that the motor is flanged to the gearbox.
• The “coupling” connection means that the motor is bolted to the coupling enclo-
sure of the gearbox and drives the gearbox via a coupling. Couplings are available
in various designs. The various model types are coded by a letter for the drive
input connection in the “Type” line on the gearbox rating plate
(see section 3.2).
3.2 Gearbox type
designation
Type designation Model code
Transmission ratio
Terminal box position
Output shaft code
Model code
A U H 40 D D - B14.0 - 40 - 1 - 22.7
Input type
D Direct drive input
L Light coupling
S Heavy coupling
Number of stages
D two-stage
T three-stage
Sizes
10, 20, 30, 40, 50, 60, 70, 80, 90
Output shaft
V Solid shaft with key K Splined hollow shaft
E Splined solid shaft B Hollow shaft with shrink disk (motor side)
H Hollow shaft with key
Housing design
22920049_enUS_230810
U Universal design M Cast-on torque bracket

G Foot mounting D Bolted-on torque bracket
F Flange design
Gearbox type
A Offset gearbox
9
3.3 Gearbox rating All gearbox features can be found in the form of a model code on the gearbox
plate rating plate.
See the legend for the example below:
1 Demag Cranes & Components GmbH

2 Typ: AUH40 DD Öl = 1,5 l
3 Bauform: B14.0 – 40 – 1 – 22,7
4 Fabr. - Nr: 300 919 45
5 Auftr.Nr.: 604 206 00
6 ASN: 00601
787 095 44 Made in Germany 41677944.eps
1 Manufacturer
2 Type AUH Gearbox designation
40 Size
D Number of stages
D Input type “Direct drive input”
L Input type “Coupling, light”
S Input type “Coupling, heavy”
Oil Lubricant and quantity

3 Model B14.0 Model and mounting position
40 Output shaft code
1 Terminal box position
Transmission ratio
4 Serial number
5 Order number
6 Entry number
Remarks: • The rating plate is attached to the side of the gearbox housing.
• The type and model details are needed for general enquiries on the housing,
mounting position and transmission ratio, etc. For more detailed information on the
drive, e.g. for spare parts, the order, serial and entry number (ASN) are required.
22920049_enUS_230810
10
4 Assembling the drive
4.1 Transport Use the lifting eyes provided for transport purposes.
4.2 Checking the Before installing the motor, check whether it has suffered any damage during trans-
condition of the motor portation or while in storage, such as corrosion, leaks, deformation or
breakage.
i Do not clean drives with compressed air.
4.3 Checking the The standard drive is suitable for operation in normal industrial conditions. If the
installation site ambient temperature, atmosphere or humidity are other than indicated on the rating
plate, the offset gearbox must only be operated with special equipment or features
(see rating plate).
Ambient temperature: from –10 °C to +40 °C
i Installation height: up to 1000 m above sea level
The site at which the offset gearbox is installed must be designed in such a way that
• air may circulate to allow heat to be exchanged,
• no residue from operating processes can accumulate on the offset gearbox, fall
between the drive elements or damage the sealing ring,
• the oil inlet and outlet and rating plate are accessible.
4.4 Installing the Before installing the offset gearbox, check that it will be operated in the mounting
offset gearbox position specified on the rating plate. The quantity of oil depends on the mounting
position.
Gearbox sizes A 10 - A 40
These gearbox sizes are not vented.
If the gearbox has to be vented (breather screw or valve) – non-standard design –
i the plug screw at the highest point of the gearbox must be replaced by the breather
screw or valve.
The mounting position for the breather is shown in section 4.4.2.
For technical reasons, oil mist or drops may occur when a breather valve is fitted.
See below for the tightening torque.
Gearbox sizes A 50 - A 90
A breather valve is supplied as standard. This must be fitted in place of the plug
screw at the highest point of the gearbox.
The mounting position for the breather is shown in section 4.4.2.
For technical reasons, oil mist or drops may occur when a breather valve is fitted.
See below for the tightening torque.
Note: The breather screw or valve is enclosed together with the assembly in-
structions separate from the delivery
Tightening torque – plug screw; breather screw, valve
Size Seal Screw Tightening torque

22920049_enUS_230810
A 10 - A 50 O-ring M10 x 1 5 Nm
A 60 O-ring M12 x 1.5 10 Nm
A 70 - A 90 Copper seal M16 x 1.5 15 Nm
11
The support or flange surface must be designed in such a way that no forces are
transmitted to the gearbox housing as a result of mounting distortions. The following
conditions (table 1 and 2) must be satisfied by the bolted connections to the support-
ing structure to ensure correct functioning of the offset gearbox:
Table 1 Tightening torques for foot connection to the superstructure
Gearbox Washer Tightening

Screw 1) 2)
2) Screw 1) Tightening torque
size torque
DIN 912 or 931 DIN 125 Nm Locking bolt Nm
A 10 – – – –
A 20 – – – – –
AG 30 ( 4x ) M8, grade 8.8 A 8.4 25 ( 4x ) M8 35
AG 40 ( 4x ) M10, Strength 8.8 A 10.5 51 ( 4x ) M10 75
AG 50 ( 4x ) M12, Strength 8.8 A 13 87 ( 4x ) M12 115
AG 80 ( 4x ) M24, Strength 8.8 A 25 740 – –
AG 90 ( 4x ) M30, Strength 8.8 A 31 1500 – –
Table 2 Tightening torques for flange connection to the superstructure

Gearbox Washer Tightening
Screw 1) 2)
2) Screw 1) Tightening torque
size torque
DIN 912 or 931 DIN 125 Nm Locking bolt Nm
A 10 – – – – –
AF 20 ( 4x ) M8, grade 8.8 A 8.4 25 ( 4x ) M8 35
AF 30 ( 4x ) M10, Strength 8.8 A 10.5 51 ( 4x ) M10 75
AF 40 ( 4x ) M12, Strength 8.8 A 13 87 ( 4x ) M12 115
Flanges:
Centre edge tolerance to DIN 42948
- ISO j6 for b1 ≤ 230 mm
- ISO h6 for b1 > 230 mm
The drive shaft must be carefully cleaned to remove the corrosion protection before
i drive elements such as couplings, chain sprockets, gear wheels or belt pulleys are
fitted.
Ensure the cleaning agent used will not damage the sealing ring.
Drive elements may only be fitted or removed with suitable devices, using a centre
bore hole to DIN 332 in the journal shaft, if required. It is advisable to heat the hub to
22920049_enUS_230810
approx. 100 °C.

The drive element must fixed on the shaft in the position specified for the drive ar-
rangement. The manufacturer's recommendations relating to pretension settings and
maintenance must be complied with in the case of chains and wheels.
1) optional
12 2) galvanized, dry
4.4.1 Quantity of lubricant
dependent on size and model
code/mounting position
Table 3 Quantity of oil in litres
Size AU, AD, AG, AF and AM
10 20 30 40 50 60 70 80 90
Transmission ratio i
from... 8.32 6.21 7.78 8.78 8.69 8.91 9.83 78.9 9.89 80.3 10.2 76.2
to ... 52.5 123 156 256 218 297 68.1 267 68.9 281 69.7 274
B14.0
B 6.0
B 7.1
B 5.0 0.35 0.5 0.9 1.5 2.2 4.0 10 12 16 17.5 28 29
M0
D 1.0
41678644.eps
B14.1
B 8.0
B 3.1 0.35 0.5 0.9 1.5 2.2 4.5 8.0 7.0 14 12 24 22
B 5.1
M1
D 1.1
41678744.eps
B14.2
B 7.0
B 6.1
B 5.2 0.35 0.5 0.9 1.5 2.5 5.0 11 10 18 16 30 28
M2
D 1.2
Model code/mounting position
41678844.eps
B14.3
B 3.0
B 8.1 0.35 0.5 0.9 1.5 2.2 4.0 7.5 12 11 17.5 17 28
B 5.3
M3
D 1.3
41678944.eps
V19
V 6.0
V 6.1
V3
M4
D 1.4 0.4 0.6 1.1 2.0 2.5 5.5 13 12 20 19 34 32
41679244.eps
V18
V 5.0
V 5.1
V1
M5
D 1.5
0.4 0.6 1.0 1.9 2.5 5.0 15 15 23 23 37 36
22920049_enUS_230810
41679344.eps
13
Quantities of lubricant in inclined mounting positions
The quantities of lubricant in inclined mounting positions correspond to the
following model codes/mounting positions:
as B14.0
as B14.3 as B14.1
as B14.2
41679744.eps
22920049_enUS_230810
14
4.4.2 A10 - A90 model Gearboxes must be operated according to the model code and the mounting position
code/mounting position specified on the rating plate. This ensures the optimum quantity of lubricant
overview is used.
Breather Oil inlet screw Oil drain screw
Table 4
B14.0 B 6.0 B 7.1 B14.1 B 8.0 B 3.1
B 5.0 M0 D 1.0 B 5.1 M1 D 1.1
A10 – A90 A10 – A90
A10 – A90
A10, A20, A50 – A90 A30, A40
41678655.eps 41678744.eps
B14.2 B 7.0 B 6.1 B14.3 B 3.0 B 8.1

B 5.2 M2 D 1.2 B 5.3 M3 D 1.3
A10 - A20 A30 - A90
A10 – A90
A10 – A90
A10 – A90
41678855.eps 41678944.eps
V19 V 6.0 V 6.1 V18 V 5.0 V 5.1

V3 M4 D 1.4 V1 M5 D 1.5
A10, A20, A50 – A90 A30, A40
A10 – A90
A10 – A90
22920049_enUS_230810
A30 - A40 A10, A20, A50 - A90
41679255.eps 41679355.eps 15
4.4.4 Fitting offset gearboxes with Before fitting the geared motor unit, ensure the machine shaft and the hollow shaft
hollow shaft, key or splined of the gearbox are undamaged and free of burrs and foreign particles. The machine
profile shaft shaft must feature a centre bore hole with a thread to DIN 332 and be slightly lubri-
cated with Demag special assembly grease
(sufficient quantity is supplied with the gearbox).
Fitting the offset gearbox

• Offset gearboxes must only be fitted using the threaded pin and a suitable
thrust washer.
• Refer to the “Fitting dimensions” overview for the dimensions.
• The machine shaft must be guided on both sides in the hollow shaft.
Fitting with threaded pin
Fitting arrangement diagram 1 Machine shaft

2 Gearbox hollow shaft
3 Threaded pin
4 Thrust washer
5 Nut
1 2 3 4 5
M
d
l1 l1
l
The scope of delivery does not include the threaded pin and thrust washer.
41677444.eps
Table 5 Overview: Fitting dimensions
d l l1
Gearbox size M
mm mm mm
A 10 35 M8 90 20
A 20 40 M8 9 20
A 30 50 M12 116 2
A 40 55 M16 133 25
A 50 70 M16 157 30
A 60 90 M20 187 40
A 70 100 M20 240 50
A 80 120 M24 274 50
A 90 140 M24 332 70

22920049_enUS_230810
16
Removing the gearbox
A special extractor can be used to remove the offset gearbox. The extractor engages
the groove which holds the protective cap.
Diagram of extractor 1 Machine shaft

1 2 3 4 5 6 3 Retaining ring
4 2-part outer section
5 Threaded section
6 Spindle
41677544.eps
It may be assumed that splined shaft connections are easier to disconnect than shaft
connections with a key.
22920049_enUS_230810
17
4.4.4 Fitting offset geared motors Hollow shaft with shrink disc connection
with hollow shaft, shrink disc The same procedure applies for fitting the gearbox on the machine shaft as for
connection splined profile shafts and hollow shafts with key.
Fitting and removing the shrink disc connection
1 2 3 4 5 6
Free from grease
Apply
grease
Free
from
grease 1 Machine shaft
2 Tensioning screw
3 Tapped hole for extractor screw
4 Inner ring
5 Outer ring
40239944.eps
General As standard, the shrink disc is fitted to the hollow shaft of the gearbox and only lightly
tightened for transport.
Fitting 1. Before the gearbox is placed on the machine shaft, the inside and the outside of
the hollow shaft must be degreased using a solvent.
2. Release the tension in the shrink disc by unscrewing all tensioning screws a few
turns anticlockwise, and slide the gearbox, together with the shrink disc, onto the
machine shaft and position them.Slide the shrink disc inner ring up to the stop on
the hollow shaft.
3. Tighten all tensioning screws.
It will be necessary to go round the pitch circle several times until all the front faces
of the outer and inner rings are flush. The correct tightness of the HSD shrink disc
can be easily checked at any time, since when correctly fitted, the front faces of
the outer and inner rings must be flush.After having reaching the max. screw tight-
ening torque (see table), the tightening torque should be checked all around again
two times.
Shrink discdesignation Gearbox size Tensioning screwthread Tightening torque[Nm]
HSD 36-22 A20 M8 29

HSD 44-22 A30 M8 29
HSD 50-22 A40 M8 29
HSD 62-22 A50 M8 29
HSD 75-22 A60 M10 58
HSD 90-22 A70 M10 58
HSD 110-22 A80 M10 58
HSD 100-22 A90 M12 100
Disassembly 1. Loosen all tensioning screws by unscrewing them anticlockwise. If necessary, the
22920049_enUS_230810
outer ring can be released from the inner ring by tightening screws in the tapped
holes provided. The tensioning screws can be used for this purpose.
2. Any rust which may have formed on the machine shaft in front of the hollow shaft
must be removed.
3. Remove the gearbox from the machine shaft.
18
Cleaning and lubrication Shrink discs which have been removed do not need to be disassembled and relubri-
cated before they are fitted again.
Shrink discs must only be cleaned and relubricated if they are dirty.
One of the following solid lubricants should be used for the conical surfaces.
Commercial lubricant with high MoS2 content
Molykote 321 R (lubricating varnish) Order no. 972 398 44 Spray
Molykote spray (powder spray) Spray
Molykote G Rapid Spray or paste
4.4.5 Shrink disc cover The following bolt-on sets for covering the shrink disc are available.
42691544.eps
Table 6
Dimensions in mm
Gearboxes Part no.: Tightening torque
b1 b2 d s
A 20 350 203 84 104 37.5 dia. 80 (2 x) M5 x 10 10 Nm
A 30 350 212 84 181 41 dia. 91 (2 x) M8 x 12 10 Nm
A 40 350 209 84 211 50 125 x 125 (4 x) M12 x 20 20 Nm
4.4.6 Torque bracket connection
4.4.6.1 D2 torque bracket for AM 10 The torque bracket is inserted into the opening in the gearbox housing and com-
pressed to retain it in the opening by tightening a nut.
min. 5 mm
M16 compression nut, 14 Nm
M16 retaining nut , 200 Nm

22920049_enUS_230810
Shoulder of shaft
41679444.eps 41679644.eps 41679544.eps
19
4.4.6.2 D2 torque bracket for for A20 – A90
Bore hole template A10 – A90 D2 - gearbox tightening torque

2) A20 = 50 Nm
A10 A20 – A60 A70 – A80 A90 X A30/40 = 100 Nm
A50 = 200 Nm
A60/70 = 300 Nm
A80 = 300 Nm
A90 = 550 Nm
Detail X
Bore hole template centre
Bolt, DIN 933

Gearbox centre
Gearbox centre
Gearbox centre
Gearbox centre
1), 2)
Set nut, quality 8

Washer, DIN 6919
41805945.eps
Table 7
Torque bracket Connecting bolts quality 10.9 Bore hole template

Gearbox
Part no. 3) Size Qty. Tightening torque d H11 f ±0.3 g h1 h2 h4 a± 2) u± 1), 2)
AM 10 785 139 44 M 16 1 200 N 18 – – 0 132 – –
AU 20 811 950 44 2 – 27.5 150 83.5 ±6 22.5 ±6
AU 30 818 645 44 M 12 115 Nm 14 35 182 88 ±7 31 ±7

25 20.5
AU/AD 40 818 649 44 206 91.5 ±4 30 ±4
4 –
AU/AD 50 811 208 44 65 20 255 140 ±6 54.5 ±6
AU/AD 60 787 989 44 309 73 ±12

60 120 ±12
AU/AD 70 787 990 44 M 16 300 Nm 18 100 83 366 68.5 ±12
6
AU/AD 80 787 991 44 440 118 ±12 64.5 ±12
AU 90 787 995 44 8 90 184 40 10 520 159 ±12 93 ±12
1) To flange contact surface 2) Tolerance due to torque bracket slot 3) Check drive shafts fitted into hollow shafts for tight fit.
The paint finish thickness between the torque bracket and connecting surface
i must not exceed 60 μm!
22920049_enUS_230810
20
4.5 Assembling,
disassembling motor
and gearbox
4.5.1 Direct drive input A 10 to A 60
2-stage (D) and 3-stage (T)
42032644.eps
Disassembly
1) Drain the oil (see section 6.3).
2) Undo connecting bolts/nuts (4)
3) Remove motor (3).
4) Remove seal (2) and clean the sealing surface.
Fitting
5) Place seal (2) on gearbox sealing surface. Fit motor (3) to gearbox (1).
Tighten connecting screws/nuts (4).
For tightening torque see table 8.

i 6) Fill with oil (see sections 4.4.1, 4.4.2 and 6.3).
7) Put geared motor into operation and check for leaks.
4.5.2 Direct drive input A 70 to A 90

42042644.eps
Disassembly
1) Drain the oil (see section 6.3).
2) Undo connecting screws/nuts (4)
3) Remove motor (3). Leave centring pins (5) in remaining half.
4) Remove seal (2) and clean the sealing surface.
Fitting
22920049_enUS_230810
5) Place seal (2) on gearbox sealing surface. Fit motor (3) to gearbox (1). Tighten
connecting screws/nuts (4).
For tightening torque see table 8.
i 6) Fill with oil (see sections 4.4.1, 4.4.2 and 6.3).
7) Put geared motor into operation and check for leaks.
21
Table 8
Tightening torque for direct drive input
Bolted connection motor – gearbox housing

Gearbox size Bolt tightening torque
Motor size
Nm
A 10 D Z.. 63 – Z.. 90 A 45
A 20 D Z.. 63 – Z.. 100

45
A 20 T Z.. 63 – Z.. 90A
A 30 D Z.. 63 – Z.. 132

75
A 30 T Z.. 63 – Z.. 90B
A 40 D Z.. 63 – Z.. 132

75
A 40 T Z.. 63 – Z.. 100
A 50 D Z.. 80 – Z.. 180A

120
A 50 T Z.. 80 – Z.. 132A
A 60 D Z.. 80 – Z.. 180 A

120
A 60 T Z.. 80 – Z.. 160 A
Z.. 80 – Z.. 132 51

A 70 D/A 70 T
Z.. 160 75
Z.. 80 – Z.. 132 51

A 80 D/A 80 T
Z.. 160 - Z.. 225 75
Z.. 100 87
A 90 D Z.. 132 120
Z.. 160 - Z.. 225 115
Z.. 100 87
A 90 T Z.. 132 120
Z.. 160 - Z.. 180 115
22920049_enUS_230810
22
4.5.3 Coupling connection 2-stage (D) and 3-stage (T)
A 10 to A 60
1 Gearbox with coupling housing
11 Roller spider
12 Motor
13 Fastening bolt
14 Intermediate flange
15 Screw
42134344.eps
Disassembly
1) Undo connecting bolts (13).
2) Remove motor (12) from gearbox coupling housing (1). The roller spider (11) will
lie loose in the coupling half.
Fitting
3) Place roller spider (11) into the gearbox coupling half (1).
4) Align motor (12) into centre of gearbox coupling housing (1) and fasten it using
the connecting bolts (13).
5) When replacing the motor, undo bolts (15) connecting the gearbox to intermediate
flange (14) and retighten following replacement of the motor.
i For tightening torque see table 9.
4.5.4 Coupling connection

A 70 to A 90
1 Gearbox
8 Coupling housing
11 Roller spider
12 Motor
13 Fastening bolt
14 Intermediate flange
15 Bolt
42040744.eps
Disassembly
1) Undo connecting bolts (13).
2) Remove motor (12) from gearbox coupling housing (8). The roller spider (11) will
lie loose in the coupling half.
Fitting
3) Place roller spider (11) into the gearbox coupling half.
4) Align motor (12) in centre of gearbox coupling housing (8) and fasten it with con-
necting bolts (13).
22920049_enUS_230810
5) When replacing the motor, undo bolts (15) connecting the gearbox to intermediate
flange (14) and retighten following replacement of the motor.
i For tightening torque see table 9.
23
Table 9
Motor size Tightening torque of the bolts in Nm
Gearbox size
Z.. KB. Intermediate gearbox flange Intermediate motor flange
63, 71 71 18
A 10 45
80, 90A 80 35
63, 71 71 18
A 20 45
80, 90A 80, 90 45
63, 71 71 18
A 30 80, 90A 80, 90 75 45
90B, 100 100 75
63, 71 71 18
A 40 80, 90A 80, 90 75 45
90B, 100 100, 112 75
63, 71 71 16
80, 90A 80, 90 35
A 50 75
90B, 100A 100, 112 75
112A, 132 125, 140 115
63, 71 71 16
80, 90A 80, 90 35
A 60 90B, 100 100, 112 115 75
112A, 132 125, 140 115
160, 180A – 300
63, 71 71 16
80, 90A 80, 90 75 35
90B, 100 100 75
A 70
– 112 75
112A, 132 125, 140 115 115
160, 180A 160 300
80, 90A 80, 90 35
75
90B, 100 100 75
– 112 115
A 80
112A, 132 125, 140 300
300
160, 180A 160, 180 300
180B, 200 200 300
– 112 75
112A, 132 125, 140 115
A 90 160, 180A 160, 180 300 300
180B, 200 200 300
225 225 300
4.6 Installing the offset Before installing the offset geared motor, check that it will be operated in the mount-
ing position specified on the rating plate.
geared motor
4.7 Direction of rotation When the three L1, L2 and L3 phases are connected in sequence to the motor termi-
nals U1, V1, W1, the motor will run in the clockwise direction when viewed from the
of the offset output shaft on the gearbox cover side of a 2-stage geabox
geared motor (anti-clockwise rotation with 3-stage gearbox)
(in accordance with DIN EN 60034-8).
The same procedure is used for geared motors with several speeds.
If the motor is operated outdoors in vertical mounting positions V18 / V5.0 / V5.1 /
4.8 Special instructions V1 / M5 / D1.5 or in an inclined mounting position with the shaft facing downwards, it
for installing the offset
22920049_enUS_230810
should be protected by a canopy.

geared motor For motors with condensation water openings which can be closed with a threaded
plug, the drain holes must be arranged at the lowest point of the motor as otherwise
water may enter. If the mounting position of the offset geared motor is changed and
the drain holes are no longer required, the openings must be
24 permanently sealed.
5 Commissioning
5.1 Requirements Before the drive unit is put into service:

• the terminal box be must be closed,
• the fan cover must be fitted (status at the time of delivery),
• the line voltage and frequency specified on the rating plate must match the given
power supply,
• the motor must be checked for correct connection (check direction of rotation),
• heat must be able to dissipate (e.g. air vent slits must be free).
• it must be ensured that the drive unit does not constitute a hazard
(e.g. no hazards caused by rotating or live parts),
• there are no other hazard sources.
5.2 Check when Check that:

commissioning • the motor runs correctly (e.g. no speed fluctuations or excessive noise
development),
• no oil escapes from the unit,
• there is no extreme vibration.
5.3 Geared motors Also refer to the motor operating instructions for geared motors!
i
22920049_enUS_230810
25
6 Maintenance and repair
6.1 Inspection before start- If defects or damage are detected, the geared motor must not be put into op-
eration or it must be taken out of service! It may only be put back into service
ing work and when the defect has been eliminated.
during operation
Check the gearbox for: Inspection Measure

• External damage → Inform person responsible
• Oil leaks → Inform person responsible
• Unusual running noises → Inform person responsible
• Dirt accumulation → Remove dirt accumulation
Check the motor for: • External damage → Inform person responsible
• Unusual running noises → Inform person responsible
• Dirt accumulation → Remove dirt accumulation
Maintenance schedule
Interval Component Maintenance work Seesection
In accordance with the operating conditions, at least

Brake Check brake of motors fitted with brake.
every 3000 hours of operation.
In accordance with the operating conditions, at least Check roller spider or elastic transmission element for play, defor- 3.1 or 4.5.3
Coupling
every 3000 hours of operation. mation or initial wear. and 4.5.4
Every 3000 hours of operation. Torque bracket Check for play in direction in which force is applied.
Every 10000 hours of operation. Motor Inspect the motor and clean the cooling air channels.
Oil change intervals: Check the oil every 3000

operating hours or at least every 6 months
Change oil
Mineral lubricants (oils, greases): every 10000 (under unusual operating conditions, as e.g. increased ambient
Gearboxes 6.3
operating hours or after 4 years temperatures or extreme temperature fluctuations, the oil must be
changed sooner).
Synthetic lubricants (oils, greases):every 15000

operating hours or after 6 years
22920049_enUS_230810
26
6.3 Gearbox/oil Gearboxes are filled with lubricant before leaving the factory. The quantity of oil de-
pends on the model and mounting position of the geared motor unit. The quantity of
lubrication oil is indicated on the rating plate. Standard lubricant is used unless specified other-
wise.
Oil quality A mineral oil to DIN 51 502, CLP 220 is used as standard, e.g.
ISO, Ambient Castrol Castrol

DIN (ISO) temperatureS ARAL BP Castrol Klüber Mobil Esso Shell Fuchs
NLGI Flb Optimol Tribol
A10-A90
D11-D90
Castrol
Standard BP Shell
Aral Alpha Optimol Tribol Esso Fuchs
Mineral Öl VG -10ºC ··· Energol Klüberoil Mobil Gear Omala
Degol BG SP 220 Optigear 1100 / Spartan Renolin
/ Oil / Huile 220 +50ºC GR-XP GEM 1-220 630 S2 G
220 MW 220 BM 220 220 EP 220 CLP 220
W60 - W100 CLP (CC) 220
MAX 220
220
FG06-FG10
Shell
Standard BP Fuchs
W10-W50 Spirax
Hypoid Öl / SAE -10ºC ··· Energear Castrol Titan
S3 AD
Oil / HuileAPI 90 +50ºC Hypo EPX 90 GearLS
80W-
GL5 SAE 90 SAE 90
90
VG -30ºC ··· Klübersynth

68 +20ºC 1) GH 6-68
A10- Sonder / BP Shell
A90D11- Aral Castrol Optimol Mobil Esso
special VG -20ºC ··· Enersyn Tribol 800 Klübersynth Omala
Degol GS Alphasyn Optiflex A Glygoyle Glycolube
D90W10- Synthet.-Öl 220 +60ºC SG-XP / 220 GH 6-220 S4 WE
220 PG 220 220 HE 220 220
W100FG06- / Oil / Huile 220 220
FG10 CLP PG Shell
VG -20ºC ··· Klübersynth Omala
680 +80ºC GH 6-680 S4 WE
680
42708344.xls
Information for back-orders W10 - W50 A10 - A90, D11 - D90, W60 - W100
Quantity
Part no.: Part no.:
1l container – 472 902 44
2.5l container – 472 900 44
Demag special assembly

Quantity Shaft type Gearboxes
grease25g tube
1tube Key A gearboxes
1 tube 665 015 44 A10 - A60
2 tubes – Involute spline A70 - A80
3 tubes A90
22920049_enUS_230810
Please refer to our technical department in the following cases:

• if the ambient operating temperature exceeds the given values,
• if the lubricant has to meet special requirements, e.g. foodstuffs sector, drinking
water protection, biologically degradable, silicone-free, etc.
• application under arduous ambient conditions.
27
Checking the oil level A visual check of the oil level is only possible, if the gearbox has been orderd with an
oil-level sight glass.
Oil change intervals Under normal operating conditions, replace the lubricant after 10000 hours of service,
however, at least every 4 years.
Under unusual operating conditions, as e.g. increased ambient temperatures or ex-
treme temperature fluctuations, the oil must be changed sooner.
Checking condition of oil The oil should only be checked when the gearbox is at operating temperature imme-
diately after switching off to ensure optimum distribution of the oil.
The position of the oil inlet and outlet screw is described in section 4.4.2.
The oil inlet screw is located at the highest point, the oil outlet screw at the lowest
point of the gearbox (observe model code/mounting position!).
Risk of burning from hot gearbox oil.
• Take an oil sample at the oil outlet screw (screw to DIN 908).
• Check the oil (colour, consistency, metal abrasion).
• Change the oil if it is not clean.
• Dispose of drained oil in an environment-friendly manner.
Oil change sequence Only change the oil when the gearbox is at operating temperature to ensure all the oil
is fully drained (cold oil flows poorly).
Risk of burning from hot gearbox oil.
• Place a container below the oil drain screw.
• Remove the oil drain screw and an oil inlet screw.
• Drain all the oil.
Flush as necessary if the old oil is very dirty (see Flushing).
Fill in new oil at oil inlet (oil quantity as specified on the rating plate).
Tightening torque – plug screw; breather screw, valve
Size Seal Screw Tightening torque
A 10 - A 50 O-ring M10 x 1 5 Nm
A 60 O-ring M12 x 1.5 10 Nm
A 70 - A 90 Copper seal M16 x 1.5 15 Nm
Flushing If the old oil is particularly contaminated when it is replaced, it is advisable to flush the
gearbox before filling it with new oil.
The flushing oil should have a viscosity of 46 – 68 mm²/s at 40 °C. The quantity of
flushing oil should be approx. twice that specified for lubrication. Run the gearbox for
22920049_enUS_230810
a few minutes at no load and then drain the flushing oil. By flushing several times,
also with the gearbox running at no load and preferably in alternate directions of rota-
tion, the rest of the old lubricant can be flushed out and drained.
Note Dispose of drained oil in an environment-friendly manner.
28
7 Technical data
Gearbox Operating conditions for standard design
Transport temperature -20...+40°C
Storage temperature 0...+40°C
Storage conditions dry rooms
Ambient operating temperature -10...+50°C
Ambient conditions low dust level, acid-free
Coolant fresh air
Coolant temperature max. +40°C
Site altitude up to 1.000 m above sea level
Air flow free-flowing
Type of enclosure IP 55
Structure low-vibration
Mounting distance ensure cooling
Max. input speed 3600 rpm
Lubricant see rating plate

22920049_enUS_230810
29
0110 1/ 1
Hereby we,

declare that the products:
Demag A offset gearbox

Demag D helical gearbox
Demag W angular gearbox
Demag FG microspeed unit
as series products are intended to be incorporated into machinery and that they must not be put
into service until the machinery into which these products are to be incorporated has been declared
in conformity with all relevant provisions of
delivery, are met by application ofthe following harmonised standards:
EN 12100 Safety of machinery
The special technical documentation based on Annex VII Part B of Directive 2006/42/EC has been
compiled and will be made availableto authorised national authorities by the designated authorised
representative in response to a justified request.
Wetter, 04.04.2013
ppa. Dr. Rainer Harkort ppa. Dirk Schulte

Head of Plant Wetter Handling Technology & Drives
Material Handling
U04282
22920049_enUS_230810
Notes
31
The current addresses of the sales offices in Germany and the subsidiaries and agencies
worldwide can be found on the Demag Cranes & Components homepage at
Demag Cranes and Components GmbH

29201 Aurora Road
Printed in Germany
Telephone: (440) 248-2400

Fax: (440) 248-3086
DFW-L-E and DFW-L-Z endtrucks with DRS
0599 US/EN 229 255 49 720 IS 845.1

1
Manufacturer Mannesmann Dematic Corp.
29201 Aurora Road, Solon, Ohio 44139
Telephone (440) 248-2400, Fax (440) 248-3086
Internet http://www.dematic-us.com
Please fill in the following table before first putting into service
This provides you with definitive documentation of your endtruck and important infor-
mation if you ever have to contact the manufacturer or his representative.
Owner
Where in use
Travel wheel diameter
Wheel base (ekt)
Part number (if existing)
Gearbox designation (i.e. AME 20 D)
Motor designation (i.e. ZBF 90 B 8/2)
Travelling speed
Operating voltage
Mains frequency
Further documents EC Manufacturer‘s declaration DFW-L-E 237 490 44

EC Manufacturer‘s declaration DFW-L-Z 237 491 44
DFW-L-E endtruck 229 254 49 714 IS 845.1
DFW-L-Z endtruck 229 256 49 714 IS 845.1
DRS wheel block system 203 350 44 714 IS 845
Component parts lists

DFW-L-E endtrucks 229 248 49 721 IS 845.1
DFW-L-Z endtrucks 229 258 49 721 IS 845.1
DRS 112 wheel block 229 204 49 721 IS 845.5

A..10 gearboxes 229 210 49 721 IS 983.1

A..20 gearboxes 229 211 49 721 IS 983.1
A..30 gearboxes 229 212 49 721 IS 983.1
A..40 gearboxes 229 213 49 721 IS 983.1
A..50 gearboxes 229 214 49 721 IS 983.1
Z.. motors size 63 229 240 49 721 IS 919

Z.. motors size 71 229 241 49 721 IS 919
Z.. motors size 80 229 242 49 721 IS 919
Z.. motors size 90 229 243 49 721 IS 919
Z.. motors size 100 229 245 49 721 IS 919
Z.. motors size 112 229 246 49 721 IS 919
Z.. motors size 132 229 247 49 721 IS 919
DRS wheel block 214 276 44 720 IS 845.5
(A. and Z..) offset gearmotors 229 200 49 720 IS 983
2
You have purchased a Mannesmann Dematic product. This equipment was manu-
Foreword factured in accordance withstate-of-the-art engineering principles.
Every person given the task of transporting, installing, commissioning, operating, main-
taining and repairing our products and additional equipment must have read and under-
stood
• the safety instructions in the individual chapters and sections.
The operating instructions must be abailable to the operating personnel at all times in
order to prevent operating errors and to ensure smoot and trouble-free operation of our
products.
For safety information on this product, see 206 751 44; 720 IS 100
206 752 44; 720 IS 100
206 753 44; 720 IS 100
The following symbols and recommendations indicate potential safety hazards or

Safety instructions causes of damage, or provide useful information.
Symbols
Hazard warning
safety at work wherever a potential hazard to life and limb exists.
Pass on safety instructions to all persons entrusted with working on the crane, the
runway and the power supply system.
In addition to the safety instructions, observe all general safety regulations at all
times.

plied with, may result in damage to the crane or the load.
3
Description
Demag endtrucks are designed according to state-of-the-art dynamically loaded com-

ponents. They are the result of systematic development and up-to-date design. All
design and production processes as well as the components are subject to permanent
comprehensive quality assurance in accordance with DIN ISO 9001.
Operation Inside a building, outdoor operation.
Supporting structure The steel structure is designed and built according to DIN 15018, lifting class H2, stress
group B3 (other classes on request). The endtruck girder is of box-girder de-sign and
resists bending and torsional stresses. It is connected to a crane girder by means of
high-tensile bolts.
Travel drives The practically maintenance-free flange-guided individual drive units directly drive the
endtruck. The special Demag winding of the motor ensures smooth starting of the
endtruck.
Electrical key data Operating voltage: 230V, 460V, 575V; control voltage: 42V, 48V, 110V, 230V;
frequency: 60Hz; type of enclosure: IP54.
Corrosion protection As standard, the steel structure parts are provided for corrosion protection with a syn-
thetic resin coating (layer thickness 60 µm; color: RAL 1004/golden yellow) after tho-
rough pre-treatment (purity class Sa 2 to DIN 55928), the same applies to the travel
drives (RAL 5009/azure blue).
Accident prevention The relevant accident prevention regulations and the codes of practice have to be com-
plied with for operation and maintenance of Demag endtrucks.
In addition, the following items have to be ensured:

• Unlock any locking devices, if fitted, before starting operation.
• In the event of a hazard, switch off the mains connection switch.
• Safety equipment does not relieve the operating personnel from the need to be
cautious. The endtruck (crane) has to be operated as if the safety equipment
were not fitted.
• The endtruck (crane) must not be used for tearing free, pulling, dragging or
pulling loads at an angle.
• At the end of operation, the endtruck (crane) must be moved to the required
standstill position. Any locking devices (if required) must be applied and the
endtruck must be switched off.
In accordance with the relevant accident prevention regulations, a maintenance ac-
cess arrangement (stationary or mobile) must be provided for maintenance and repair
of endtrucks (cranes).
Maintenance work must only be carried out on unloaded endtrucks. and when the
mains connection switch has been switched off and secured and locked against un-
authorized switching on. The mains connection switch of our endtrucks provides the
possibility of fitting several padlocks so that any person working on the endtruck (crane)
can secure the switch with his own padlock.
Any stipulated inspection and maintenance work required for accident prevention pur-
poses and safe operation of the endtruck must not be delayed or omitted.
Regardless of any other operating instructions for individual sub-assemblies (drives,
motors, etc.), the inspection intervals of the maintenance schedule apply to all parts of
the endtruck. They are valid for normal endtruck operating conditions. For more
arduous operation, the maintenance intervals have to be shortened as required.
4
Weather influence and dirt accumulation
Our endtrucks are intended for use in the following operating conditions:
• ± 0 °C to +40 °C (32 °F to 104 °F)
• Air humidity up to 80%
• Installation height up to 1000 m (3300 ft) above sea level
Other operating conditions are possible after clarification of the measures required to
be taken.
General Travelling operation must be stopped if safe operation (controlled handling of the
endtruck) can no longer be guaranteed due to adverse weather conditions.
First deposit loads safely.
During tuhnderstorms it is forbidden to walk on crane runway(s) and crane(s). It is also

forbidden to leave the cab, if any.
Cranes sometimes operating outdoors For endtrucks that operate mostly indoors and only some of the time outdoors a wind
portection device is not necessary.
When a storm or strong winds are approaching, the operator must move the endtruck
into shelter in the building in good time.
Cranes operating outdoors Endtrucks operating all or most of the time outdoors are equipped with wind protec-
tion devices.
The wind protection device(s) must be engaged on finishing work, during longer inter-
ruptions to work or when a storm or strong winds are approaching.
We suggest that cranes for outdoor usage should be kept under shelter when not in
operation.
Influence of weather and dirt on run- For safety reasons, all runways must be kept clear of oil, grease and/or dirt, since such
ways contamination impairs the start-up and braking of cranes and endtrucks.
Influence of winter weather on runways For the same reason all runways must also, if necessary, be freed of ice and snow be-
fore starting operation.
Check the function of current collectors and the power supply before starting up and, if
necessary, de-ice them in a disconnected state.
Viscous oil may impair or prevent crane or endtruck start-up.
De-ice frozen brakes on travelling gears before starting work or, if necessary, after long
downtimes and apply the brakes “warm.“
Precautionary measures to ensure safe crane operation are the responsibility of the
owner.
5
Technical data
Overview Demag DFW endtrucks are compact, driven, rail-mounted endtrucks for direct connec-
tion to load-bearing structures.
The endtruck design is based on the latest principles for box structures and, even with
high loads, has excellent travelling characteristics due to the fine tolerances of the
endtruck regarding track gauge errors, diagonal position and misalignment.
The endtruck includes a Demag DRS wheel block for fitting the gearbox and the motor
as well as the non-driven DRS wheel block.
Specially adapted heavy-duty motors provide excellent speed/torque characteristics,
which ensure smooth starting for both the unloaded and the loaded endtruck.
Connection of main girder/endtruck Only a crane of perfect geometrical alignment can perform with smooth travel char-
acteristics. Therefore care has to be excercised when endtrucks are fitted to the crane
girders, in order to maintain the accuracy adhered to during manufacturing.
Endtruck with one crane girder connection on the side (standard)

Weld (tack) distance washers into the bore recesses of the main girder
mounting plate always from underneath
Endtruck Crane girder
Mounting plate
Plug
Recesses
214 361 01.eps
HV mark
Bevel under bolt Bevel on nut

head side
1 3 4 3 2
214 361 02.eps
The recesses on the endtruck and the distance washers on the mounting surfaces of
the connecting sleeves and the bore holes in the girder mounting plates must be free
from rust, dust, grease, paint and other contaminants.
Bolted connection variant:

• Remove plugs from the access holes.
• Weld (tack) distance washers into the bore recesses of the main girder
moun ting plate always from underneath.
• Connect endtruck and main girder as shown in the above illustration (bolt
heads inside endtruck).
Use exclusively the following parts which are supplied with the endtruck:
1 Hexagon head screw M20 x 85 x 46 DIN 6914 property class 10.9 HV
2 Hexagon nut M20 DIN 6915 property class 10 HV
3 Hardened washers 21 x 37 x 8 DIN 6916 property class C45 V HV
4 Distance washers 22 x 50 x 10 tensile strength 520 N/mm2
• Tighten diagonal pairs of screws with torque wrench.
Tightening torque: 554 Nm (409 lb ft)
• Close access holes with fitting plugs.
• For operation outdoors, seal the gap between the endtruck and the mounting
plate on the top and on the side with silicone.
6
Jacking up the endtruck
Adjoining plate
Diaphragm
plate
203 (8.0 in) for travel wheel 112


214 361 03.eps
Jacking-up the endtruck is necessary for certain fitting operations so that the load is
removed from the travel wheels (wheel block).
For this purpose, a winch or similar hoisting unit is applied below the diaphragm plate of
the endtruck girder and the endtruck is lifted.
Lifting the endtruck so that the wheel just clears the crane rail is sufficient.
The rased endtruck should be held in position by placing spacers between rail and
endtruck underside at points where the endtruck is strengthened with diaphragm plates
to prevent it from being damaged.
7
Technical description
Demag DRS wheel block system The travel unit consists of a DRS wheel block on the non-drive side and a DRS wheel
block with drive kit (torque arm set, gearbox and motor) on the driven side.
Together with the torque arm set, the gearbox connection provides different mount-ing
positions relative to the wheel block. The drive shaft transmits the torque directly into
the splined travel wheel hub with virtually no play via a splined journal shaft.
Drive kit:
- Motor
- Gearbox
- Torque arm set
Endtruck
Safety washer
End plate
Retaining ring
Support washer Spacer elements Bumper

DRS Wheel block
214 361 04.eps
Pin
Removing the • Jack up the endtruck girder (see page 7).

Demag DRS wheel block system • Loosen bolted connection on torque arm set (optional, only on drive side) and
pull off gearbox.
• Unscrew bumper and end plate.
• Remove retaining rings, support washers and any shims
• Remove spacer elements (mark left and right side).
• Pull out pins
• Roll wheel block out of endtruck.
Fitting the • Slide wheel block into endtruck.

Demag DRS wheel block system • Insert pins
• Fill gap between endtruck and wheel block with spacer elements (note marks).
• Slide on support washers, retaining rings and any shims (see fig. 214 361
06.eps).
• Fit bumper and end plate.
• Clean drive shaft and grease shaft splining with grease DG 69
(part no. 472 915 44) before fitting gearmotor.
• Slide in gearmotor with torque bracket.
• Bolt torque arm set together with endtruck and tighten with the following
tightening torques:
MA112-1 to MA125-2 screw M8 Ma=35 Nm (26 lb ft)
MA160-1 to MA200-1 screw M10 Ma=65 Nm (48 lb ft)
8
Spacer elements
Support washer
(compensate
play with shims)
Pin
Retaining ring
214 361 06.eps
Adjusting the span By re-arranging the spacer elements, the span can be adjusted. The standard as-sign-
Demag DRS wheel block system ment and the max. adjustment possibilities are specified in the following table.
Measurements in mm (in)
DFW
b4 b Max. adjustment
112 70 (2.76) 10 (0.39) ± 6 (0.24)
125 70 (2.76) 6 (0.24) ± 4 (0.16)
160 85 (3.35) 15 (0.59) ± 6 (0.24)
200 95 (3.74) 15 (0.59) ± 10 (0.39)
250 105 (4.14) 10 (0.39) ± 6 (0.24)
315 125 (4.93) 15 (0.59) ± 10 (0.39)
400 140 (5.52) 15 (0.59) ± 10 (0.39)
Fill gap with

spacer elements
b
Spacer elements Spacer elements
b4
214 361 05.eps

9
Maintenance
Routine inspections In accordance with the accident prevention regulations for cranes and the principles of
the inspections by experienced technicians (ZH 1/27).
Component Type of inspection Inspection item Inspection interval
Months
3 6 12
Limit stops Visual inspection - damage

x
- tight fit
Limit switches Function check - cut-off

x
- run-on path
Main girder/endtruck Check tightening - tightening torques/

bolted connections torques; check property classes,
property class for data see adhesive
x
spec. plate near bolted
connection
Connections/attach- Check tightening - Works standard,

ments torques Standard tightening
x
torques
Ident. no. 011 938 99
Endtrucks Visual inspection - for maintenance

Function instructions with
Travel wheel flange wear inspection intervals and
x
repairs, see operating
instructions of
components
Travel wheels Demag DFW endtrucks provide the possibility of adjusting the travel wheels or the DRS
wheel blocks in the axial direction, i.e. for adjusting the span (see Adjusting the span).
The travel wheel flange wear mark indicates sufficiently in advance when the travel
wheel must be replaced. In conjunction with the next scheduled inspection, preventive
measures can therefore be taken to ensure the availability of the installation..
Travel wheel flange wear

mark
214 361 07.eps
Wheel blocks The DRS wheel blocks are maintenance-free, due to their technical design.
For further information, see DRS wheel block system documents (see page 2).
10
Disposal Waste materials resulting from assembly, installation, maintenance, repair and
disassembly work must be disposed of appropriately and in accordance with the
relevant laws, regulations and codes of practice.
In addition to relevant local statutory and other regulations and guiedlines, the follow-
ing must be observed:
• Never pour harmful waste fluids such as oil, grease and poisonous chemical
substances into the waste system nor allow them to disperse into the ground.
• Always pour waste oil and grease into the appropriate containers
• Always put spent batteries, scrap appliances such as electronic components
and plastic materials in the appropriate containers.
11
British Columbia North Carolina
19292 60th Ave., Suite 116 • Surrey, British Columbia V3S 8E5 14001 South Lakes Drive • Charlotte, NC 28273
California Ohio
5435 Industrial Parkway • San Bernardino, California 92407 29201 Aurora Road • Cleveland, Ohio 44139
Connecticut Ontario
99 Rainbow Road, Suite C • East Granby, CT 06026 1155 North Service Road West • Oakville, Ontario L6M 3E3
Georgia Pennsylvania
3625 Swiftwater Park Drive • Suwanee, Georgia 30174 2148 Embassy Drive • Lancaster, Pennsylvania 17603
Illinois Quebec
12040 Raymond Court • Huntley, Illinois 60142 2700 Sabourin • St-Laurent, Quebec H4S 1M2
Michigan Texas
24541 Maplehurst Drive • Clinton Township, Michigan 48036 16430 Aldine-Westfield Road • Houston, Texas 77032
500 Plymouth Ave. N.E. • Grand Rapids, Michigan 49505-6098 8600 W. Royal Lane • Suite 100 B • Irving, Texas 75063
Missouri Washington
529 E. 5th Street • Washington, Missouri 63090 16771 N.E. 80th Street, Suite 205 • Redmond, Washington 98052
Mannesmann Dematic Corporation

29201 Aurora Road
Telephone: (440) 248-2400
Telefax: (440) 248-3086
Internet: http://www.dematic-us.com
Application guidelines/operating instructions
Dedrive Compact frequency inverters (2 to 110 A)
Valid for software version 4.2.4/050-7 and DIC-4-xxx-E-0000-01 hardware
43205844_xml.eps
200710 en GB 214 716 44 720 IS 922

Manufacturer

Drives
P.O. Box 67
D -58286 Wetter
Phone: +49 (0) 2335 92-0
Telefax +49 (0) 2335 92-7298
www.drives.demagcranes.com
E-mail: drives@demagcranes.com
Accompanying documents
Order no.
General documents
DE EN FR ES
Demag Dedrive Compact 214 707 44 214 708 44 214 709 44 214 710 44
frequency inverter quick-
step operating instructions
(0,75 to 55 kW)
Application guidelines/op‐ 214 715 44 214 716 44 214 717 44 214 718 44
erating instructions Demag
Dedrive Compact frequen‐
cy inverters (0,75 to 55 kW)
CM – PDP (Profibus-DP) 214 769 44 214 770 44 214 771 44 214 772 44
communication module op‐
erating instructions
CM – CAN (CANopen) 214 773 44 214 774 44 214 775 44 214 776 44
communication module op‐
EM – UNI - 01 extension 211 124 44 211 125 44 211 126 44 211 127 44
module operating instruc‐
tions
Operating instructions for Z 214 227 44 214 228 44 214 229 44 214 230 44
motor range
Encoders for Z motors op‐ 214 371 44 214 372 44 214 373 44 214 374 44
CD
„Product documentation 213 136 44
Dedrive Compact“ CD-
ROM including application
guidelines/operating in‐
structions and operating in‐
structions for option mod‐
ules
Tab. 1
214 716 44/200710
2
Table of contents
0 Foreword ................................................................................................................................................................... 12
0.1 General...................................................................................................................................................................... 12
0.2 Copyright ................................................................................................................................................................... 12
0.3 Customer service ...................................................................................................................................................... 12
0.4 Liability for defects..................................................................................................................................................... 12
0.5 Limitations of liability ................................................................................................................................................. 13
0.6 Definitions.................................................................................................................................................................. 13
1 Safety ........................................................................................................................................................................ 14
1.1 Symbols/signal words................................................................................................................................................ 14
1.2 Intended use.............................................................................................................................................................. 14
1.3 Prohibited practises, improper use ............................................................................................................................ 15
1.5 Transportation and storage ....................................................................................................................................... 16
1.6 Handling and installing .............................................................................................................................................. 16
1.8 Operation................................................................................................................................................................... 17
1.9 Maintenance .............................................................................................................................................................. 17
2 Scope of delivery ....................................................................................................................................................... 18
2.1 General...................................................................................................................................................................... 18
2.2 DIC-4-002 to 009 frequency inverters ....................................................................................................................... 18
2.3 DIC-4-014 to 040 frequency inverters ...................................................................................................................... 19
2.4 DIC-4-045 to 110 frequency inverters ...................................................................................................................... 20
3 Technical data ........................................................................................................................................................... 21
3.4 Operating diagrams ................................................................................................................................................... 23
3.4.1 General...................................................................................................................................................................... 23
3.4.2 Site altitude................................................................................................................................................................ 24
3.4.3 Coolant temperature.................................................................................................................................................. 25
3.4.4 Line voltage ............................................................................................................................................................... 25
4 Mechanical installation .............................................................................................................................................. 26
4.1 General...................................................................................................................................................................... 26
4.5 Fitting CM-xxx and EM-xxx hardware modules ......................................................................................................... 32
4.5.1 General fitting instructions ......................................................................................................................................... 32
4.5.2 Instructions for fitting the EM extension module........................................................................................................ 32
4.5.3 Instructions for fitting the CM communication module............................................................................................... 32
5 Electrical installation .................................................................................................................................................. 34
5.1 General...................................................................................................................................................................... 34
5.2 EMC notes................................................................................................................................................................. 35
214 716 44/200710
5.3 Block diagram............................................................................................................................................................ 36

5.4 Line connection ......................................................................................................................................................... 37
5.4.1 General...................................................................................................................................................................... 37
5.4.2 DIC-4-002 to 009 frequency inverters ....................................................................................................................... 38
3
5.4.3 DIC4-014 to 040 frequency inverters ........................................................................................................................ 39
5.5 Motor connection ....................................................................................................................................................... 42
5.5.1 General...................................................................................................................................................................... 42
5.6 Control terminals ....................................................................................................................................................... 47
5.6.1 General...................................................................................................................................................................... 47
5.6.2 Relay output S3OUT ................................................................................................................................................. 48
5.6.3 Control terminals – connection diagram .................................................................................................................... 48
5.6.4 Configurations 1xx and 4xx - without encoder .......................................................................................................... 49
5.6.5 Configurations 2xx – with encoder ............................................................................................................................ 49
5.7 Hardware modules .................................................................................................................................................... 50
5.7.1 General...................................................................................................................................................................... 50
6 KP500 operating unit................................................................................................................................................. 51
6.1 Key assignment and displays .................................................................................................................................... 51
6.2 Menu structure .......................................................................................................................................................... 52
6.3 Main menu................................................................................................................................................................. 52
6.4 Actual value menu (VAL)........................................................................................................................................... 53
6.5 Parameter menu (PARA) .......................................................................................................................................... 54
6.6 Copy menu (CPY) ..................................................................................................................................................... 55
6.6.1 General...................................................................................................................................................................... 55
6.6.2 Reading the memory infomation ............................................................................................................................... 55
6.6.3 Menu structure .......................................................................................................................................................... 56
6.6.4 Selecting the source .................................................................................................................................................. 56
6.6.5 Selecting the destination ........................................................................................................................................... 57
6.6.6 Copy operation .......................................................................................................................................................... 57
6.6.7 Error messages ......................................................................................................................................................... 58
6.7 Control menu (CTRL) ................................................................................................................................................ 58
6.8 Controlling the motor via the operating unit............................................................................................................... 59
7 Putting into operation in practice ............................................................................................................................... 61
7.1 General...................................................................................................................................................................... 61
7.2 Switching on the power supply .................................................................................................................................. 61
7.3 Set-up by means of the operating unit ...................................................................................................................... 61
7.3.1 General notes on set-up ............................................................................................................................................ 61
7.3.2 Configuration ............................................................................................................................................................. 62
7.3.3 Data set ..................................................................................................................................................................... 63
7.3.4 Motor data ................................................................................................................................................................. 63
7.3.5 Rotary encoder data .................................................................................................................................................. 64
7.3.6 Plausibility check ....................................................................................................................................................... 64
7.3.7 Parameter identification............................................................................................................................................. 65
7.3.8 Reference values ...................................................................................................................................................... 67
7.4 Checking the direction of rotation .............................................................................................................................. 68
7.5 Set-up by means of the communication interface ..................................................................................................... 68
214 716 44/200710
8 Programming parameters with the Parcom Compact software................................................................................. 70

8.1 General...................................................................................................................................................................... 70
8.2 Window layout ........................................................................................................................................................... 70
4
9 Inverter data .............................................................................................................................................................. 71
9.1 General...................................................................................................................................................................... 71
9.2 Serial number ............................................................................................................................................................ 71
9.3 Optional modules ...................................................................................................................................................... 71
9.4 Inverter software version ........................................................................................................................................... 71
9.5 Set password............................................................................................................................................................. 71
9.6 Control level .............................................................................................................................................................. 71
9.7 User name ................................................................................................................................................................. 72
9.8 Configuration ............................................................................................................................................................. 72
9.8.1 General...................................................................................................................................................................... 72
9.8.2 Configuration 110 – V/f without encoder ................................................................................................................... 72
9.8.3 Configuration 111 – V/f with technology controller .................................................................................................... 72
9.8.4 Configuration 210 – FOR speed control with encoder............................................................................................... 72
9.8.5 Configuration 230 – FOR N or M controlled .............................................................................................................. 72
9.8.6 Configuration 410 – FOR speed control without encoder.......................................................................................... 72
9.8.7 Configuration 430 – FOR N or M controlled without encoder .................................................................................... 73
9.9 Language .................................................................................................................................................................. 73
9.10 Programming ............................................................................................................................................................. 73
10 Motor data ................................................................................................................................................................. 74
10.1 General...................................................................................................................................................................... 74
10.2 Rated motor parameters ........................................................................................................................................... 74
10.3 Additional motor data ................................................................................................................................................ 74
10.3.1 General...................................................................................................................................................................... 74
10.3.2 Stator resistance ....................................................................................................................................................... 74
10.3.3 Leakage factor........................................................................................................................................................... 74
10.3.4 Magnetising current ................................................................................................................................................... 75
10.3.5 Rotor time constant correction factor ........................................................................................................................ 75
10.4 Rotary encoder .......................................................................................................................................................... 75
10.4.1 General...................................................................................................................................................................... 75
10.4.2 Operation mode encoder 1........................................................................................................................................ 76
10.4.3 Operation mode encoder 2........................................................................................................................................ 76
10.4.4 Division marks encoder 1 .......................................................................................................................................... 76
10.4.5 Filter time constant encoder 1 ................................................................................................................................... 77
10.5 System data .............................................................................................................................................................. 77
11 Operating behaviour .................................................................................................................................................. 78
11.1 General...................................................................................................................................................................... 78
11.2 Start-up behaviour ..................................................................................................................................................... 78
11.2.1 General...................................................................................................................................................................... 78
11.2.2 Start-up behaviour of the V/f characteristic ............................................................................................................... 78
11.2.2.1 General...................................................................................................................................................................... 78
11.2.2.2 DC magnetisation ...................................................................................................................................................... 79
11.2.2.3 Starting current .......................................................................................................................................................... 79
11.2.2.4 Frequency limit .......................................................................................................................................................... 79
11.2.3 Starting behaviour of the FOR................................................................................................................................... 79
11.3 Stopping behaviour ................................................................................................................................................... 80
11.4 Auto-start ................................................................................................................................................................... 80
11.5 Search run ................................................................................................................................................................. 81
214 716 44/200710
11.6 Positioning ................................................................................................................................................................. 82

11.6.1 General...................................................................................................................................................................... 82
11.6.2 Reference positioning................................................................................................................................................ 82
11.6.3 Axle positioning ......................................................................................................................................................... 84 5
11.7 Brake control ............................................................................................................................................................. 86
11.7.1 General...................................................................................................................................................................... 86
11.7.2 Start delay ................................................................................................................................................................. 87
11.7.3 DC pre-magnetisation time........................................................................................................................................ 87
11.7.4 DC post-magnetization time ...................................................................................................................................... 87
11.7.5 Brake release delay................................................................................................................................................... 88
11.7.6 Brake application time ............................................................................................................................................... 88
11.8 Brake release monitoring .......................................................................................................................................... 90
11.8.1 General...................................................................................................................................................................... 90
11.8.2 Watchdog N............................................................................................................................................................... 90
11.8.3 Brake release monitoring warning ............................................................................................................................. 90
11.9 Load spectrum calculation......................................................................................................................................... 90
11.9.1 General...................................................................................................................................................................... 90
11.9.2 Load spectrum calculation mode............................................................................................................................... 91
11.9.3 Theoretical duration of service .................................................................................................................................. 91
11.9.4 Lifting correction factor .............................................................................................................................................. 92
11.9.5 Lowering correction factor ......................................................................................................................................... 92
11.9.6 Duration of service specification................................................................................................................................ 92
11.9.7 Actual duration of service .......................................................................................................................................... 92
11.9.8 Remaining service life ............................................................................................................................................... 93
11.9.9 Relative torque .......................................................................................................................................................... 93
11.9.10 Ramp factor ............................................................................................................................................................... 93
11.9.11 Frequency at rated hoist speed ................................................................................................................................. 93
11.9.12 Factor ........................................................................................................................................................................ 93
11.10 Limit switch functions ................................................................................................................................................ 94
11.10.1 Reference value limitation ......................................................................................................................................... 94
11.10.2 Setpoint val. limit 1+ and setpoint val. limit 1- ........................................................................................................... 94
11.10.3 Setpoint val. limit 2+ and Setpoint val. limit 2-........................................................................................................... 95
11.10.4 Limit switch monitoring frequency ............................................................................................................................. 95
11.10.5 Limit switch status ..................................................................................................................................................... 95
11.11 External error / quick stop ......................................................................................................................................... 95
12 Error and warning behaviour ..................................................................................................................................... 97
12.1 General...................................................................................................................................................................... 97
12.2 Overload Ixt ............................................................................................................................................................... 97
12.3 Temperature .............................................................................................................................................................. 97
12.4 Controller status ........................................................................................................................................................ 97
12.5 IDC compensation limit ............................................................................................................................................. 97
12.6 Frequency switch-off limit .......................................................................................................................................... 98
12.7 Motor temperature ..................................................................................................................................................... 98
12.8 Phase failure ............................................................................................................................................................. 98
12.9 Automatic error acknowledgement ............................................................................................................................ 99
12.10 Frequency monitoring................................................................................................................................................ 99
12.11 Max. frequency deviation .......................................................................................................................................... 99
13 Reference values .................................................................................................................................................... 100
13.1 General.................................................................................................................................................................... 100
13.2 Frequency limits ...................................................................................................................................................... 100
13.3 Percentage limits ..................................................................................................................................................... 100
214 716 44/200710
13.4 Reference frequency channel ................................................................................................................................. 101

13.4.1 General.................................................................................................................................................................... 101
13.4.2 Table of switch positions ......................................................................................................................................... 101
6 13.4.3 Block diagram.......................................................................................................................................................... 102
13.5 Reference percentage channel ............................................................................................................................... 103
13.5.1 General.................................................................................................................................................................... 103
13.5.2 Operation mode 476................................................................................................................................................ 103
13.5.3 Block diagram.......................................................................................................................................................... 104
13.6 Fixed reference values ............................................................................................................................................ 105
13.6.1 General.................................................................................................................................................................... 105
13.6.2 SOST reference value steps ................................................................................................................................... 105
13.6.3 JOG frequency ........................................................................................................................................................ 106
13.6.4 Fixed percentage values ......................................................................................................................................... 106
13.7 Frequency ramps .................................................................................................................................................... 107
13.8 Percentage ramps ................................................................................................................................................... 109
13.9 Blocking frequencies ............................................................................................................................................... 109
13.10 SOSP reference value memory............................................................................................................................... 110
13.10.1 Operating principle: General information................................................................................................................. 110
13.10.2 SOSP parameter ..................................................................................................................................................... 110
13.10.3 Reference value memory diagram .......................................................................................................................... 111
13.11 Keypad motor potentiometer ................................................................................................................................... 111
13.12 Repetition frequency input....................................................................................................................................... 111
13.13 ProHub function....................................................................................................................................................... 112
13.13.1 General.................................................................................................................................................................... 112
13.13.2 ProHub function operation mode............................................................................................................................. 113
13.13.3 Field weakening enable........................................................................................................................................... 113
13.13.4 Field weakening start .............................................................................................................................................. 113
13.13.5 Lifting correction value ............................................................................................................................................ 114
13.13.6 Lowering correction value ....................................................................................................................................... 114
13.13.7 Start of measurement .............................................................................................................................................. 114
13.13.8 Field weakening factor ............................................................................................................................................ 114
13.13.9 Current measuring value ......................................................................................................................................... 115
13.13.10 Valid maximum frequency ....................................................................................................................................... 115
13.13.11 Hoist rating factor .................................................................................................................................................... 115
13.14 Additional setpoint value ......................................................................................................................................... 115
13.14.1 General.................................................................................................................................................................... 115
13.14.2 Additional setpoint value operation mode ............................................................................................................... 115
13.14.3 Additional control ..................................................................................................................................................... 116
13.14.4 Additional setpoint value frequency limits ............................................................................................................... 116
13.14.5 Additional setpoint value frequency ramps.............................................................................................................. 116
13.14.6 Additional setpoint value bus operation................................................................................................................... 116
13.14.7 Additional fixed frequencies .................................................................................................................................... 117
14 Control inputs and outputs ...................................................................................................................................... 118
14.1 General.................................................................................................................................................................... 118
14.2 Multi-function input MFI1 ......................................................................................................................................... 118
14.2.1 General.................................................................................................................................................................... 118
14.2.2 Analogue input MFI1A ............................................................................................................................................. 118
14.2.2.1 General.................................................................................................................................................................... 118
14.2.2.2 Characteristic curve................................................................................................................................................. 118
14.2.2.3 Scaling..................................................................................................................................................................... 119
14.2.2.4 Tolerance range and hysteresis .............................................................................................................................. 120
14.2.2.5 Error and warning behaviour ................................................................................................................................... 121
14.3 Multi-function output MFO1 ..................................................................................................................................... 121
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14.3.1 General.................................................................................................................................................................... 121

14.3.2 Operation mode analogue MFO1A ......................................................................................................................... 122
14.3.2.1 General.................................................................................................................................................................... 122
14.3.2.2 Output characteristic ............................................................................................................................................... 122
7
14.3.3 Operation mode repetition frequency MFO1F ......................................................................................................... 123
14.4 Digital outputs.......................................................................................................................................................... 123
14.4.1 General.................................................................................................................................................................... 123
14.4.2 Setting frequency .................................................................................................................................................... 124
14.4.3 Reference value reached ........................................................................................................................................ 124
14.4.4 Flux-forming finished ............................................................................................................................................... 125
14.4.5 Release brake ......................................................................................................................................................... 125
14.4.6 Current limitation ..................................................................................................................................................... 125
14.4.7 Comparator ............................................................................................................................................................. 125
14.4.8 Warning mask ......................................................................................................................................................... 126
14.5 Digital inputs ............................................................................................................................................................ 128
14.5.1 Assignment.............................................................................................................................................................. 128
14.5.2 Starting command ................................................................................................................................................... 129
14.5.3 Data set change-over .............................................................................................................................................. 129
14.5.4 SOST reference value step change-over ................................................................................................................ 129
14.5.5 Fixed percentage value change-over ...................................................................................................................... 130
14.5.6 SOSP reference value memory function ................................................................................................................. 130
14.5.7 Motor thermal contact.............................................................................................................................................. 130
14.5.8 Timers ..................................................................................................................................................................... 130
14.5.9 Additional fixed frequency selection ........................................................................................................................ 130
14.5.10 Additional setpoint value release............................................................................................................................. 131
14.5.11 Fast-to-slow limit switch limitation ........................................................................................................................... 131
14.5.11.1 General.................................................................................................................................................................... 131
14.5.11.2 Fast-to-slow limit switch limitation 1+ and fast-to-slow limit switch limitation 1- ...................................................... 131
14.5.11.3 Fast-to-slow limit switch limitation 2 ........................................................................................................................ 131
14.5.11.4 Operating limit switches .......................................................................................................................................... 132
14.5.12 Error Acknowledgment ............................................................................................................................................ 132
14.5.13 n-/M-control change-over ........................................................................................................................................ 132
14.5.14 Percent motor potentiometer ................................................................................................................................... 132
14.6 Timer function.......................................................................................................................................................... 132
14.6.1 General.................................................................................................................................................................... 132
14.6.2 Timer time constant ................................................................................................................................................. 133
14.7 Logic function .......................................................................................................................................................... 134
15 V/f characteristic...................................................................................................................................................... 136
15.1 General.................................................................................................................................................................... 136
15.2 Dynamic voltage pre-control.................................................................................................................................... 137
16 Control functions ..................................................................................................................................................... 138
16.1 General.................................................................................................................................................................... 138
16.2 Intelligent current limits............................................................................................................................................ 138
16.3 Voltage controller .................................................................................................................................................... 138
16.3.1 General.................................................................................................................................................................... 138
16.3.2 Operation mode overvoltage controller ................................................................................................................... 139
16.3.3 Operation mode mains support ............................................................................................................................... 140
16.4 Control functions of the V/f characteristic ................................................................................................................ 142
16.4.1 General.................................................................................................................................................................... 142
16.4.2 Slip compensation ................................................................................................................................................... 142
16.4.3 Current limit controller ............................................................................................................................................. 142
16.4.4 Technology controller .............................................................................................................................................. 143
16.4.4.1 General.................................................................................................................................................................... 143
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16.4.4.2 Operation mode standard........................................................................................................................................ 145

16.4.4.3 Operation mode level 1 ........................................................................................................................................... 145
16.4.4.4 Operation mode level 2 ........................................................................................................................................... 145
16.4.4.5 Operation mode speed control ................................................................................................................................ 145
8
16.4.4.6 Operation mode indirect volumetric flow control ..................................................................................................... 145
16.5 Functions of field-oriented regulation ...................................................................................................................... 146
16.5.1 General.................................................................................................................................................................... 146
16.5.2 Current controller..................................................................................................................................................... 146
16.5.3 Torque controller ..................................................................................................................................................... 147
16.5.4 Limit value sources.................................................................................................................................................. 147
16.5.5 Speed controller ...................................................................................................................................................... 147
16.5.5.1 General.................................................................................................................................................................... 147
16.5.5.2 Limitation of the speed controller ............................................................................................................................ 149
16.5.5.3 Limit value sources.................................................................................................................................................. 149
16.5.6 Acceleration pre-control .......................................................................................................................................... 150
16.5.7 Field controller ......................................................................................................................................................... 150
16.5.7.1 General.................................................................................................................................................................... 150
16.5.7.2 Limitation of the field controller................................................................................................................................ 151
16.5.7.3 KB de-magnetization time ....................................................................................................................................... 151
16.5.8 Modulation controller ............................................................................................................................................... 152
16.5.8.1 General.................................................................................................................................................................... 152
16.5.8.2 Limitation of the modulation controller..................................................................................................................... 152
17 Special functions ..................................................................................................................................................... 153
17.1 General.................................................................................................................................................................... 153

17.2 Pulse width modulation ........................................................................................................................................... 153
17.3 Fan .......................................................................................................................................................................... 153
17.4 Brake chopper ......................................................................................................................................................... 154
17.5 Motor chopper ......................................................................................................................................................... 154
17.6 Motor protective switch............................................................................................................................................ 155
17.7 Bus controller .......................................................................................................................................................... 157
17.8 Temperature adjustment ......................................................................................................................................... 157
17.9 Rotary encoder monitoring ...................................................................................................................................... 158
18 Actual values ........................................................................................................................................................... 160
18.1 General.................................................................................................................................................................... 160
18.2 Actual frequency inverter values ............................................................................................................................. 160
18.3 Actual machine values ............................................................................................................................................ 160
18.4 Actual system values............................................................................................................................................... 161
18.5 Actual value memory ............................................................................................................................................... 161
19 Error protocol........................................................................................................................................................... 163
19.1 General.................................................................................................................................................................... 163
19.2 Error list ................................................................................................................................................................... 163
19.2.1 General.................................................................................................................................................................... 163
19.2.2 Error messages ....................................................................................................................................................... 164
19.3 Error environment.................................................................................................................................................... 165
20 Operation and error diagnosis................................................................................................................................. 167
20.1 General.................................................................................................................................................................... 167
20.2 Status display .......................................................................................................................................................... 167
20.3 Status of the digital signals...................................................................................................................................... 168
20.4 Controller status ...................................................................................................................................................... 169
20.5 Warning status ........................................................................................................................................................ 170
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21 Parameter list .......................................................................................................................................................... 171

21.1 General.................................................................................................................................................................... 171
21.2 Actual value menu (VAL)......................................................................................................................................... 171 9
21.3 Parameter menu (PARA) ........................................................................................................................................ 175
22 Accessories for Dedrive Compact frequency inverters ........................................................................................... 186
22.1 Size 1 DIC - 4 - 002 to 004 ...................................................................................................................................... 186
22.2 Size 2 DIC - 4 - 006 to 009 ...................................................................................................................................... 187
22.3 Size 3 DIC - 4 - 014 to 017 ...................................................................................................................................... 188
22.4 Size 4 DIC - 4 - 025 to 040 ...................................................................................................................................... 189
22.5 Size 5 DIC - 4 - 045 to 060 ...................................................................................................................................... 190
22.6 Size 6 DIC - 4 - 075 to 110 ...................................................................................................................................... 191
22.7 Braking resistors...................................................................................................................................................... 192
22.7.1 General.................................................................................................................................................................... 192
22.7.2 Frequency inverter → braking resistor assignment .................................................................................................. 192
22.7.3 Thermal overload protection for braking resistors ................................................................................................... 195
22.7.4 Thermal overload relay............................................................................................................................................ 195
22.7.4.1 General.................................................................................................................................................................... 195
22.7.4.2 Braking resistor → thermal overload relay assignment ............................................................................................ 196
22.7.5 Braking resistor dimensions .................................................................................................................................... 200
22.7.5.1 Cement-coated single, double and triple-tube fixed resistors ................................................................................. 200
22.7.5.2 Steel-grid resistors of standard design .................................................................................................................... 202
22.7.5.3 Steel-grid resistors of compact design .................................................................................................................... 204
22.7.5.4 Compact resistors type PWR .................................................................................................................................. 206
22.8 Line reactors and line filters .................................................................................................................................... 207
22.8.1 Assignment.............................................................................................................................................................. 207
22.8.1.1 General.................................................................................................................................................................... 207
22.8.1.2 "Footprint" and "Book" format line filters.................................................................................................................. 207
22.8.1.3 Limit value class B................................................................................................................................................... 208
22.8.1.4 Limit value class A group 1 ..................................................................................................................................... 210
22.8.1.5 Limit value class A group 2 ..................................................................................................................................... 212
22.8.1.6 Definition of the environments and categories ........................................................................................................ 213
22.8.1.7 Comparison of the limit values ................................................................................................................................ 214
22.8.2 Line reactor technical data ...................................................................................................................................... 214
22.8.2.1 Line reactor electrical data ...................................................................................................................................... 214
22.8.2.2 Line reactor mechanical data and dimensions ........................................................................................................ 215
22.8.3 Line filter technical data........................................................................................................................................... 216
22.8.3.1 Electrical data .......................................................................................................................................................... 216
22.8.3.2 Mechanical data and dimensions of line filters ........................................................................................................ 217
22.9 Output filters (du/dt)................................................................................................................................................. 221
22.9.1 Assignment and electrical data ............................................................................................................................... 221
22.9.2 Mechanical data and dimensions ............................................................................................................................ 222
22.9.3 Motor cable lengths ................................................................................................................................................. 223
23 Project engineering ................................................................................................................................................. 224

23.1 General.................................................................................................................................................................... 224
23.2 Selecting the motor according to the drive requirement .......................................................................................... 224
23.3 Speed range of the selected motor ......................................................................................................................... 224
23.4 Field weakening operation ...................................................................................................................................... 225
23.5 Static torque for speed values of approx. "0 rpm" ................................................................................................... 225
24 Block wiring diagram ............................................................................................................................................... 226
24.1 Circuit diagram ........................................................................................................................................................ 226
24.2 Pulse generator connection to the Dedrive Compact DIC-4-xxx ............................................................................. 227
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24.2.1 General.................................................................................................................................................................... 227

24.2.2 Selection of the pulse generator and interface electronics...................................................................................... 227
24.2.2.1 General.................................................................................................................................................................... 227
24.2.2.2 EG integral pulse generator with 30 pulses per revolution...................................................................................... 227
10 24.2.2.3 EGS integral pulse generator with 30 pulses per revolution ................................................................................... 228
24.2.2.4 AG external pulse generator with 1024 pulses per revolution................................................................................. 228
24.2.3 Electrical connection/terminal assignment .............................................................................................................. 229
24.2.4 S1 electrical protection on the Dedrive Compact .................................................................................................... 229
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11
0 Foreword
0.1 General
You have purchased a Demag product. This equipment was manufactured in accordance with state-of-the-art en‐
gineering principles.
These operating instructions are designed to provide the operator with appropriate instructions for safe and correct
operation and to facilitate maintenance.
frequency inverters and their additional equipment must have read and understood the following documents.
errors and to ensure smooth and trouble-free operation of our products.
0.2 Copyright
These operating 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 compensatory damages. All industrial rights reserved.
0.3 Customer service

For technical information on Demag products and their systematic application, please refer to one of our after-sales
service centres, the relevant representative or to our main office in Wetter.
0.4 Liability for defects

These operating instructions must be read carefully before installing and putting the product into operation.
We assume no liability for any damage and malfunctions resulting from failure to comply with the operating instruc‐
tions.
Liability claims for defects must be made by quoting the order number immediately on detecting the defect.
● 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.

214 716 44/200710
12
0.5 Limitations of liability
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 further development of the frequency
inverters which are the subject of these operating instructions. The information, illustrations and descriptions con‐
tained in these operating instructions are therefore only intended for information purposes. The descriptions and
illustrations contained in these operating instructions do not necessarily 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 approved by us may be used. Ac‐
cordingly, 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 Cranes & Components from any liability for damages resulting there‐
from.
With the exclusion of any further claims, our liability for defects and liability obligations for any defects pertaining to
the products supplied or faults in the documentation delivered or any negligence on our part are exclusively based
on the stipulations of 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.
0.6 Definitions
Owner
Owners (employer, company) are defined as persons who own the product and who use it appropriately or allow it
to be operated by suitable persons.
Operating personnel
Operating personnel are defined as persons assigned by the owner of the product to operate the product.
Specialist personnel are defined as persons assigned by the owner to carry out specific tasks, such as installation,
setting-up, maintenance and fault elimination.
the product and electrical installations as well as knowledge of the relevant standards, codes of practice and regu‐
lations, 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 technicians are defined as persons, who, owing to their technical training and experience, have suffi‐
cient knowledge of the product and are familiar with the relevant national industrial safety regulations, codes of
practice, accident prevention regulations, directives and generally accepted engineering standards (e.g. EC Direc‐
tives, German VDE and VBG regulations) enabling them to judge the safe operating condition of frequency inverters.
214 716 44/200710
13
1 Safety

Important safety information and instructions are marked by corresponding symbols and signal words.
The safety instructions must be followed. Exercise particular caution to ensure that accidents, injuries and damage
are avoided in such cases.
The relevant local accident prevention regulations for the application and general safety instructions must also be
complied with.
The following symbols and instructions warn against possible personal injuries or damage to property and are in‐
tended to assist you in your work.
DANGER
This symbol indicates an immediate hazard which can result in serious injury or death.
WARNING
This symbol indicates a possibly hazardous situation which might result in serious injury or death.
CAUTION
This symbol indicates a possibly hazardous situation which might result in medium to light injury or damage.

● This symbol indicates information on the appropriate use of machinery.
● This symbol in the operating instructions indicates all warnings which, if not complied with, may result in mal‐
functions or damage.
1.2 Intended use

Frequency inverters are electrical drive components which are intended to be incorporated into electrical installations
or machines. Frequency inverters are available to a limited extent and only intended for professional use in the sense
of the standard EN 61800-3. The unit must not be put into operation (i.e. designated/intended operation must not
commence) until it has been established that the machinery complies with the provisions of EC Directive 2006/42/
EC (Machinery Directive) and with the provisions of EN 60204. The frequency inverters are marked with the CE
symbol and thus meet the requirements of Low Voltage Directive 2006/95/EC and comply with standard EN 50178 /
DIN VDE 0160.
The user is responsible for compliance with EMC directive 2004/108/EC.
The requirements of CSA standard C22.2-No. 14-95 are also fulfilled with the granting of UL approval in accordance
with UL508c. Refer to the rating plate and documentation for the technical data and information on connecting these
units as well as on the ambient conditions; these conditions and data must not be exceeded.
214 716 44/200710
14
1.3 Prohibited practises, improper use
Refer to the rating plate and documentation for the technical data and information on connecting these units; these
conditions and data must not be exceeded.
Under certain conditions, operation of frequency inverters is prohibited as this could result in malfunctions, equipment
failure or hazard to life and limb, e.g. in the case of:
● Acidic, corrosive air as coolant
● Operation outside the permitted temperature range
● Operation beyond the normal air pressure
● Operation under conditions of high humidity or splashwater
● Manipulation of electrical modules
Safety devices must not be rendered inoperable or modified or used in any way other than that for which they have
been designed.
WARNING
Non-compliance with the safety instructions

There is danger to life and limb in the case of non-compliance.
The relevant national accident prevention regulations and the general safety conditions must always be observed
when our products are operated in order to avoid accidents and damage to machinery. Failure to observe the safety
instructions given in these operating instructions in any way may result in personal injury or death.
DANGER
Electric shock, live components

Contact with live components can result in danger to life and limb.
Only carry out maintenance and installation work,
– if the frequency inverter is at zero voltage,
– if the frequency inverter is secured against accidental restoration of the power supply,
– if all cables, motor terminals and capacitors are at zero potential (establish with a voltmeter),
– with insulated tools.
To ensure that the inverters are switched off independently of the mains supply, a circuit interrupter or a line contactor
must be installed between the power supply and inverter.
Control, power supply and motor leads must be laid separately.
DANGER

Always verify the safe isolation from the power supply before starting work on the frequency inverter. If the light
emitting diodes go out or fail, this does not indicate that the frequency inverter is de-energized.
According to current legislation, the owner of an installation must fulfil certain obligations with a view to protecting
personnel. These are:
● Ensuring proper instruction of personnel
214 716 44/200710
● Ensuring that the operating instructions are available for reference at the point of application of the equipment
● Compliance with additional instructions including supervisory and reporting obligations, making allowance for
particular operational aspects, e.g. with respect to work organization, operating sequences, personnel employed
15
● Review of personnel to ensure that they are aware of the safety requirements and hazards involved in the work
and the associated operating instructions
● Ensuring that frequency inverters are operated only when in perfect operating condition and that all relevant safety
requirements have been allowed for.
● Immediate shut-down of the frequency inverter as soon as a defect or irregularity is established.
Commissioning the frequency inverter
Do this only
● if you have read the operating instructions – in particular the warnings ⇒ "Putting into operation in practice",
Page 61 – and the owner has instructed you in all details,
● if these operating instructions are available for reference at the place where the frequency inverter is in operation,
● if you are qualified specialist personnel,
● if you are not under the influence of drugs, alcohol or medication that can adversely affect your ability to react,
● if the general accident prevention, operating and installation regulations (e.g. DIN-VDE 0100/0113/prEN50178)
have been observed.
1.5 Transportation and storage

Operating hazard for the installation if inappropriately transported or stored.
● Transportation and storage must be carried out appropriately in the original packaging.
● The frequency inverter must be stored in dry places protected against dust and moisture with only minor tem‐
perature fluctuations.
● Observe the climatic conditions according to EN 50178 and the symbols on the packing.
● The unit must not be stored for more than one year without being connected to the permissible rated voltage.
1.6 Handling and installing

The frequency inverter must be used in accordance with the documentation, regulations and standards. Ensure that
it is handled with due care and avoid any mechanical overloading or stresses. Do not bend any components while
transport or handling the unit and do not change any insulation distances. Do not touch any electronic components
and contacts. The equipment contains electrostatically sensitive components which can be easily damaged by in‐
correct handling. Damaged or destroyed components must not be put into operation, since they may constitute a
danger for your health and compliance with applicable standards is not ensured.

Comply with relevant standards BGV A2 (VBG 4), VDE 0100 and other national regulations when working on the
frequency inverter. Follow the instructions given in the documentation on electrical installation and the relevant
regulations. The manufacturer of the industrial installation or machine is responsible for compliance with and check‐
ing the limit values specified by EMC product standard 61800-3 for variable-speed electrical drives. See ⇒ "Definition
of the environments and categories", Page 213
The documentation contains information for installation to satisfy EMC requirements. Suitable precautions must be
taken before the cables connected to the frequency inverter are subjected to insulation tests at high test voltages.
214 716 44/200710
16
1.8 Operation
All covers must be fitted and the terminals must be checked before commissioning and starting intended operation.
Check additional monitoring and safety equipment in accordance with EN 60204 and relevant safety regulations
(e.g. technical equipment regulations, accident prevention regulations, etc.). Before starting work on the frequency
inverter, it must be de-energized without touching any live contacts, since the capacitors may be charged. Comply
with the instructions and symbols on the frequency inverter.
1.9 Maintenance
Unauthorized opening and inappropriate intervention may result in personal injury or material damage. Repair work
on the frequency inverter must only be carried out by the manufacturer or by personnel authorized by the manufac‐
turer.
214 716 44/200710
17
2 Scope of delivery
2.1 General
Due to the modular hardware components frequency inverters can easily be integrated into the automation concept.
The scope of delivery described can be supplemented with optional components and adapted to customer-specific
requirements. The plug-in connection terminals ensure reliable functioning and efficient installation.
2.2 DIC-4-002 to 009 frequency inverters
A H B C D
X1
X10
X210A
X210B
X2
F E G 42392244_xml.eps
Fig. 1 Scope of delivery for DIC-4-002 to 009 frequency inverters
A Frequency inverter F Terminal strip X2 (Phoenix ZEC 1,5/...ST7,5)

B Terminal strip X1 (Phoenix ZEC 1,5/..ST7,5) Plug-in terminal for braking resistor and motor
Plug-in terminals for the mains connection and connection
DC link G Control terminals X210A / X210B (Wieland
C Terminal strip X10 (Phoenix ZEC 1,5/3ST5,0) DST85 / RM3,5)
Plug-in terminals for the relay output Plug-in terminal to connect the control signals
D Standard fasteners for mounting on a wall panel H CD-ROM documentation
E Quick-step operating instructions
Immediately check the goods received for quality, quantity and type. Notice of obvious defects, such as external
damage to the packing or unit, must be given to the sender within seven days for insurance reasons.
214 716 44/200710
18
A H B C
X10
X210A
X210B
D E
42392344_xml.eps
Fig. 2 Scope of delivery for DIC4-014 to 040 frequency inverters
A Frequency inverter D Quick-step operating instructions

B Terminal strip X10 (Phoenix ZEC 1,5/3ST5,0), E Control terminals X210A / X210B (Wieland
plug-in terminals for the relay output DST85 / RM3,5)
C Standard brackets with fastening screws Plug-in terminal to connect the control signals
(M4x20, M4x60) for wall-mounting H CD-ROM documentation
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19
A C B
X10
X210B
X210A
42392444_xml.eps
Fig. 3 Scope of delivery for DIC-4-045 to 110 frequency inverters
A Frequency inverter D Quick-step operating instructions

B Terminal strip X10 (Phoenix ZEC 1,5/3ST5,0), E Control terminals X210A / X210B (Wieland
plug-in terminals for the relay output DST85 / RM3,5)
C Standard mounting frame for wall-mounting with Plug-in terminal to connect the control signals
screws for mounting the frame on the inverter
(M5x16, M5x20, M5x70)
214 716 44/200710
20
3 Technical data

The following data are related to the rated point of the frequency inverter. The nominal working point of the frequency
inverter is defined for a permissible mains voltage of 400 V and a modulation frequency of 2 kHz.
Size 1 2
Current code DIC-4-… 002 003 004 006 007 009
Motor-side output
Output current I A 2,4 3,2 3,8 5,8 7,8 9,0
Output voltage U V 3 x 0 … Line voltage
Overload capability at - - 1,5 for 60s; 2,0 for 10s
2 kHz and 4 kHz (10 min. cycle)
Protection - - Short-circuit/earth-fault-proof
Output frequency f Hz 0 … 300 depending on the modulation frequency
Modulation frequency f kHz 2 … 16
Output braking resistor
Min. braking resistance R Ω 462 300 220 148 110 92
Line-side input
Line current 1) 3ph/PE I A 2,4 2,8 2) 3,3 2) 5,8 6,4 2) 7,8 2)
Line voltage U V 3 x 380 to 480 + 10% / -15%
Line frequency f Hz 50 / 60 ±10%
Fuses 3ph/PE I A 6 10
Mechanical
Dimensions: HxWxD mm 190x60x180 250x60x180
⇒ „DIC-4-002 to 009 frequency
inverters“, Page 27
Weight (approx.) m kg 1,3 1,7
Type of enclosure - - IP20 (EN60529)
Connection terminals A mm2 0,2 … 1,5
Ambient Conditions
Power loss P W 46 58 68 87 108 130
Coolant temperature Tn °C 0 … 40 (3K3 DIN IEC 721-3-3)
Storage temperature TL °C -25 … 55
Transport temperature TT °C -25 … 70
Rel. humidity - % 15 … 85, non-condensing
Tab. 2
Depending on the customer-specific requirements the modulation frequency may be increased, if the output current
is reduced. The standards and regulations must be observed for this working point.
Frequency inverter Modulation frequency

current code 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz
002 2,4 A 2,4 A 2,4 A 2,0 A 1,6 A
003 3,2 A 2) 3,2 A 2) 3,2 A 2) 2,7 A 2) 2,2 A
004 3,8 2) 3,8 A 2)3) 3,8 A 2)3) 3,2 A 2)3) 2,6 A 3)
006 5,8 A 5,8 A 5,8 A 4,9 A 3,9 A
007 7,8 A 2) 7,8 A 2) 7,8 A 2) 6,6 A 2) 5,3 A
009 9,0 A 2) 9,0 A 2)3) 9,0 A 2)3) 7,6 A 2)3) 6,1 A 3)
Tab. 3
214 716 44/200710
1) Mainscurrent with a relative line impedance of 1% (see section 5)

2) Line
reactor required for a duty factor > 60% CDF
3) Modulation frequency reduced in thermal limit range 21
Size 3 4
Current code DIC-4-… 014 017 025 032 040
Motor-side output
Output current I A 14 16,5 25 32 40
Overload capability at 2 kHz - - 1,5 for 60s; 2,0 for 10s 1,4 f. 60s
(10 min. cycle) 1,6 f. 10s
Overload capability at 4 kHz - - 1,5 for 60s; 2,0 for 10s 1,4 f. 60s 1,3 f. 60s
(10 min. cycle) 2,0 f. 10s 1,6 f. 10s
Modulation frequency f kHz 2 … 16
Min. braking resistance R Ω 58 48 32 24 24
Line-side input
Line current 4) 3ph/PE I A 14,2 14,5 5) 26 28,2 5) 35,6 5)
Fuses 3ph/PE I A 16 20 35 50
Mechanical
⇒ „DIC-4-014 to 040 frequency in‐
verters“, Page 28
Connection terminals A mm2 0,2 … 6 0,2 … 16
Ambient Conditions
Power loss P W 145 200 240 310 420
Tab. 4

current code 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz
014 14,0 A 14,0 A 14,0 A 11,8 A 9,5 A
017 16,5 A 5) 16,5 A 5) 16,5 A 5) 13,9 A 5) 11,2 A
025 25,0 A 25,0 A 25,0 A 21,0 A 17,0 A
032 32,0 A 5) 32,0 A 5) 32,0 A 5) 26,9 A 5) 21,8 A
040 40,0 A 5) 38,3 A 5) 6) 35,0 A 5) 6) 29,4 A 5) 6) 23,8 A 5) 6)
Tab. 5
214 716 44/200710
4) Mainscurrent with a relative line impedance of 1% (see section 5)

5) Line
reactor required for a duty factor > 60% CDF
22 6) Modulation frequency reduced in thermal limit range
Size 5 6
Current code DIC-4-… 045 060 075 090 110
Motor-side output
Output current I A 45 60 75 90 110
Overload capability at 2 and 4 kHz - - 1,5 for 60s; 2,0 for 10s
(10 min. cycle)
Modulation frequency f kHz 2…8
Min. braking resistance R Ω 15 7,5
Line-side input
Line current 7) 3ph/PE I A 52 58 8) 72 86 8) 105 8)
Fuses 3ph/PE I A 63 80 100 125
Mechanical
⇒ „DIC-4-045 to 110 frequency in‐
verters“, Page 29
Connection terminals A mm2 1,5 … 25 Max. 70 (threaded studs)
Ambient Conditions
Power loss P W 420 540 660 770 1060
Tab. 6

current code 2 kHz 4 kHz 8 kHz
045 45,0 A 45,0 A 45,0 A
060 60,0 A 8) 60,0 A 8) 60,0 A 8)
075 75,0 A 75,0 A 75,0 A
090 90,0 A 8) 90,0 A 8) 90,0 A 8)
110 110,0 A 8) 110,0 A 8) 110,0 A 8)
Tab. 7
3.4 Operating diagrams
3.4.1 General
The technical data for the frequency inverter relates to the nominal working point that was selected for a wide range
of applications. It is possible to apply a functionally safe and economical dimensioning (derating) of the frequency
inverter via the following diagrams for specific applications.
214 716 44/200710
7) Mains current with a relative line impedance of 1% (see section 5)

8) Line reactor required for a duty factor > 60% CDF 23
3.4.2 Site altitude
Derating; 5%/1000 m above 1000 m above sea level; hmax = 4000 m
Fig. 4
1 Output current in %
2 Installation height in m above sea level
Max. coolant temperature; 3,3 °C/1000 m above 1000 m above sea level
Fig. 5
1 Coolant temperature in °C
2 Installation height in m above sea level
214 716 44/200710
24
3.4.3 Coolant temperature
Derating; 2,5%/K above 40 °C; Tmax = 55 °C
Fig. 6
2 Coolant temperature in °C
3.4.4 Line voltage
Derating; 0,22%/V above 400 V; Tmax = 480 V
Fig. 7
2 Mains voltage in V
214 716 44/200710
25
4 Mechanical installation
4.1 General
Standard frequency inverters of the IP20 type of enclosure are designed for fitting in the switchgear cabinet. For
fitting the installation and safety regulations as well as the specification of the devices must be observed.
DANGER

The frequency inverters only comply with safety class IP20 if the covers and connection terminals are inserted
properly. Only then operation is permitted.

● The combination of Dedrive Compact fitted on footprint line filters does not satisfy vibration resistance require‐
ments to IEC 68-2-6 (max. 5g).
● For increased vibration resistance demands, Dedrive Compact units must be fitted next to the line filter on the
mounting panel.
For all sizes:
If a KP module is plugged to the frequency inverter, the depth dimension is increased.
KP500 operating unit: Depth + 19 mm
KP232 interface adapter: Depth + 25 mm
214 716 44/200710
26
b c
x b1 c1
a2
a1
a
x
<
X 100mm
42392944_xml.eps
Fig. 8 Dimensions size 1+2
Installation is done with the standard fasteners in a vertical position onto the installation plate.
The inverter is fitted on the line filter on the upper side by means of the mounting tab included in the line filter scope
of supply. ⇒ "Mechanical data and dimensions of line filters", Page 217.
Installation is done by inserting the long side of the fastening sheet into the heat sink and fixing it to the installation
plate with screws.
Dimensions Mounting dimensions in mm

Frequency inverter a b c a1 a2 b1 c1
Size 1 DIC-4-002 … 004 190 60 180 210 … 230 255 30 130
Size 2 DIC-4-006 … 009 250 60 180 270 … 290 315 30 130
Tab. 8
CAUTION
Hot components due to insufficient cooling

Risk of burns in the case of contact or fire hazard
The units must be fitted with sufficient clearance, so that the cooling air can circulate without any hindrance.
Take care that the air is not polluted by dust, grease, aggressive gases etc.
214 716 44/200710
27
b c
x
b1 c1
a
a2
a1
x
<
X 100mm
42393044_xml.eps
Installation is done with the standard fasteners onto the installation plate.
Installation is done by fixing the two angle brackets with the heat sink of the frequency inverter onto the installation
plate with screws. The frequency inverters of sizes 3 and 4 are supplied with angle brackets which are fixed on the
heat sink by means of four screws, each. The upper angle brackets are fixed with M4x20 screws, the lower angle
brackets with M4x60 screws. The dimensions and mounting dimensions are in millimeters and apply to the standard
unit without optional components.

Size 3 DIC-4-014 … 017 250 100 200 270 … 290 315 12 133
Size 4 DIC-4-025 … 040 250 125 200 270 … 290 315 17,5 133
Tab. 9
CAUTION

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28
b c
b1 c1
x
a1
a2
xa
<
X 100mm
42393144_xml.eps

214 716 44/200710
29
M4x20
M5x20
M4x20
M5x20
4 x M5x10
M4x70 M4x70
M5x70 M5x70
42393244_xml.eps
Fig. 11 Fastening size 5

214 716 44/200710
30
Fig. 12 Fastening size 6
Size 5 and 6 frequency inverters are supplied with a mounting frame, which is attached to the heat sink. It is fixed
at the top and bottom by means of cheese-head screws and by means of counter-sunk screws on the sides. M6
screws must be used for attaching size 5 units to the mounting plate, and M8 screws for size 6.

Size 5 DIC-4-045 … 060 250 200 265 270 … 290 315 20 165
Size 6 DIC-4-075 … 110 400 275 265 430 … 450 470 20 165
Tab. 10
CAUTION

214 716 44/200710
31
4.5 Fitting CM-xxx and EM-xxx hardware modules
4.5.1 General fitting instructions
CM communications modules and EM extension modules are supplied pre-assembled in an enclosure. They are
fitted into slots B and C, ⇒ "Hardware modules", Page 50.
DANGER

The inverter must be disconnected from the power supply before any hardware is fitted. Modules must not be fitted
when the inverter is connected to a power supply as the inverter and/or the hardware modules will otherwise be
destroyed.
Wait at least 5 minutes after disconnecting from the line supply, before starting fitting.
The circuit board visible on the rear must not be touched, as parts may be damaged.
4.5.2 Instructions for fitting the EM extension module
Remove the cover before fitting the extension module into slot C.
4.5.3 Instructions for fitting the CM communication module
3
1
42393444_xml.eps
Fig. 13
A PE spring is also included to connect the PE conductor (screen).
Fitting the CM communication module
1. Remove the cover.

214 716 44/200710
2. The slot for the module sub-assembly is accessible.
3. First install the PE spring included in the delivery using the screw fitted in the unit.
32 The spring must be centred when fitted.
4. The unit can now be fitted and secured to the PE spring using the spring on the module.
5. Break out the pre-stamped opening in the cover for connector X310 and refit the cover.
214 716 44/200710
33
5 Electrical installation
5.1 General
The electrical installation must be carried out by qualified personnel according to the general and regional safety
and installation regulations. Safe operation of the frequency inverter is ensured provided that the documentation and
the specification of the unit are complied with during installation and putting into service. Under special application
conditions, further regulations and guidelines may also have to be considered.
DANGER

The mains, DC and motor terminals may carry dangerous voltages after the frequency inverter has been released
for operation.
– Work on the unit may only be carried out after a few minutes have elapsed and the link capacitors have
discharged.
The connecting cables must be protected externally in compliance with the maximum voltage and current values of
the fuses. The mains fuses and cable cross-sections must be designed for the rated working point of the frequency
inverter according to EN 60204-1 or DIN VDE 0298, part 4. According to UL/CSA the frequency inverter is suitable
for operation in a power supply network of max. 480 VAC, which supplies a symmetrical current of max. 5000 A root-
mean-square value, if it is protected with fuses of the RK5 class. Only use copper cables with a temperature range
of 60/75 °C.
DANGER

The frequency inverters must be connected to earth with a large surface area to ensure good conductivity. The
leakage current of frequency inverters may be > 3.5 mA, a fixed connection must be provided in accordance with
the EN 50178 standard. The protective earth conductor cross-section required for earthing the installation surface
must be at least 10 mm² or a second protective earth conductor must be connected in parallel to the first. The
cross-section in these applications must correspond to the recommended cable cross-section.
Conditions for connection

● According to the technical data, the frequency is suitable for connection to the public or industrial supply network.
If the transformer power of the supply network ≤ 500 kVA, the optional line reactor is only required for those
frequency inverters marked accordingly in the technical data. All other frequency inverters are suitable for con‐
nection without line reactor at a relative system fault level (relation between active-power input and system fault
level) ≥ 1%.
● The connection to the public supply network without further measures must be checked in accordance with the
provisions of the standard EN 61000-3-2. Frequency inverters ≤ DIC-4-017 with integrated mains filter and a
motor cable length of up to 10 m comply with the emission limit values according to the product standard EN
61800-3 without any further measures. Increased requirements due to the application of the frequency inverter
must be met using optional components. Line reactors and filters are optionally available for this product series.
● Operation in a non-earthed system (IT system) is allowed after the Y capacitors inside the unit have been dis‐
connected.
Line filters cannot be used in IT systems.
● Fault-free operation with a residual-current-operated circuit-breaker is ensured with a tripping current ≥ 30 mA if
the following items are considered:
- Use of residual-current-operated circuit-breakers sensitive to all types of currents (type B acc. to EN 50178)
e.g. Siemens 5SZ3…G00
- Residual-current-operated circuit-breakers protect frequency inverters with leakage-current reduced filter or
without line filter.
- The length of the screened cable is ≤ 10 m and no further capacitive components exist between the mains or
214 716 44/200710
motor cables and PE.

- The Y capacitors inside the unit must be disconnected. Thus cable-bound emitted interference (EMB) is in‐
creased.
34
5.2 EMC notes
The frequency inverters are designed with an interference immunity (EMI) for operation in industrial applications
according to the requirements and limit values of the product standard EN 61800-3. Electromagnetic interference
must be avoided by appropriate installation and compliance with the specific product information.
Measures
● The frequency inverter and the line reactor must be fitted on the ideally galvanized mounting panel on a large
surface.
● Take care for a good equipotential bonding within the system or installation. Installation parts such as switchgear
cabinets, control desks, machines frames etc. must be connected with PE conductors with a large surface area
to ensure good conductivity.
● Ensure that the frequency inverter, the line choke, external filters and other components are connected to each
other via short cables with one earthing point.
● Excessive cable lengths and freely hanging cables must be avoided when installation work is carried out.
● Contactors, relays and magnet valves in the switchgear cabinet must be provided with suitable interference sup‐
pression components.
● Cable shields must be earthed or connected to the unit with a low resistance and a large surface area. Provide
a 360° earth connection using appropriate screen clamps.
● Unplaiting screens and making contacts by means of long single conductors (so-called pig tails) must be avoided.
Connections
Connection A
Line connection: Provided the maximum permissible voltage drop is con‐

A sidered, the mains supply line can be of any length, but it must be laid
separated from control, data and motor cables. We recommend screened
B
cables be fitted between the line filter and the frequency inverter if an
external line filter is used. The screen of control cables must be connected
to earth on both sides with good conductivity over a large area using
screen clamps (360° earth connection).
Connection B
DC link connection: For the DC link connection the frequency inverters

must be connected via the same line potential or to a common DC source.
Connection C
Control connection: Ensure that EMC requirements are considered, par‐

ticularly when control and signal cables are laid. The control and signal
cables must be laid separately from the power cables. The screen of con‐
trol and signal cables must be connected to earth on both sides with good
C conductivity over a large area using screen clamps (360° earth connec‐
D tion). The screen of analogue signal cables must be connected to earth
at one end with the inverter.
Connection D
Motor and braking resistor: The shielded motor cable is to be connected

to the motor with a metallic PG screw fitting and to the frequency inverter
with a suitable and highly conductive clip (360° earth connection) with
earth potential. The signal cable for monitoring the motor temperature
must be laid separately from the motor cable.
Fig. 14
The frequency inverters meet the requirements of Low Voltage Directive 2006/95/EC and the requirements of EMC
Directive 2004/108/EC. EMC product standard EN 61800-3 relates to the drive unit system. The documentation
includes information how to satisfy the standards to be applied, if the frequency inverter is a components of the
drive system. The declaration of conformity must be supplied by the company installing the drive system.
214 716 44/200710
35
5.3 Block diagram
X10
S3OUT
A 1
2 X1 L1 L2 L3 + -
3
X210A
1 +24V / 180mA
2 GND 24V
S1IND
B 3
S2IND + -
C 4
S3IND
5 U, I
S4IND
6
S5IND CPU
7
X210B
S6IND
1
2 GND 24V
S1OUT
D 3
MFO1
E 4
5 +10V / 4mA
I
MFI1 A
F 6
D
7 GND 10V X2 U V W Rb1 Rb2
42393644_xml.eps
Fig. 15
CAUTION
Incorrect load for DC

The component may get damaged.
For DC, the relay contact must not be subjected to inductive load.
Operation of a 24 V DC coupling relay is not permitted.
Change-over contact: Response time approx. 40 ms

Relay connection
A Normally open: 240 V AC / 5 A (ohmic and inductive) ; 24 V DC / 5 A (ohmic load)
S3OUT
Normally closed: 240 V AC / 3 A (ohmic and inductive) ; 24 V DC / 1 A (ohmic load)
Digital input Controller enable, response time approx. 16 ms (On), 10 μs (Off)
B Digital signal:
S1IND Umax = 30 V, 10 mA at 24 V, PLC compatible
Digital input Digital signal: Response time approx.16 ms, Umax= 30 V, 10 mA at 24 V, PLC compatible
C
S2IND … S6IND Frequency signal: 0 … 30 V, 10 mA at 24 V, fmax = 150 kHz
Digital output
D Digital signal: 24 V, Imax =40 mA, PLC-compatible, overload proof and short-circuit proof
S1OUT
Digital signal: 24 V, Imax =40 mA, PLC-compatible, overload proof and short-circuit proof
Multi-function output
E Analogue signal: 24 V, Imax =40 mA, pulse width modulated, fPWM=116 Hz
MFO1
Frequency signal: 0 … 24 V, Imax = 40 mA, fmax = 150 kHz
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Multi-function input Digital signal: Response time approx.16 ms, Umax= 30 V, 0,4 mA at 24 V, PLC compatible
F
MFI1 Analogue signal: Resolution 12 Bit, 0 … 10 V (Ri = 70 kΩ), 0 … 20 mA (Ri = 500 Ω)
Tab. 11
36
5.4 Line connection
5.4.1 General
The mains fuses and cable cross-sections must be designed for the rated working point of the frequency inverter
according to EN 60204-1 or DIN VDE 0298, part 4. According to UL/CSA approved copper cables of class 1 with a
temperature range of 60/75°C must be used for the cable lengths and the corresponding mains fuses. The electrical
installation must be carried out according to the specification of the unit and to the standards and regulations to be
applied.
DANGER

Control, power supply and motor cables must be laid separately. Suitable precautions must be taken before the
cables connected to the frequency inverter are subjected to insulation tests at high test voltages.
CAUTION
Impermissible inching
Damage/malfunction of the frequency inverter
Frequency inverters may only be connected to the line supply every 60 seconds.
This means that inching of line contactors is not permitted.
214 716 44/200710
37
5.4.2 DIC-4-002 to 009 frequency inverters
Fig. 16 DIC-4-002 to 009 line connection
1 DIC-4-002 to 004; 3ph / 400 V AC 3c with wire end ferrule without plastic sleeve; 0,25
2 DIC-4-006 to 009; 3ph / 400 V AC … 1,5 mm2; AWG 22 … 16
3 Phoenix ZEC 1,5 / … ST 7,5 3d with wire end ferrule with plastic sleeve; 0,25 …
1,5 mm2; AWG 22 … 16
3a Rigid cable; 0,2 … 1,5 mm2; AWG 24 … 16
3b Flexible cable; 0,2 … 1,5 mm2; AWG 24 … 16
Frequency inverters are connected to the mains power supply via terminal strip X1: Type of enclosure IP20
(EN60529) is only ensured, when terminal X1 is plugged in.
DANGER

No power must be applied to plug-in terminal X1 which is protected against polarity reversal when it is connected
and disconnected. The mains and DC terminals may carry dangerous voltages after the frequency inverter has
been disconnected safely. Work on the unit may only be carried out after a few minutes have elapsed to allow the
link capacitors to discharge.
214 716 44/200710
38
5.4.3 DIC4-014 to 040 frequency inverters
Fig. 17 DIC4-014 to 040 line connection
1 DIC-4-014 to 040; 3ph / 400 V AC 3 DIC-4-025 to 040; WAGO series 745 / 16 mm2 /
2 DIC-4-014 to 017; WAGO series 745 / 6 mm2 / RM10+15
RM7.5 3a Rigid cable; 0,2 … 16 mm2; AWG 24 … 6
2a Rigid cable; 0,2 … 6 mm ; AWG 24 … 10
2
3b Flexible cable; 0,2 … 16 mm2; AWG 24 … 6
2b Flexible cable; 0,2 … 6 mm2; AWG 24 … 10 3c with wire end ferrule without plastic sleeve; 0,25
2c with wire end ferrule without plastic sleeve; 0,25 … 10 mm2; AWG 22 … 8
… 4 mm2; AWG 22 … 12 3d with wire end ferrule with plastic sleeve; 0,25 …
2d with wire end ferrule with plastic sleeve; 0,25 … 10 mm2; AWG 22 … 8
4 mm2; AWG 22 … 16
DANGER

No power must be applied to connection terminal X1 when it is connected and disconnected. The mains and DC
terminals may carry dangerous voltages after the frequency inverter has been disconnected safely. Work on the
unit may only be carried out after a few minutes have elapsed to allow the link capacitors to discharge.
214 716 44/200710
39
X1
1 a
L1 L2 L3 - +
b
c
2,5 Nm
L1 L2 L3 PE 22 lb-in
d
42393944_xml.eps
Fig. 18 DIC 4-045 to 060 line connection
1 DIC-4-045 to 060; 3ph / 400 V AC 2c with wire end ferrule without plastic sleeve; 1,0 …
2 Phoenix MKDSP 25 / 6-15.00-F 25 mm2; AWG 18 … 4
2a Rigid cable; 0,5 … 35 mm2; AWG 20 … 2 2d with wire end ferrule with plastic sleeve; 1,5 … 25
mm2; AWG 16 … 4
DANGER

No power must be applied to connection terminal X1 when it is connected and disconnected. The mains and DC
terminals may carry dangerous voltages after the frequency inverter has been disconnected safely. Work on the
unit may only be carried out after a few minutes have elapsed to allow the link capacitors to discharge.
214 716 44/200710
40
X1
X1 L1 L2 L3 - +
L1 L2 L3 PE
10 Nm
89 lb-in
42394044_xml.eps
Fig. 19 DIC 4-075 to 110 line connection
1 DIC-4-075 to 110; 3ph / 400 V AC
Line connection: stud bolt M8 x 25; conductor cross section up to 70 mm2
DANGER

No power must be applied to the X1 connection studs when they connected and disconnected. The connection
studs and the DC terminals may still bear dangerous voltages even after the frequency inverter has been properly
disconnected. Work on the unit may only be carried out after a few minutes have elapsed to allow the link capacitors
to discharge.
214 716 44/200710
41
5.5 Motor connection
5.5.1 General
The motor and the braking resistor (Rb) must be connected to terminal X2 of the frequency inverter via screened
cables which must be connected to the PE potential on both ends with a good conductivity. Control, power supply
and motor cables must be laid separately. Depending on the application, the motor cable length and modulation
frequency, the limit values of national and international regulations must be complied with.
Frequency inverters ≤ DIC-4-017 with integrated EMC filter comply with the emission limit values of the product
standard EN 61800-3, for a motor cable length of up to 10 m. Optional filters can be used to meet any customer-
specific requirements.
Owing to the design, frequency inverters produce voltage peaks and switching edges which load the motor insulation
and bearings to a higher extent. Due to the edge steepness and the inverter output voltage level as well as due to
the electrical properties of the motor supply cable, voltage rises of almost two times the inverter link voltage may be
applied to the motor. The insulation of the motor winding must be designed appropriately.
Even if a du/dt filter is used, the operation of motors wihout phase insulation cannot be ensured definitively, since
the electric strength is not sufficient in many cases. However, the filter reduces the load on the motor. The use of
du/dt filters can also make it possible to achieve greater cable lengths between motors and frequency inverters.
Motor cable lengths without output filter

Frequency inverter Unscreened cables Screened cables
DIC-4-002 to 007 50 m 25 m
DIC-4-009 to 040 100 m 50 m
DIC-4-045 to 110 150 m 100 m
Tab. 12
Motor cable lengths with du/dt filter

Frequency inverter Unscreened cables Screened cables
DIC-4-002 to 007 75 m 50 m
DIC-4-009 to 040 150 m 100 m
DIC-4-045 to 110 300 m 150 m
Tab. 13
Parameter identification may not be carried out when the du/dt filter is connected.
214 716 44/200710
42
X2
X2 Rb1 Rb2 U V W
M
3~
42394144_xml.eps
Fig. 20 DIC-4-002 to 009 motor connection
1 Phoenix ZEC 1,5/ … ST7,5 1c with wire end ferrule without plastic sleeve; 0,25
1a Rigid cable; 0,2 … 1,5 mm2; AWG 24 … 16 … 1,5 mm2; AWG 22 … 16
1b Flexible cable; 0,2 … 1,5 mm2; AWG 24 … 16 1d with wire end ferrule with plastic sleeve; 0,25 …
1,5 mm2; AWG 22 … 16
DANGER

No power must be applied to plug-in terminal X2 which is protected against polarity reversal when it is connected
and disconnected. The motor terminals and the terminals of the braking resistor may carry dangerous voltages
after the frequency inverter has been released for operation. Work on the unit may only be carried out after a few
minutes have elapsed and the link capacitors have discharged.
The motor and the braking resistor are connected to the frequency inverter via plug-in terminal X2. Type of enclosure
IP20 (EN60529) is only ensured when terminal X2 is plugged in.
214 716 44/200710
43
1 DIC-4-014 to 017; WAGO series 745 / 6mm2 / 2 DIC-4-025 to 040; WAGO series 745 / 16mm2 /
RM7.5 RM10+15
1a Rigid cable; 0,2 … 6 mm2; AWG 24 … 10 2a Rigid cable; 0,2 … 16 mm2; AWG 24 … 6
1b Flexible cable; 0,2 … 6 mm ; AWG 24 … 10
2
1c with wire end ferrule without plastic sleeve; 0,25 2c with wire end ferrule without plastic sleeve; 0,25
… 4 mm2; AWG 22 … 12 … 10 mm2; AWG 22 … 8
1d with wire end ferrule with plastic sleeve; 0,25 … 2d with wire end ferrule with plastic sleeve; 0,25 …
4 mm2; AWG 22 … 16 10 mm2; AWG 22 … 8
DANGER

No power must be applied to connection terminal X2 when it is connected and disconnected. The motor terminals
and the terminals of the braking resistor may carry dangerous voltages after the frequency inverter has been
released for operation. Work on the unit may only be carried out after a few minutes have elapsed and the link
capacitors have discharged.
214 716 44/200710
44
X2
X2 U V W Rb1 Rb2
a
M
3~
b
2,5 Nm
c 22 lb-in
d
42394344_xml.eps
1 DIC-4-045 to 060; WAGO series 745 / 6mm2 / 1c with wire end ferrule without plastic sleeve; 1,0 …
RM7.5 25 mm2; AWG 18 … 4
1a Rigid cable; 0,5 … 35 mm2; AWG 20 … 2 1d with wire end ferrule with plastic sleeve; 1,5 … 25
1b Flexible cable; 0,5 … 25 mm ; AWG 20 … 4
2 mm2; AWG 16 … 4
DANGER

No power must be applied to connection terminal X2 when it is connected and disconnected. The motor terminals
and the terminals of the braking resistor may carry dangerous voltages after the frequency inverter has been
released for operation. Work on the unit may only be carried out after a few minutes have elapsed and the link
214 716 44/200710
45
X2
X2 U V W Rb1 Rb2
M
3~
10 Nm
89 lb-in
42394444_xml.eps
Line connection: stud bolt M8 x 25; conductor cross section up to 70 mm2
DANGER

No power must be applied to the X2 connection studs when they are connected and disconnected. The motor
terminals and the terminals of the braking resistor may carry dangerous voltages after the frequency inverter has
been released for operation. Work on the unit may only be carried out after a few minutes have elapsed and the
link capacitors have discharged.
214 716 44/200710
46
5.6 Control terminals
5.6.1 General
Fig. 24 Control terminals
1 Wieland DST85 / RM3.5 1c with wire end ferrule without plastic sleeve; 0,25
1a Rigid cable; 0,14 … 1,5 mm2; AWG 30 … 16 … 1,0 mm2; AWG 22 … 18
0,75 mm2; AWG 22 … 20
The control and software functions can be freely configured to ensure safe and efficient operation. These operating
instructions describe the factory setting of the standard connections in the corresponding Configuration 30 and
the software parameters for setting.
CAUTION
Incorrect connection/disconnection of the control terminals

Damage/malfunction of the frequency inverter
No power must be applied to the control inputs and outputs which are protected against polarity reversal when they
are connected and disconnected.
Terminal Description of control terminal X210A

X210A.1 Voltage output 24 V, Imax = 180 mA 9)
X210A.2 Ground / GND
X210A.3 Digital input S1IND, Umax = 30 V, 10 mA at 24 V, PLC compatible, response time approx. 16 ms (on), 10 μs (off)
X210A.4 Digital input S2IND, Umax = 30 V, 10 mA at 24 V, PLC compatible, response time approx. 16 ms
X210A.5 Digital input S3IND, Umax = 30 V, 10 mA at 24 V, PLC compatible, response time approx. 16 ms
X210A.6 Digital input S4IND, Umax = 30 V, 10 mA at 24 V, PLC compatible, frequency signal, 0 … 30 V, 10 mA at 24 V, fmax = 150 kHz
X210A.7 Digital input S5IND, Umax = 30 V, 10 mA at 24 V, PLC compatible, frequency signal, 0 … 30 V, 10 mA at 24 V, fmax = 150 kHz
Terminal Description of control terminal X210B
X210B.1 Digital input S6IND, Umax = 30 V, 10 mA at 24 V, PLC compatible, response time approx. 16 ms
X210B.2 Ground / GND 24 V
X210B.3 Digital output S1OUT, U = 24 V, Imax = 40 mA, overload and short-circuit-proof
X210B.4 Multi-function output MFO1,
digital signal: 24 V, Imax =40 mA, PLC-compatible, overload proof and short-circuit proof,
Analogue signal: 24 V, Imax =40 mA, pulse width modulated, fPWM=116 Hz
Frequency signal: 0 … 24 V, Imax = 40 mA, fmax = 150 kHz
X210B.5 Reference output 10 V, Imax = 4 mA
X210B.6 Multi-function input MFI1,
Analogue signal, resolution 12 Bit, 0 … +10 V (Ri = 70 kΩ), 0 … 20 mA (Ri = 500 Ω)
Digital signal, response time approx. 16 ms, Umax = 30 V, 0,4 mA at 24 V, PLC compatible
X210B.7 Ground / GND
Tab. 14
214 716 44/200710
9) The power supply on terminal X210A.1 can be loaded with a max. current of I
max = 180 mA. Depending on the application, the max. available
current is reduced by digital output S1OUT and multi-function output MFO1. 47
5.6.2 Relay output S3OUT
1
X10
a
X10
1 b
2 S3OUT
3 c
42394644_xml.eps
Fig. 25 Relay output S3OUT
1 Phoenix ZEC 1,5/3ST5,0 1c with wire end ferrule without plastic sleeve; 0,25
1a Rigid cable; 0,2 … 1,5 mm ; AWG 24 … 16
2 … 1,5 mm2; AWG 22 … 16
1,5 mm2; AWG 22 … 16
The freely programmable relay output is linked to the brake release function by default.
Terminal Description of control terminal X10

1…3 Relay output, floating changeover contact, response time approx. 40ms, max. contact load
- Normally open: 240 V AC / 5A (ohmic and inductive); 24 V DC / 5A (ohmic)
- Normally closed: 240 V AC / 3A (ohmic and inductive); 24 V DC / 1A (ohmic)
Tab. 15
CAUTION
Incorrect load of the relay contact

Damage/malfunction
For DC, the relay contact must not be subjected to inductive load. Operation of a 24 V DC coupling relay is not
permitted.
5.6.3 Control terminals – connection diagram
The control hardware and software of the frequency inverters can be configured almost freely, this means that certain
functions can be assigned to the control connections.
The modular concept therefore makes it possible to adapt the frequency inverter to a wide variety of drive applica‐
tions.
The requirements to the control hardware and software are known for established drive applications. Thus certain
functions can be assigned to control connections and the internal interconnection of the software modules can be
configured. These assignments can be selected by means of the Configuration 30 (CONF) parameter.
214 716 44/200710
48
5.6.4 Configurations 1xx and 4xx - without encoder
Control terminal X210A

X210A.1 Supply voltage
X210A.2 GND
X210A.3 Controller release / acknowledge fault
X210A.4 programmable, SW-step 1+
X210A.5 programmable, SW-step 1-
X210A.6 freely programmable
X210A.7 freely programmable
Control terminal X210B
X210B.1 programmable, (SOST) step 2 / (SOSP) accelerate
X210B.2 GND
X210B.3 programmable, (digital) Ready message
X210B.4 programmable, Error (digital message)
X210B.5 Supply, reference value potentiometer
X210B.6 programmable, analogue setpoint voltage value
X210B.7 GND
Tab. 16
Fig. 26
5.6.5 Configurations 2xx – with encoder
Control terminal X210A

X210A.1 Supply voltage
X210A.2 GND
X210A.3 Controller release / acknowledge fault
X210A.4 programmable, SW-step 1+
X210A.5 programmable, SW-step 1-
X210A.6 Rotary encoder channel B 10)
X210A.7 Rotary encoder channel A 10)
Control terminal X210B
X210B.1 programmable, (SOST) step 2 / (SOSP) accelerate
X210B.2 GND
X210B.3 programmable, (digital) Ready message
X210B.4 programmable, Error (digital message)
X210B.5 Supply, reference value potentiometer
X210B.6 programmable, analogue setpoint voltage value
X210B.7 GND
Tab. 17
Fig. 27
For further information on connection of the different rotary encoders to the basic unit as well as to the optional EM
– UNI-01 extension module, please refer to ⇒ "Selection of the pulse generator and interface electronics",
Page 227.
214 716 44/200710
10) The signal level must be 24V. Rotary encoder signal only effective if Operation mode encoder 1 490 is not at "0 – Off". 49
5.7 Hardware modules
5.7.1 General
Due to the modular hardware components frequency inverters can easily be integrated into the automation concept.
Optional hardware modules are detected during initialisation and the control functions are adapted automatically.
For the necessary information on the installation and operation of the optional extensions, please refer to the asso‐
ciated documentation.
⇒ "Fitting CM-xxx and EM-xxx hardware modules", Page 32
Hardware modules
A KP500 operating unit

KP232 Interface adapter
Connection of the optional KP500 operating unit or a KP232 interface adapter.
B CM communication module
Socket for interfacing to different communication protocols:
CM – 232: RS232 interface
CM – 485: RS485 interface
CM – PDP-24: Profibus DP interface
CM – CAN: CANopen interface
C EM extension module
Socket for customer-specific adaptation of the control inputs and outputs to different appli‐
cations:
EM – UNI-01: additional rotary encoder evaluation (RS-422), analogue and digital
inputs or outputs, PTC thermistor evaluation, system bus, semi-con‐
ductor relay
Tab. 18
Fig. 28
DANGER

Only carry out installation and dismantling work on the hardware modules of sockets B and C once the frequency
inverter concerned has been disconnected. Work on the unit may only be carried out after a few minutes have
elapsed to allow the link capacitors to discharge.

● If two optional components with a CAN protocol controller (e.g. CM – CAN and EM – UNI-01) are installed, the
system bus interface in the EM extension module is deactivated.
214 716 44/200710
50
6 KP500 operating unit
6.1 Key assignment and displays
Fig. 29 Key assignment and displays
Parameters can be set and displayed and the frequency inverter can be controlled by means of the optional KP500
operating unit. The operating unit is not absolutely necessary for the operation of the frequency inverter and can be
plugged in during operation, if required.
Keys
A RUN Start the drive and change into the CTRL menu. Press the RUN key to access the motor potentiometer function.
STOP Change into the CTRL menu and stop the drive. Acknowledge the fault.
J ▲▼ Navigate in the menu structure and select parameters. Increase and decrease parameter values.
ENT Call parameters or change within the menu structure. Acknowledge the selected function or parameter.
ESC Exit parameters or return within the menu structure. Abort the function or reset the parameter value.
FUN Change key functions and access special functions.
Tab. 19
Display
B Three-digit 7-segment display of the parameter number, if a password display cod has been assigned ⇒ „Set password“, Page 71
C One-digit 7-segment display of the active data set, direction of rotation etc.
D Display the selected sub-menu:
VAL Display actual values
PARA Select parameters and edit parameter values
CTRL Select functions which can be used via the operating unit:
SEtUP: guided setup
CTRL: Motor potentiometer and jog function
CTRL cannot be selected if the „REM“ display is active.
CPY Parameter copy function via the operating unit:
ALL All parameter values are copied
FOr Memory in the operating unit is formatted or deleted
E Status and operational messages:
WARN Warning against critical operating behaviour
FAULT Fault switching-off, with the associated message
RUN Flashing: indicates readiness for operation
Continuously on: indicates operation and release of the output stage
REM Active remote control via interface connection
Statemachine or remote contacts via Local/Remote 412 is activated. CTRL sub-menu is not possible.
See also ⇒ „Control menu (CTRL)“, Page 58.
F Change of functions by means of FUN key
F Five-digit 7-segment display of the parameter value and sign
G Physical unit of the parameter value displayed
H Active acceleration or deceleration ramp
I Current direction of rotation of the drive
Tab. 20
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51
6.2 Menu structure
42395144_xml.eps
Fig. 30
The menu structure is arranged on the operating unit according to the graphical overview. The PC user interface
divides the functions and parameters into different levels. Complete information is saved in the software and allows
the flexible use of the options for programming and controlling the frequency inverter.
6.3 Main menu

Sub-menu Function
VAL Display of actual values
PARA Display and change parameters
CPY Parameter copy function
CTRL Selection of control and test functions
Tab. 21
Fig. 31
The various frequency inverter parameters and information can be displayed by means of the operating unit. The
various functions and parameters are grouped in four sub-menus in the menu structure depending on the subject.
Press the ESC key for a longer time or several times to return to the main menu within the menu structure.
Select the required sub-menu by using the arrow keys. The selected sub-menu flashes in the display. Press the ENT
key to select the sub-menu. The display changes to the first parameter or to the first function in the selected sub-
menu. Pressing the ESC key returns to the main menu of the operating unit.
Keys
▲+▼ Navigate the menu structure and select a sub-menu.
ENT Change to the selected sub-menu
ESC Exit the sub-menu and return to the main menu.
Tab. 22
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52
6.4 Actual value menu (VAL)
ESC
ENT
A ENT
ESC
D
B C
42395344_xml.eps
Fig. 32 Actual value menu (VAL)
In the VAL sub-menu, the operating unit displays many actual values depending on the configuration selected and
on the options installed. The operating instructions show the parameters and basic functions of the software which
are linked to the corresponding actual value.
A You select the desired number from the actual values displayed in numerical order by means of the arrow keys. If data sets of actual
value parameters can be changed, the current data set is displayed with the associated data set number. The 7-segment display
shows data resetcord 0, if the actual values of the four data sets are equal.
Keys
▲+▼ Change to the actual value parameter when switching on
FUN , ▲ Display last actual value parameter (highest number)
FUN , ▼ Display first actual value parameter (smallest number)
B By pressing the ENT key you select the actual value which is displayed with the current parameter value, unit and active data set.
C During putting into service and operation and fault analysis, it is possible to monitor each actual value parameter in detail. The actual
value parameters are partially arranged in the four available data sets. If the parameter values in the four data sets are identical, the
actual value is displayed in data set 0. Different actual values in the four data sets are displayed in data set 0 by the display dIFF.
Keys
▲,▼ Change of data set when actual values can be changed
FUN , ▲ Maximum actual value is continuously determined and displayed
FUN , ▼ Minimum actual value is continuously determined and displayed
FUN , ENT Mean value of the actual value during the monitoring period
D By pressing the ENT key, the selected actual value is saved as a parameter when the unit is switched on. The SEt message with the
parameter number appears for a short time. This actual value will be automatically displayed when the frequency inverter is switched
on in future.
E You can monitor and display the value again when the parameter has been saved. Press the ESC key to change into the parameter
selection section of the VAL sub-menu.
Tab. 23
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53
6.5 Parameter menu (PARA)
ESC
ENT
A ENT
ESC
D
B C
42395444_xml.eps
Fig. 33 Parameter menu (PARA)
The parameters polled during guided set-up have been selected from existing applications and should be supple‐
mented by further settings in the PARA sub-menu, if required.
If cod is displayed instead of the parameter number, this indicates that a password has been set in the Dedrive
Compact ⇒ "Set password", Page 71.
A You select the desired number from the parameters displayed in numerical order by means of the arrow keys. If data sets of parameters
can be changed, the current data set is displayed with the associated data set number. The 7-segment display shows data set 0, if
the parameter values of the four data sets are equal.
Keys
▲+▼ Change to the parameter changed at last
FUN , ▲ Display last parameter (highest number)
FUN , ▼ Display first parameter (smallest number)
B By pressing the ENT key you select the parameter which is displayed with the current parameter value, unit and active data set.
Settings in data set 0 change the parameter values in the four data sets.
C The parameter value can be adapted using the arrow keys. Depending on the parameter, the value must be changed or an operation
mode be selected. Pressing the arrow keys for a longer period of time increases the changed value. After an interruption the speed
of change is reduced to one tenth of the difference in value reached before. When the parameter value starts flashing, the increment
has been reset to the original value.
Keys
▲ +▼ The parameter is set to the factory setting.
FUN , ▲ The parameter is set to the highest value.
FUN , ▼ The parameter is set to the smallest value.
FUN , ENT Change of data set when parameters can be changed
D By pressing the ENT key, the selected actual value is saved as a parameter when the unit is switched on. The SEt message with the
parameter number appears for a short time. This actual value will be automatically displayed when the frequency inverter is switched
on in future.
Messages
Err1: EEPrO Parameter could not be saved
Err2: STOP Parameter can only be read during operation
Err3: Error Other error
E Once the parameter has been saved, you can change the value again if you wish, or else you should press the ESC key to switch to
parameter selection.
Tab. 24
214 716 44/200710
54
6.6 Copy menu (CPY)
6.6.1 General
The copy function of the operating unit makes it possible to copy parameter values from the frequency inverter to a
non-volatile memory (upload) in the operating unit and to download the values to a frequency inverter.
The copy function facilitates the programming of parameters for repeated applications. The function files all param‐
eters independent of the access control and the value range. The memory capacity available for four files in the
operating unit is scaled dynamically according to the scope of data.
● This function is only available in control level 3.

● Downloading is not possible with set hardware enable (FUF).
6.6.2 Reading the memory infomation
Information on the data saved in the operating unit must be read out when
the CPY sub-menu is called up. This process will take some seconds.
During this period init and a progress display are displayed. After initiali‐
sation, the function can be selected in the copy menu.
42395544_xml.eps
Fig. 34
If the memory information saved in the operating unit is not valid, initiali‐
sation is aborted with an error message. In this case, the memory in the
operating unit must be formatted. Please carry out the following steps:
42395649_xml.eps
Fig. 35
Confirm the error message by pressing the ENT key.
Select the FOr memory formatting function and confirm the selection by
means of the ENT key.
During formatting the display shows FCOPY and a progress display.
42395744_xml.eps
Fig. 36
After a few seconds the process is finished. The display shows rdY.
Confirm the display by pressing the ENT key.
42395844_xml.eps
Fig. 37
Now you can continue to select the copy function.
42395944_xml.eps
214 716 44/200710
Fig. 38
55
6.6.3 Menu structure
The copy menu CPY is divided into two basic partial functions. You can select between the memory function and
deleting the saved data by means of the arrow keys. The source and the destination must be selected for this process.
The three-digit 7-segment display provides information on the available memory capacity in the non-volatile memory
of the operating unit.
FOr function
The FOr function can be used to format and delete the memory in the
operating unit. This may be necessary when the operating unit is used for
the first time.
42396044_xml.eps
Fig. 39
ALL function
All parameter values which can be written or read are transferred. For a
normal copy operation confirm this selection by means of the ENT key
and continue by selecting the source.
42396144_xml.eps
Fig. 40
Act function
Only the parameters of the current configuration are transferred.
6.6.4 Selecting the source
The partial function ALL in the CPY sub-menu can be programmed for specific applications. You select the source
of data for the copy operation (upload) from the sources being available by means of the arrow keys. The 7-segment
display shows the available memory capacity in the operating unit.
The data sets in the inverter are marked with a number between 0 and 4. The 0 here stands for all data sets and 1
to 4 for the individual data set. The memory locations in the operating unit are designated F1 to F4.
Display Description
Src. 0 The data of the four data sets are copied from the frequency inverter.
Src. 1 The data from data set 1 are copied.
Src. E An empty data set for deleting a file in the operating unit
Src. F1 File 1 is transferred from the memory
Tab. 25
Example 1:
All data sets from the frequency inverter are to be saved in file 1 of the operating unit:
Thus the source is SRc 0 and the destination is dSt F1.
Example 2:
The content of file 1 of the operating unit is to be reloaded to all data sets of the inverter.
Thus the source is SRc F1 and the destination is dSt 0.
214 716 44/200710
56
6.6.5 Selecting the destination
The parameters of the destination for the copy operation can also be set specifically for the application. The data
source is transferred to the selected destination (download). The destinations that are available correspond to the
logical assignment of the selected data source.
Display Description
dSt. 0 The four data sets of the frequency inverter are overwritten.
dSt. 1 The data are copied to data set 1.
dSt. F1 The data are transferred to file 1.
Tab. 26
6.6.6 Copy operation
WARNING
Parameter values outside the value range

The value range and parameter setting may be different depending on the power range of the frequency inverter.
The transfer of parameter values outside the value range results in an error message.
Before transferring the parameter setting to the frequency inverter, the individual parameter values must be
checked.
A copy operation should only be carried out between frequency inverters with the same "current code".
e.g. 014 for DIC-4-014-E-0000-00
During the copy operation the display shows COPY and the number of
the parameter currently being copied as progress display. Parameters will
also be copied which have no importance for the configuration selected.
42396244_xml.eps
Fig. 41
After approx. 100 seconds the copy operation is completed and the dis‐
play shows rdY.
The display changes to the copy menu when the ENT key is pressed and
to selection of the destination when the ESC key is pressed.
42396344_xml.eps
Fig. 42
If the ESC key is pressed during the copy operation, the copy operation
is aborted and the data are transferred incompletely. The display shows
Abr and the number of the last parameter which has been copied.
By pressing the ENT key you return to the selection in the copy menu and
by pressing the ESC key to the selection of the destination.
214 716 44/200710
42396444_xml.eps
A reset is carried out automatically after data has been copied from the
Fig. 43
operating unit to the Dedrive Compact unit.
57
6.6.7 Error messages
The copy function files all parameters independent of the access control
and the value range. Some of the parameters can only be written when
the frequency inverter is not in operation. The controller enable (S1IND)
must not be activated while parameters are being copied, as otherwise
data transmission will be aborted. The display shows FUF and the number
of the last parameter which has been copied. If the control enable is de-
42396544_xml.eps
activated, the aborted copy operation is continued.
Fig. 44
Data transmission from the source selected to the destination is continu‐

ously monitored by the copy function. If an error occurs, the copy opera‐
tion is aborted and the Err message is displayed with an error code.
42396644_xml.eps
Fig. 45
Error messages
Code Meaning
0 1 Write error in the memory of the operating unit;
repeat the copy operation or format the memory if multiple errors occur.
2 Read error in the memory of the operating unit;
repeat the copy operation or format the memory if multiple errors occur.
3 The memory capacity of the operating unit has been determined incorrectly;
if this error occurs several times, the operating unit must be replaced.
4 Insufficient memory, incomplete data;
delete the incomplete file and any data that is no longer required from the operating unit.
5 Communication has been disrupted or interrupted;
repeat the copy operation, delete the incomplete file, if required.
1 0 Invalid identifier of a file in the operating unit;
delete the corrupt file and format the memory, if required.
2 The memory location for the selected target file is full;
delete the file or use a different target file in the operating unit.
3 The source file to be read in the operating unit is empty;
only select files as source which contain useful data.
4 Corrupt file in the operating unit;
2 0 The memory of the operating unit is not formatted;
Run the format function in the copy menu.
3 0 Read error of a parameter from the frequency inverter;
check the connection and repeat the read operation.
1 Write error of a parameter from the frequency inverter;
check the connection and repeat the write operation.
2 Unknown parameter type;
4 0 Communication has been disrupted or interrupted;
repeat the copy operation, delete the incomplete file, if required.
Tab. 27
6.7 Control menu (CTRL)

The frequency inverter can be controlled by means of the operating unit. Select various functions in the CTRL sub-
menu to facilitate putting the unit into operation and for controll via the operating unit.
Control of the frequency inverter via an optional communication module must be set by means of the
Local/Remote 412 parameter. The parameter can be used for the selecting or limiting the control possibilities
being available. Depending on the operation mode selected, the control menu is only available to a limited extent.
Operation modes 412 Function

214 716 44/200710
0- Control via Contacts The start and stop command and the specification of the direction of rotation are transmitted via digital
signals.
1- Control via Statemachine The start and stop command and the specification of the direction of rotation are transmitted via the DRIV‐
ECOM state machine of the communication interface.
58
Operation modes 412 Function
2- Control via Remote-Contacts The start and stop command and the specification of the direction of rotation are transmitted via logic
signals through the communication protocol.
3- Ctrl. KP, direction contacts The start and stop command is specified via the operating unit and the direction of rotation is specified via
digital signals.
4- Ctrl. KP or Cont., direction cont. The start and stop command is specified via the operating unit or via digital signals. The direction of rotation
is only specified via digital signals.
13 - Control via KP, Direction KP The start and stop command and the direction of rotation are specified via the operating unit.
14 - Control KP+Cont., Direction KP The start and stop command is specified via the operating unit or via digital signals. The direction of rotation
is only specified via the operating unit.
20 - Control Contacts, Clockw. The start and stop command is transmitted via digital signals. The direction of rotation is set to clockwise
rotation only.
23 - Control Keypad, Clockw. The start and stop command is specified via the operating unit. The direction of rotation is set to clockwise
rotation only.
24 - Control Cont. + KP, Clockw. The start and stop command is specified via the operating unit or via digital signals. The direction of rotation
is set to clockwise rotation only.
30 to 34 Operation mode 20 to 24, only anti-clockwise rotation
43 - Crtl. KP, Dir. Cont. + KP The start and stop command is specified via the operating unit. The direction of rotation is specified via the
operating unit or via digital signals.
44 - Crtl. Cont. + KP, Dir. Cont. + KP The start and stop command and the direction of rotation are specified via the operating unit or via digital
(factory setting) signals.
Tab. 28
DANGER
Non-compliance with operating regulations

There is danger to life and limb and of considerable material damage.
The control of the drive via the operating unit requires the release of the power module via digital input control
enable S1IND. Only qualified persons may work on the devices. Qualified persons must be familiar with installation,
assembly, putting into operation and operation and have the necessary qualification for their task. Carefully read
the documentation before starting work and follow the safety instructions.
6.8 Controlling the motor via the operating unit

The operating unit enables control of the connected motor depending on the operation mode selected by means of
the Local/Remote 412 parameter.
DANGER
Non-compliance with operating regulations

The control of the drive via the operating unit requires the release of the power module via digital input control
enable S1IND. Only qualified persons may work on the devices. Qualified persons must be familiar with installation,
assembly, putting into operation and operation and have the necessary qualification for their task. Carefully read
the documentation before starting work and follow the safety instructions.
Navigate to the CTRL sub-menu within the menu structure. The CtrL
function includes sub-functions that are displayed according to the oper‐
ating point of the frequency inverter. Press the RUN key to go from any
point within the menu structure to motor potentiometer function Pot, or
internal reference value int.
42396744_xml.eps
Fig. 46
Motor potentiometer function Pot
Use the cursor keys to set the output frequency of the frequency inverter
214 716 44/200710
from the minimum frequency 418 up to the maximum frequency

419. The acceleration corresponds to the factory setting (2 Hz/s) of the
Ramp Keypad-Motorpoti 473 parameter. The Acceleration 420
42396844_xml.eps
Fig. 47 59
and Deceleration 421 parameters are considered at lower
acceleration values.
Internal reference value int
The drive is operating and the current actual value is displayed. Use the
cursor keys to change to the Pot motor potentiometer function, which will
cause the current value for the frequency to be accepted.
42396944_xml.eps
Fig. 48
JOG frequency JOG
Press the FUN key to change from internal reference value int, or motor
potentiometer function Pot to the JOG frequency 489. The frequency
can be set by means of the arrow keys. When the FUN key is released,
the drive stops and the display changes to the original function Pot or
42397044_xml.eps int. The last frequency value is saved in the JOG frequency 489 pa‐
Fig. 49 rameter.
Key functions
ENT Switch over the direction of rotation independent of the control signal on the terminals clockwise rotation S2IND or anti-clockwise rotation
S3IND.
ESC Exit function and return to the menu structure
FUN Pressing the key changes to the JOG frequency and starts the drive. Releasing the key changes to the subordinate function and stops
the drive.
RUN Start drive, alternative to the control signal SW-Step 1 + or SW-Step 1 –
STOP Stop drive, alternative to the control signal SW-Step 1 + or SW-Step 1 –
Tab. 29
DANGER
Possible change of the direction of rotation

Pressing the ENT key results in a change of the direction of rotation independent of the control signal SW-Step 1
+ or SW-Step 1–. If the minimum frequency 418 has been set to 0 Hz, a change in the sign of the frequency
reference value produces a change in the direction of rotation of the motor.
214 716 44/200710
60
7 Putting into operation in practice
7.1 General
DANGER
Unintended start-up of the drive

Risk of death
When programming Dedrive Compact parameters via a KP500 control unit or the Parcom Compact parameter
programming software, settings may be selected which cause unintended start-up of the drive.
This applies both for manual parameter programming and for loading of a parameter file.
These instructions also apply to programming parameters via the CAN bus or Profibus.
In order to avoid unintended start-up of the drive, controller enable on input S1IND MUST be de-activated while
parameters are being programmed.
Controller enable on input S1IND must only be activated following the "FUF" message for the duration of parameter
identification by the motor.
Take further suitable measures to avoid unintended start-up of the drive or transmission of critical control com‐
mands between Dedrive Compact and the installation. These may be, for example, disconnecting the control
terminals (e.g. X210A, X210B, X10 …) or switching of the supply voltage for the electrical brake.
Depending on the application, further additional safety devices must be provided in order to avoid any hazard for
persons and machinery.
The following sections describe how to proceed with the KP500 operating unit.
When the unit is put into operation with Parcom Compact, the parameters must be called up and processed indi‐
vidually before the "Read inverter information" function is called up.
7.2 Switching on the power supply

Please observe the safety instructions ⇒ "Safety instructions", Page 15 and ⇒ "General", Page 61.
Once the installation work has been completed, you should check all control and power connections again before
turning on the mains voltage. If all the electrical connections are correct, it is necessary to ensure that you switch
off the controller enable of the frequency inverter (control input S1IND open). After the mains is switched on, the
frequency inverter carries out a self-test and reports "Fault" during this short period.
The frequency inverter concludes the self-test after a few seconds.
When controller enable has been applied to control input S1IND, the frequency inverter activates the "Ready" digital
signal (to digital output S1OUT by default).
Guided set-up is automatically carried out when the unit is first supplied and when it is reset to the default settings.
The control unit displays menu item "SEtUP" from the CTRL sub-menu.
7.3 Set-up by means of the operating unit
7.3.1 General notes on set-up
Please observe the safety instructions ⇒ "Safety instructions", Page 15 and ⇒ "General", Page 61.
Guided set-up of the frequency inverter determines all the relevant parameter settings for the desired application.
Once the SETUP routine has been successfully concluded, the Actual frequency 241 actual value from the VAL
sub-menu is subsequently displayed in the control unit. Subsequently the user should check whether further pa‐
rameters are relevant for the application.
Incorrect parameter setting

● Guided set-up includes the function for parameter identification. The parameters are determined by measure‐
ment and set accordingly. The motor should be cold on starting the measurement since some of the motor data
214 716 44/200710
depend on the operating temperature.
61
The "SEtUP" guided set-up display automatically appears when the unit
is first supplied and after parameter identification has been aborted.
Following successful set-up you can select the CTRL sub-menu in the
main menu and call up the "SEtUP" function again by means of the arrow
keys.
Confirm the "SEtUP" display by pressing the ENT key.
Depending on the selected Control level 28, the configurations being

available are automatically displayed. The configurations are described
in the following chapter of the operating instructions. Select the number
of the desired configuration by means of the arrow keys and confirm the
ENT selection by means of the ENT key.
If the configuration has been changed, the hardware and software func‐
tions are configured and the inverter is re-initialised. Guided "SEtUP"
starts again from the beginning. Please confirm the configuration by
pressing the ENT key.
ENT
42397144_xml.eps
Fig. 50
7.3.2 Configuration
The Configuration 30 parameter determines the assigment and basic function of the control inputs and outputs
and the software functions. The frequency inverter software offers several configurations for selection. The major
difference between the configurations is how to control the drive. In the operating instructions the following config‐
urations and associated parameters are described in the third Control level 28.
Configuration 110 – V/f without encoder
Configuration 110 includes the functions for the variable speed control of
a motor.
Detailed description of the configuration ⇒ "Configuration", Page 72.

42397244_xml.eps
Fig. 51
Configuration 111 – V/f with technology controller
Configuration 111 extends the V/f characteristic by software functions

which facilitate adaptation to customer requirements for different appli‐
cations
42397344_xml.eps
Fig. 52
Configuration 210 – FOR speed control with encoder
Configuration 210 includes the functions for the variable-speed field-ori‐

ented regulation of a motor with rotary encoder feedback.

42397444_xml.eps
Fig. 53
Configuration 230 – FOR N or M controlled
Configuration 230 extends configuration 210 by the functions for the field-
oriented regulation depending on the torque.
214 716 44/200710

42397544_xml.eps
Fig. 54
62
Configuration 410 – FOR speed control without encoder
Configuration 410 includes the functions for the field-oriented regulation

of a motor without encoder.

42397644_xml.eps
Fig. 55
Configuration 430 – FOR speed without encoder N or M controlled
Configuration 430 extends configuration 410 by the functions for the field-
oriented regulation depending on the torque.

42397744_xml.eps
Fig. 56
7.3.3 Data set
After configuration, selection of the data set is displayed. Select the re‐
quired Data set ds with the cursor keys and confirm with the ENT key.
The Data set dS parameter makes it possible to select between four

data sets to save the parameter settings.
42397844_xml.eps
Fig. 57
Data sets 1 to 4 are saved with the same parameter values in data set 0 (factory setting). The standard application
of the frequency inverter uses data set 1 without utilising any change-over between data sets.
Parameter setting Data set dS Function

0 All data sets (DS0)
1 Data set 1 (DS1)
2 Data set 2 (DS2)
3 Data set 3 (DS3)
4 Data set 4 (DS4)
Tab. 30
7.3.4 Motor data
The motor data that is input in the following guided set-up sequence must
be taken from the rating plate and the data sheet of the motor. The motor
data set in the factory refer to the rated data of the frequency inverter. The
other motor data required for the control and regulation processes are
calculated from the settings made during the setup which are checked for
plausibility.
42397944_xml.eps
Fig. 58
The rated values used in the factory settings must be checked and, if necessary, changed by the user. Change the
values with the cursor keys and confirm entry with the ENT key.
For Demag ZBA motors with a wide voltage range, e.g. 380 – 400 V, enter the smaller of the two voltages as
Rated voltage 370.
Parameter identification may provide an unsatisfactory result for motors with a cyclic duration factor (CDF) of 60%
or 40%. In such cases, the motor may run unevenly and tend to vibrate. In such cases, the
Cyclic duration factor 812 parameter must be set to the value stamped on the motor. A new parameter
identification run must then be carried out.
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If motors with a CDF of 60% or 40% are operated with calculated 100% rated data, the
Cyclic duration factor 812 parameter must be set to 100%.
63
Parameters Setting
No. Description Min. Max. Factory set.
370 Rated voltage 0,17 * UFUN 2 * UFUN UFUN
371 Rated current 0,01 * IFUN 10 * ü* IFUN IFUN
372 Rated speed 96 rpm 60000 rpm nN
374 Rated cosinus Phi 0,01 1,00 cos(φ)N
375 Rated frequency 10,00 Hz 1000,00 Hz 50,00 Hz
376 Rated mech. power 0,01 * PFUN 10 * PFUN PFUN
812 Cyclic duration factor 40 - 40% CDF 100 - 100% CDF 100 - 100% CDF
490 Operation mode encoder 1 1 - single 4 - quadruple 0 - off
491 Division marks encoder 1 1 8192 1024
493 Operation mode encoder 2 1 - single 4 - quadruple 0 - off
766 Source Actual Speed 1 - Encoder 1 2 - Encoder 2 2 - Encoder 2
Tab. 31
7.3.5 Rotary encoder data
Configurations 210 and 230 of the field-oriented regulation require the connection of an incremental rotary encoder.
The channel signals of the rotary encoder must be connected to the digital inputs S5IND (channel A) and S4IND
(channel B).
The Operation Mode Encoder 1 490 defines the way in which the signals are scanned.
A further encoder input is available when an extension module is fitted. It is programmed by means of the
Operation Mode Encoder 2 493 parameter.
For further information on the rotary encoder please refer to ⇒ "Rotary encoder", Page 75.
7.3.6 Plausibility check
The check of the motor data should only be left out by qualified users. The
configurations include complex regulation processes which largely de‐
pend on correctly entered motor data. Therefore the warning and error
messages displayed during the check must be observed. If a critical sit‐
uation is detected during the guided set-up procedure, it is displayed in
the operating unit. In Parcom Compact, this is displayed in the parameter
42398044_xml.eps
Status of motor parameter identification 797 ⇒ "Set-up by
Fig. 59 means of the communication interface", Page 68. Depending on the de‐
viation from the expected parameter value, a warning or error message
is displayed.
The warning message can be acknowledged by means of the ENT key and guided set-up is continued.
The parameter values entered can be corrected by subsequently pressing the ESC key.
In Parcom Compact the parameter Motor parameter identification 796 must be set to "1 – continue".
Warning messages
Code Measures / Remedy
SA000 No warning message existing. This message can be read out via an optional communication card.
SA001 The rated voltage 370 is outside the FI nominal voltage range. The maximum rated voltage is indicated on the type plate of the
frequency inverter.
SA002 The rated current 371, the rated mech. power 376 and the rated voltage 370 must be checked. The efficiency calcu‐
lated for an asynchronous motor is in the limit range.
SA003 The Rated Cosinus Phi 374 is outside the standard range (0,6 to 0,95).
SA004 The rated speed 372 and the rated frequency 375 must be checked. The slip for an asynchronous motor is in the limit range.
Tab. 32
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If a fault message appears, check and enter the parameterized rated data again. Guided set-up must be repeated
until the rated values have been entered correctly. Only experienced users should prematurely terminate guided
set-up by pressing the ESC key, since some of the rated data is not correct.
64
Fault messages
SF000 No error message existing.
SF001 The rated current 371 that was entered is too low.
SF002 The rated current 371 is too high with reference to the rated mech. power 376 and the rated voltage 370.
SF003 The Rated Cosinus Phi 374 is incorrect (more than 1 or less than 0,3).
SF004 The slip frequency calculated from the rated data is negative. The rated speed 372 and the rated frequency 375 must be
checked.
SF005 The rated speed 372 and the rated frequency 375 that were entered must be checked, since the calculated slip frequency
is too large.
SF006 The total power of the drive calculated from the rated data is smaller than the entered rated mech. power.
SF007 The configuration set is not supported by the guided set-up routine.
Tab. 33
7.3.7 Parameter identification
The "PAidE" display must be confirmed by pressing the ENT key.
In Parcom Compact the function is started by setting the parameter Status

of motor parameter identification 796 to the value "10 – Complete Setup,
DS0" ⇒ "Set-up by means of the communication interface", Page 68
42398144_xml.eps
Fig. 60
In addition to the rated data, the configuration selected requires the knowledge of further motor data not being
indicated on the type plate of the motor. Guided set-up can measure the necessary motor data. The values measured
when the motor is at standstill are entered directly or after calculation of the parameter. The sequence and duration
of parameter identification varies depending on the motor and inverter output connected and may take up to a few
minutes. The connected motor is evaluated in the subsequent course of parameter identification with the displayed
signals. During this procedure the motor may be braked firmly.
If the control release signal is not applied to control input S1IND, the in‐
verter reports "FUF" on the control unit.
When the enable signal is applied, the "FUF" message is deleted and the
unit starts identifying the parameters.
42398244_xml.eps
Fig. 61
DANGER
Non-compliance with the operating instructions

The parameter identification of the frequency inverter requires the release of the power module. Only qualified
persons may work on the devices. Qualified persons must be familiar with the installation, assembly, putting into
operation and operation of frequency inverters and must have the necessary qualification for their task. Carefully
read the documentation before starting the work and comply with the safety instructions.
Noise will occur in the motor while the parameter is being identified.
The parameter identification releases the brake of KB motors.
When the parameters have been identified, the "Read inverter information" function must be performed in Parcom
Compact ⇒ "Set-up by means of the communication interface", Page 68.
214 716 44/200710
65
The final "rEAdY" message must be confirmed by pressing the ENT key.
Cancelling by pressing the ESC key or by terminating the enable of S1IND

means that incomplete values are accepted.
42398344_xml.eps
Fig. 62
When the parameters have been identified, the "Read inverter information" function must be performed in Parcom
Compact ⇒ "Set-up by means of the communication interface", Page 68.
During or after the parameter identification warning messages may be displayed.
After a warning message is output, the parameter identification run can be continued by pressing the "ENT" key
or by selecting "Next".
Warning messages
SA021 The stator resistance is very high. The following causes are possible:
- The motor cable cross-section is not sufficient.
- The motor cable is too long.
- The motor cable is not correctly connected.
- The contacts are not in good condition (possibly corroded).
SA022 The rotor resistance is very high. The following causes are possible:
SA041 The slip speed could not be correctly determined. Check the values entered for the Rated speed 372 and Rated frequency
375 parameters. Repeat identification of the parameters.
SA042 The slip speed could not be correctly determined. Check the values entered for the Rated speed 372 and Rated frequency
375 parameters. Repeat identification of the parameters.
SA051 Motor data entered for star connection, but the motor is connected for delta connection. Change the motor lead connections for
operation with star connection. Check the values entered for the rated motor parameters for operation with delta connection. Repeat
identification of the parameters.
SA052 Motor data entered for delta connection, but the motor is connected for star connection. Change the motor lead connections for
operation with delta connection. Check the values entered for the rated motor parameters for operation with star connection. Repeat
identification of the parameters.
SA053 Measurements show asymmetric phases. Check the leads on the motor and frequency inverter terminals for correct connection
and check the contacts (possibly corroded). Repeat identification of the parameters.
Tab. 34
During or after the parameter identification error messages may be displayed.
The parameter identification run must be repeated following an error message.
Error messages
SF011 Measurement of main inductance has failed because the motor has a high slip. Correct the rated motor values in parameters 370,
371, 372, 374, 375, 376 and 812. Repeat identification of the parameters.
SF012 Measurement of leakage inductance has failed because the motor has high slip. Correct the rated motor values in parameters
370, 371, 372, 374, 375, 376 and 812. Repeat identification of the parameters.
SF021 Measurement of the stator resistance provided no useful result. Check the leads on the motor and frequency inverter terminals for
correct connection and check the contacts for corrosion and secure contact. Repeat identification of the parameters.
SF022 Measurement of the rotor resistance provided no useful result. Check the leads on the motor and frequency inverter terminals for
correct connection and check the contacts for corrosion and secure contact. Repeat identification of the parameters.
Tab. 35
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66
Overview of operating unit messages
SEtUP Setup routine menu item
CALC Plausibility check running
PAidE Inverter is ready to identify parameters
FUF Controller enable on control input S1IND is missing
rEAdY Parameter identification completed
End Guided set-up routine finished
rESEt Inverter is being reset
Tab. 36
7.3.8 Reference values
The versatile drive applications resulting in many parameters to be set require that further parameters must be
checked. The parameters polled during guided set-up have been selected from existing applications and should be
supplemented by further settings in the PARA sub-menu after guided set-up has been completed.
Parameters Setting
475 Drive control 10 - SOST
418 Minimum frequency 0,00 Hz 300,00 Hz 3,50 Hz
419 Maximum frequency 0,00 Hz 300,00 Hz 50,00 Hz
420 Acceleration 0,00 Hz/s 999,99 Hz/s 10,00 Hz/s
421 Deceleration 0,00 Hz/s 999,99 Hz/s 10,00 Hz/s
480 SOST step 1 -300,00 Hz 300,00 Hz 5,00 Hz
481 SOST step 2 -300,00 Hz 300,00 Hz 50,00 Hz
Tab. 37
The control unit shows the End message that you should confirm with the
ENT key. Guided set-up of the frequency inverter is completed with a
reset and initialisation of the frequency inverter. The Dedrive Compact
signals an error during initialisation.
42398444_xml.eps
Fig. 63
The actual frequency 241 parameter that is defined in the factory

settings is displayed when the frequency inverter has initialised without
any errors.
42398544_xml.eps
Fig. 64
Guided set-up makes it easier for you to select the correct parameters and determines further rated data of the
motor. If the parameters have been set by means of the optional programming software Parcom Compact or in the
PARA sub-menu of the operating unit, display of the selected actual value must be activated manually. The setup
function appears when the frequency inverter is switched on, and you can quit this by pressing the ESC key. Change
into the VAL sub-menu and select the required actual value which is to be displayed in future. Press the ENT key
to display the value of the parameter and press the ENT key again to select the actual value for a new start.
214 716 44/200710
67
7.4 Checking the direction of rotation
Please observe the safety instructions, ⇒ "Safety instructions", Page 15, ⇒ "Connecting the electrical equipment",
Page 16 and ⇒ "General", Page 61.
The connection between the reference value and the actual direction of rotation of the drive must be checked. The
check should be carried out as follows. Specify a reference value of approx. 10% vorgeben and switch on the enable
of the freuqency inverter for a short time (control inputs FUF (S1IND) and SW-Step 1+ for clockwise or FUF (S1IND)
and SW-Step 1- for anti-clockwise rotation). Check whether the motor shaft rotates in the correct direction during
acceleration of the drive. In addition to a check of the drive, the corresponding actual values and operating messages
can be read out by means of the operating unit. If, for example, an incorrect direction of rotation is detected, two
motor phases, e.g. U and V, must be interchanged on the terminals of the frequency inverter. The connection of the
frequency inverter on the line side has no effect on the direction of rotation of the drive.
Within the field-oriented regulation with incremental rotary encoder the actual value is compared to the reference
value via the Operation mode 760. If the direction of rotation is detected as being incorrect, the digital inputs
S5IND (channel A) and S4IND (channel B) must be checked in addition to the motor connection.
Set-up of the frequency inverter is completed and can be supplemented by further settings in the PARA menu. The
set parameters are selected so that they are sufficient for a set-up in most application cases. The other settings
relevant for the application must be checked according to the operating instructions.
7.5 Set-up by means of the communication interface

The parameter setting and set-up of the frequency inverter by means of one of the optional communication interfaces
includes the functions for the plausibility check and parameter identification. The documentation must be read care‐
fully before starting work and the safety instructions must be observed, since the relevant parameters must be set
independently by a qualified user.
The Motor parameter identification 796 parameter defines the function which is carried out immediately.
The operation modes divide the automatic steps carried out subsequently during guided set-up.
Operation mode 796 Function

0- Clear status The set-up does not carry out any function.
1- Continue The warning message is acknowledged and the set-up is continued.
2- Abort The set-up is aborted and a RESET of the frequency inverter is carried out.
10 - Complete Setup, DS0 Set-up is carried out in data set 0 and identical parameter values are saved in all four data sets.
This function may only be selected if the rated values of the motor (P. 370 … 376 , 812) are identical
in all 4 data sets.
11 - Complete Setup, DS1 The parameter values of the set-up are saved in data set 1.
The rated values of the motor from data set 1 are used.
20 - Plaus. check machine data, DS0 The set-up process checks the rated motor parameters in the four data sets.
21 - Plaus. check machine data, DS1 The rated motor parameters in data set 1 are checked for plausibility.
30 - Calculation and para. ident., Set-up determines further motor data via the parameter identification, calculates dependent parameters
DS0 and saves identical parameter values in all four data sets.
This function may only be selected if the rated values of the motor (P. 370 … 376 , 812) are identical
in all 4 data sets.
31 - Calculation and para. ident., Extended motor data are measured, dependent parameters are calculated and the parameters are
DS1 saved in data set 1.
214 716 44/200710
68
Tab. 38
The individual set-up steps can be monitored and checked by means of the
Status motor parameter identification 797 parameter. The set-up via the communication interface con‐
tinuously updates the status parameter which can be read out via the interface.
State 797 Meaning

OK The set-up has been carried out.
PC phase 1 The plausibility check of the motor data is active.
PC phase 2 The calculation of dependent parameters is active.
FUF Parameter identification requires the controller enable on digital input S1IND.
Parameter identification The rated values of the motor are measured by the parameter identification.
Setup already active The set-up is carried out via the operating unit.
SF001 Rated current too low The rated current 371 that was entered is too low.
SF002 Rated current too high The rated current 371 is too high with reference to the rated mech. power 376 and the
rated voltage 370.
SF003 The Rated Cosinus Phi 374 is incorrect (more than 1 or less than 0,3).
Rated Cos-Phi
SF004 Negative Slip Frequency The slip frequency calculated from the rated data is negative. The rated speed 372 and the
rated frequency 375 must be checked.
SF005 Slip Frequency Too High The rated speed 372 and the rated frequency 375 that were entered must be checked, since
the calculated slip frequency is too large.
SF006 Power Balance The total power of the drive calculated from the rated data is smaller than the entered rated mech.
power.
SF007 The set configuration is not supported by the set-up.
Unsupported Configuration
SA001 Rated voltage The rated voltage 370 is outside the rated voltage range of the frequency inverter. The maximum rated
voltage is indicated on the type plate of the frequency inverter.
SA002 Efficiency The rated current 371, the rated mech. power 376 and the rated voltage 370 must be
checked. The efficiency calculated for an asynchronous motor is in the limit range.
SA003 The Rated Cosinus Phi 374 is outside the standard range (0,6 to 0,95).
Rated Cos-Phi
SA004 Slip Frequency The rated speed 372 and the rated frequency 375 must be checked. The slip for an asynchro‐
nous motor is in the limit range.
No Release Parameter identification requires the enable on digital input S1IND.
Error An error message was generated while the parameter was being identified. Please check the
Current error 259 parameter.
Warning Phase Asymmetry The parameter identification has detected phase asymmetry during measurement of the three motor
phases.
Tab. 39
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69
8 Programming parameters with the Parcom Compact software
8.1 General
A PC with Parcom Compact parameter programming software, and which is connected to one of the optional RS
232 modules 537 769 84 or 537 723 84 via data cable 537 237 84, can be used as an alternative for configuring
and programming the parameters of the inverter.
Communication with the inverter is only possible when the unit is supplied with power.
8.2 Window layout
1
2
42398644EN_xml.eps
Fig. 65
1 Menu bar 4 Parameter window

2 Toolbar 5 Status bar
3 Directory window
Parcom Compact software with its graphical user interface facilitates simple programming of the inverter parameters.
The mouse or the keyboard can be used.
The width and height of the windows as well as the width of the columns in the parameter window can be changed
by holding and dragging the separators.
214 716 44/200710
70
9 Inverter data
9.1 General
Dedrive Compact frequency inverters are suitable for a wide range of applications. The modular hardware and
software structure provides for adaptation to customer requirements. The available hardware functions of the fre‐
quency inverter are displayed and can be modified by setting the software parameters specifically for the application.
9.2 Serial number

The Serial number 0 is entered when the frequency inverter is manufactured. An internal 9-digit code and the 8-
digit serial number are displayed. Additionally the serial number is printed on the type label.
Serial number 0: 123 456 789; 12345678

Type plate: Dedrive Compact DIC-4-002-E-0000-01
Serial No.: 12345678
Tab. 40
9.3 Optional modules

The hardware can be extended with modules plugged into the sockets. The modules detected by the frequency
inverter are displayed with the corresponding acronyms after initialisation in the parameter Optional modules
1.
Example: CM – 232; EM – UNI-01
9.4 Inverter software version

The firmware saved in the frequency inverter defines an available parameter and function structure of the software.
The Inverter Software Version 12 is displayed.
Inverter Software Version 12 : 4.2.4/050-7
9.5 Set password

As a protection against unauthorized access the parameter Set password 27 can be set. The Set password
27 parameter is set to zero in the factory to enable changes to be made to all parameters. If a password has been
set, parameters can only be changed after this password has been entered.
Parameters Setting
27 Set password 0 999 0
Tab. 41
Set password:
● Define a number between 1 and 999 festlegen and enter it in parameter Set password 27.
Releasing the parameter change, if a password has been set:
● Parcom Compact: When starting Parcom Compact, a "Password and control level" window appears in which
control level 3 and the set password must be entered.
● KP500 operating unit: Parameter 27 must be selected and the assigned parameter must be entered in the "PARA"
menu.
Delete password:
● Release parameter change, see above.

● Enter the value 0 in the parameter Set password 27.
214 716 44/200710
9.6 Control level

Control level 28 defines the scope of functions to be programmed. The operating instructions describe the
parameters from the first to the third control level. The parameters of the third control level should only be set by
71
qualified users. Before starting work, the documentation must be read carefully and the safety instructions must be
observed. For the purposes of the operating instructions, a "Qualified person" is a person who is familiar with the
installation, assembly, putting into operation and operation of frequency inverters and has the necessary qualification
for the given task.
Parameters Setting
28 Control level 1 3 3
Tab. 42
9.7 User name

The User name 29 can be entered via the optional Parcom Compact programming software. A display via the KP
500 operating unit is possible only to a limited extent.
32 alphanumeric characters
9.8 Configuration
9.8.1 General
The Configuration 30 parameter determines the assigment and basic function of the control inputs and outputs
and the software functions. The frequency inverter software offers several configurations for selection. The major
difference between the configurations is how to control the drive. The analogue and digital inputs can be combined
within the configuration and supplemented with optional communication protocols. In the operating instructions the
following configurations and associated parameters are described in the third Control level 28.
After the configuration has been changed, the factory-set values must be activated ⇒ "Programming", Page 73.
9.8.2 Configuration 110 – V/f without encoder
Configuration 110 includes the functions for the variable speed control of a motor. The motor speed is adjusted
depending on the load and on the set reference frequency.
9.8.3 Configuration 111 – V/f with technology controller
Configuration 111 extends the V/f characteristic by software functions which facilitate adaptation to customer re‐
quirements for different applications The technology controller must be used depending on the application.
9.8.4 Configuration 210 – FOR speed control with encoder
Permitted for lifting applications
Configuration 210 includes the functions for the variable-speed field-oriented regulation of an asynchronous motor
with rotary encoder feedback. A separate regulation of the torque-forming and the flux-forming current provides for
a highly dynamic drive with a high load torque. The necessary rotary encoder feedback results in an exact speed
and torque behaviour.
If KB motors are used in lifting applications, sections ⇒ "Plausibility check", Page 64, ⇒ "Starting behaviour of the
FOR", Page 79 and ⇒ "Field controller", Page 150 must be considered.
9.8.5 Configuration 230 – FOR N or M controlled
Configuration 230 extends configuration 210 by the functions for the field-oriented regulation depending on the
torque. The torque reference value is shown as percentage and transferred into a corresponding operating behaviour
of the application. A digital control input is used for switching between variable-speed regulation and regulation
depending on the torque.
9.8.6 Configuration 410 – FOR speed control without encoder

214 716 44/200710
Factory setting
Recommended for travel applications

72
Possible min. frequency f min = 5 Hz
In configuration 410 only modulation frequencies from 4 kHz on can be used. Configuration 410 includes the functions
for the field-oriented regulation of an asynchronous motor without encoder. The current motor speed is determined
from the instantaneous currents and voltages combined with the machine parameters.
Parallel switching of different motors is not possible in this configuration.
9.8.7 Configuration 430 – FOR N or M controlled without encoder
In configuration 430 only modulation frequencies from 4 kHz on can be used.
Configuration 430 extends configuration 410 by the functions for the field-oriented regulation depending on the
torque. The torque reference value is shown as percentage and transferred into a corresponding operating behaviour
of the application. The changeover of the FOR between speed and torque control is made via a digital control input.
Parallel switching of motors is not possible in the torque control operating mode in this configuration.
9.9 Language
The parameters are saved in the frequency inverter in different languages. The description of parameters is displayed
in the language selected Language 33.
Language 33 Function
0- German Description of parameters in German
1- English Description of parameters in English
2- Espanol Description of parameters in Spanish
3- Francais Description of parameters in French
Tab. 43
9.10 Programming
The Program 34 parameter makes it possible to acknowledge an error message and to restore the factory setting.
The display of the operating unit shows the message "dEFLt" or "rESEt" and the LEDs additionally indicate the status
of the frequency inverter.
Program 34 Function
123 A reset is carried out, an existing error is acknowledged. The display of
the operating unit shows the message "rESEt".
4444 The set parameters are overwritten with the default values. The display
of the operating unit shows the message "dEFLt".
Tab. 44
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73
10 Motor data
10.1 General
The input of the motor data is the basis for the functions of the control and regulation processes. The necessary
parameters are polled according to the selected Configuration 30 during guided set-up.
10.2 Rated motor parameters

The rated motor parameters of a three-phase asynchronous motor must be set according to the type plate or the
technical data sheet of the motor. The motor data set in the factory refer to the rated data of the frequency inverter.
The other motor data required for the control and regulation processes are calculated from the settings made during
the setup which are checked for plausibility.
The rated values specified by the manufacturer must be checked by the user.
Parameters Setting
370 Rated voltage 0,17 * UFUN 2 * UFUN UFUN
371 Rated current 0,01 * IFUN 10 * ü* IFUN IFUN
372 Rated speed 96 rpm 60000 rpm nN
373 No. of pole pairs 1 24 2
374 Rated cosinus phi 0,01 1,00 cos(φ)N
375 Rated frequency 10,00 Hz 1000,00 Hz 50,00
376 Rated mech. power 0,01 * PFUN 10 * PFUN PFUN
812 Cyclic duration factor 40 - 40% CDF 100 - 100% CDF 100 - 100% CDF
Tab. 45
10.3 Additional motor data
10.3.1 General
In order to exactly calculate the machine model for the selected control and regulation process in the case of field-
oriented regulation, further data must be determined which cannot be read from the type plate of the asynchronous
motor. Parameter identification is carried out to measure further motor data during guided set-up.
10.3.2 Stator resistance
Only in the 4xx configurations; not in 2xx
The resistance of the stator winding is measured during guided set-up. The parameter is set as phase quantity and
in a delta connection it is smaller than the winding resistance by factor 3. In the factory setting the equivalent stator
resistance of a standard motor is entered suitably for the rated output of the frequency inverter.
Parameters Setting
377 Stator resistance 0 mΩ 65535 mΩ RsN
Tab. 46
The stator resistance can be optimised in the idle state of the motor. At the stationary working point the
Torque current share Isq 216 or the estimated Active Current 214 should be equal to zero. This check
should be carried out at a winding temperature that is also reached during normal operation of the motor, since the
stator resistance depends on the temperature.
10.3.3 Leakage factor
The leakage factor of the motor defines the relation between leakage inductance and main inductance. Thus the
torque-forming and the flux-forming current component are linked via the leakage inductance. In order to optimise
the leakage factor within the field-oriented regulation process, different working points of the drive must be ap‐
214 716 44/200710
proached. The Flow current share Isd 215 in contrast to the Torque current share Isq 216, should be
largely independent of the load torque. The flux-forming current component is inversely proportional to the leakage
factor. With increasing leakage factor the torque-forming current increases and the flux-forming component decrea‐
ses. The check should show a relatively constant Flow current share Isd 215, depending on the set
74 Idle current 716, independent of the load on the drive.
The regulation without encoders uses the parameter Leakage factor 378 for optimising the synchronization to
one drive.
Parameters Setting
378 Leakage factor 1,0% 20,0% 7,0%
Tab. 47
10.3.4 Magnetising current
Idle current 716 is an indicator of the flux in the motor and thus for the voltage applied to the motor at no load
as a function of the speed. This value is determined during guided set-up to approx 30 % of Rated current
371. This current is comparable to the excitation current of a DC machine with external excitation.
To optimise the value for the field-oriented regulation without encoders, the motor must be operated under no load
at a rotating frequency that is below the Rated frequency 375. The accuracy of optimisation increases with the
set Modulation frequency 400 and the idle state of the motor to be reached. The
Flow current share Isd 215 to be read out should approximatively correspond to the set Idle current
716.
The field-oriented regulation with rotary encoder feedback uses the set Idle current 716 for the flux in the motor.
The fact that the magnetisation depends on the frequency and voltage at the corresponding working point is taken
into account by a magnetisation characteristic. Especially in the field-weakening range above the rated frequency
the characteristic is calculated on the basis of three points. The parameter identification has determined the mag‐
netising characteristic of the motor and has set the parameter Magnetising current 50% flux 713,
Magnetising current 80% flux 714 and Magnetising current 110% flux 715.
Parameters Setting
713 Magnetising Current 50% Flux 1,0% 50,0% 31,0%
716 Idle current 0,01 * IFUN ü * IFUN 0,3 * IFUN
Tab. 48
10.3.5 Rotor time constant correction factor
The rotor time constant results from the inductance of the rotor circuit and the rotor resistance. Owing to the tem‐
perature dependence of the rotor resistance and the saturation effects of the core, the rotor time constant also
depends on the temperature and the current. The behaviour at load and thus the rated slip depend on the rotor time
constant. During guided setup, parameter identification determines the data of the motor and sets the
Rotor time constant correction factor 718 parameter accordingly. To adjust precisely or to check the
rotor time constant, you may proceed as follows: Load the motor at half the Rated frequency 375. Approx. half
the Rated voltage 370 must then result with a max. tolerance of 5 %. If this is not the case, adjust the
Rotor time constant correction factor 718 as required. The higher you set the correction factor, the
stronger the voltage is reduced under load. Read out the rotor time constant value calculated by the software using
the Current rotor time constant 227 actual value. This check should be carried out when the winding is
cold.
Parameters Setting
718 Rotor time constant 0,01% 300,00% 100,00%
correction factor
Tab. 49
10.4 Rotary encoder

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10.4.1 General
The speed actual value needs to be measured continuously for the control and regulation process for some of the
available Configurations 30. The necessary incremental rotary encoder must be connected to the digital control
terminals S5IND (channel A) and S4IND (channel B) of the frequency inverter. 75
Operation modes 490 and 493 for encoders 1 and 2 are deactivated by default from software version 6 on.
In 2xx configurations, the user must activate the operation mode of the encoder that is used and set
Source actual speed 766 accordingly.
10.4.2 Operation mode encoder 1
Select Operation mode 490 for encoder 1 according to the connected incremental encoder.
The Source actual speed 766 parameter must be set accordingly.
A unipolar rotary encoder can be connected to the standard control terminals.
The necessary incremental rotary encoder must be connected to the digital control terminals S5IND (channel A) and
S4IND (channel B) of the frequency inverter.
Operation mode 490 Rotary encoder 1

0- Off (factory setting) Speed measurement not active;
the digital inputs are available for further functions.
1- Single evaluation Double channel encoder with direction of rotation detection via track signals A and B;
one signal edge is evaluated for each division mark.
4- Quadruple evaluation Double channel encoder with direction of rotation detection via track signals A and B;
four signal edges are evaluated for each division mark.
11 - Single evaluation unsigned Single-channel rotary encoder via channel signal A. The actual speed value is positive. One signal
edge per pulse is evaluated. Digital input S4IND is available for further functions.
12 - Double evaluation unsigned Single-channel rotary encoder via channel signal A. The actual speed value is positive. Two signal
edges per pulse are evaluated. Digital input S4IND is available for further functions.
101 - Single evaluation inverted As operation mode 1. The actual speed value is inverted. (alternative to exchanging the channel sig‐
nals)
104 - Quadruple evaluation inverted As operation mode 4. The actual speed value is inverted. (alternative to exchanging the channel sig‐
nals)
111 - Single evaluation negative As operation mode 11. The actual speed value is negative.
112 - Double evaluation negative As operation mode 12. The actual speed value is negative.
Tab. 50
10.4.3 Operation mode encoder 2
A further encoder input is available when an extension module is fitted. It is programmed by means of the
Operation Mode Encoder 2 493 parameter.
The Source actual speed 766 parameter must be set accordingly.
Further details: see the extension module operating instructions.
Integrated encoders of KB motors with S31 electronics may only be operated with an EM – UNI-01 extension module
with a 24 V power supply if the terminating resistor of the EM – UNI-01 unit is deactivated.
Operation mode 493 Rotary encoder 2

0- Off (factory setting) Speed measurement not active.
4- Quadruple evaluation Two-channel rotary encoder with direction of rotation detection via channel signals A and B; with push-
pull operation additionally signals A/ and B/. Four signal edges per pulse are evaluated.
104 - Quadruple evaluation inverted As operation mode 4;
The actual speed value is inverted. (alternative to exchanging the channel signals)
Tab. 51
10.4.4 Division marks encoder 1
The number of increments of the rotary encoder suitable for safe evaluation must be selected according to the speed
range of the application by means of the following formulas.
Max. number of division marks Smax

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60 s / min
Smax = 150000 Hz ∙ Example: 1024' nmax = 8700 rpm
nmax
Tab. 52
76
The maximum number of division marks Smax is defined by the limit frequency fmax = 150 kHz of digital inputs S5IND
(track A) and S4IND (track B).
Min. number of division marks Smin
60 s / min
Smin = 500 Hz ∙ For quadruple evaluation with 1024': nmin = 10 rpm ≙ 0,33 Hz
A ∙ nmin
Tab. 53
To ensure good motor running characteristics, an encoder signal must be evaluated at least every 2 ms (signal
frequency f = 500 Hz). Based on this requirement, the minimum division mark Smin of the incremental encoder can
be calculated for a required minimum speed nmin.
The parameter for the actual number of increments for the connected encoder must programmed via the
Division marks encoder 1 491 parameter.
Parameters Setting
Tab. 54
10.4.5 Filter time constant encoder 1
The encoder signal can be filtered to improve the control characteristics for encoders with an unsymmetrical pulse
control factor.
Operation mode 815 Filter time constant encoder 1

0- Off Speed is measured without filtering.
1- 2 ms The filter time constant is 2 ms.
Tab. 55
10.5 System data

By means of the Factor actual value system 389 parameter a relationship can be established between the
actual frequency and the Actual value system 242.
The actual frequency is multiplied by the parameter Factor actual value system 389. The product is displayed
as Actual value system 242. In this way, a speed can be standardized to m/min, for example.
Parameters Setting
389 Factor actual value system - 100,000 100,000 1,000
Tab. 56
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77
11 Operating behaviour
11.1 General
Parameters for the operating behaviour of the frequency inverter must be set relative to the application. Particularly
the starting and stopping behaviour is freely configurable according to the selected Configuration 30. In addi‐
tional, functions such as auto-start, synchronisation and positioning facilitate integration into the application.
11.2 Start-up behaviour
11.2.1 General
Parameters for start-up of the asynchronous motor must be set relative to the control and regulation process. Field-
oriented regulation processes are based on a complex controller structure and only require, in contrast to the V/f
characteristic, the definition of the limit values Maximum flux build-up time 780 and
Current during flux formation 781. The V/f characteristic is supplemented by the selected
Operation mode 620 of the start-up behaviour.
11.2.2 Start-up behaviour of the V/f characteristic
11.2.2.1 General
The Operation mode 620 parameter of the start-up behaviour is available in configuration 110 and configuration
111. Depending on the operation mode selected, first the motor is magnetised or a starting current is applied.
Operation mode 620 Start-up behaviour

0- Start delay + DC pre-mag For the time set with the parameter Start delay 820 the modulation remains switched off. Subse‐
(factory setting) quently a DC is put out for the duration of the DC pre-magnetisation time 821 which results from
the product of DC magnetisation 823 and the set Boost for f=0 600. Subsequently the output
voltage and the output frequency are modified according to the V/f characteristic.
1- Magnetisation In this operation mode, the Current during flux formation 781 is applied to the motor for
magnetisation after release. The output frequency is kept at 0 Hz for the duration of the
Maximum flux build-up time 780. After this time has elapsed, the set V/f characteristic is con‐
tinued.
2- Magnetisation+ Operation mode 2 includes operation mode 1. After the Maximum flux build-up time 780 has
Current Impr. elapsed, the output frequency is increased according to the set acceleration. When the output frequency
reaches the value set with the parameter Frequency Limit 624, the Starting current 623 is
reduced. There is a smooth transition up to 1.4 times the frequency limit to the set V/f characteristic.
From this working point on, the output current depends on the load.
3- Magnetisation+ Operation mode 3 includes operation mode 1 of the start-up function. The boost of the output voltage
I*R-Comp. by the IxR compensation becomes effective when the output frequency reaches the value set with the
Frequency Limit 624 parameter. The V/f characteristic is shifted by the share of voltage that de‐
pends on the stator resistance.
4- Magnet.+ In this operation mode, the current set with the parameter Current during flux formation
Curr.Imp.+ 781 is applied to the motor for magnetisation after release. The output frequency is kept at 0 Hz for the
I*R-Comp. duration of the Maximum flux build-up time 780. After the time has elapsed, the output frequency
is increased according to the set acceleration. When the output frequency reaches the value set with
the parameter Frequency Limit 624, the Starting current 623 is reduced. There is a smooth
transition to the V/f characteristic and an output current depending on the load is applied. Simultane‐
ously from this output frequency on the boost of the output voltage by the IxR compensation becomes
effective. The V/f characteristic is shifted by that share of voltage which depends on the stator resist‐
ance.
12 - Magn.+ Operation mode 12 includes an additional function to ensure a start-up behaviour under arduous con‐
Curr.Imp. w. Ramp Stop ditions. The magnetisation and application of the starting current corresponds to operation mode 2. The
ramp stop takes the current consumption into account which the motor has at the corresponding working
point and controls the frequency and voltage change by means of the ramp stop.
Controller status 275 signals intervention by the controller with the message „RSTP“.
14 - Magn.+Current Imp. w. RS.+ In this operation mode, the functions of operation mode 12 are extended by compensation of the voltage
I*R-Comp. drop on the stator resistor. The boost of the output voltage by the IxR compensation becomes effective
when the output frequency reaches the value set with the Frequency Limit 624 parameter. The V/
f characteristic is shifted by the share of voltage that depends on the stator resistance.
Tab. 57
The V/f characteristic is supplemented by a current controller for the start-up behaviour, in contrast to field-oriented
regulation. The PI controller controls the application of the set Starting current 623.
214 716 44/200710
78
Parameters Setting
621 Amplification 0,01 10,00 1,00
622 Integral time 1 ms 30000 ms 50 ms
Tab. 58
11.2.2.2 DC magnetisation
In configurations 110 and 111, the DC level can be set via the DC magnetisation 823 parameter for the
DC pre-magnetisation time 821.
The DC results from the product of DC magnetisation 823 and the set Boost for f=0 600.
Parameters Setting
823 DC magnetisation 0% 250% 100%
Tab. 59
11.2.2.3 Starting current
Configurations 110, 111 (V/f characteristic) and 410 (FOR without encoders) use the application of the starting
current in operation modes 2, 4, 12 and 14. The Starting current 623 ensures a sufficient torque particularly
for starting against high-inertia loads until Frequency limit 624 is reached.
Motors with separate fans must be used for thermal reasons in applications which require a permanently high current
at low speed.
Parameters Setting
623 Starting current 0,0 A ü * IFUN IFUN
Tab. 60
11.2.2.4 Frequency limit
In configurations 110, 111 and 410 the Starting current 624 is applied until the Frequency limit 624 is
reached. Permanent working points below the frequency limit are only allowed if motors with separate fans are used.
The system switches over to the control and regulation process of the selected Configuration 30 above the
frequency limit.
Parameters Setting
624 Frequency limit 0,00 Hz 100,00 Hz 4,50 Hz
Tab. 61
11.2.3 Starting behaviour of the FOR
The field-oriented regulation in configuration 210, 230 and 410 is based on the separate regulation of the flux-forming
and torque-forming current component. When the motor starts, it is first magnetised or a current is applied. Mag‐
netising current Isd is set by the Current during flux formation 781 parameter and the maximum time for
current application is set by the Maximum flux build-up time 780 parameter.
Current is applied until the reference value of the rated magnetisation current is reached or the
Maximum flux build-up time 780 is exceeded.
Parameters Setting
780 Maximum flux build-up time 1 ms 10000 ms 1000 ms
781 Current during flux formation 0,1 * IFUN ü * IFUN IFUN
Tab. 62
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79
DANGER
Load sinking during starting

If KB motors are used for lifting applications, the parameter Maximum flux build-up time 780 must be re‐
duced to 1ms, in order to prevent load sinking possible during starting.
When the load sinks, error 1102 Max. frequency deviation occurs.
Parameters 780 und 781 are also used for operation mode 1 – magnetisation of the V/f characteristic; ⇒ "Start-up
behaviour of the V/f characteristic", Page 78.
11.3 Stopping behaviour

The stopping behaviour of the motor can be defined via Operation mode 630. The following operation modes are
defined by different combinations of the logic signals SW-Step 1+ 68 and SW-Step 1- 69.
Operation mode 630 stopping behaviour

SW-Step 1+ = 0 and SW-Step 1- = 0
Operation mode 630
Stopping behaviour 1 Stopping behaviour 4
SW-Step 1+ = 1 and Stopping behaviour 1 11 (Factory setting) 14
SW-Step 1- = 1 Stopping behaviour 4 41 44
Tab. 63
Example: When the Operation mode 630 parameter is set to 41, stopping behaviour 4 is activated for SW-Step
1+ = 1 and SW-Step 1- = 1 (according to the left number of the set value), and stopping behaviour 1 for SW-Step 1
+ = 0 and SW-Step 1- = 0 (according to the right number of the set value).
Stopping behaviour
Stopping behaviour 1 The drive is stopped with the set deceleration. At standstill the power
Shutdown + switch-off inverter is blocked.
Stopping behaviour 4 The drive is stopped with the emergency stop deceleration
Emergency stop + switch-off Emergency stop clockwise 424 or
Emergency stop anticlockwise 425. At standstill the power inver‐
ter is blocked.
Tab. 64
11.4 Auto-start
The auto-start function is suitable for applications which, due to their function, allow a start-up when the power supply
is switched on. When the auto-start function is activated with the Operation mode 651 parameter, the frequency
inverter will accelerate the drive when the supply voltage has been applied. The control signal controller enable and
the starting command are required by the regulations.
The motor is accelerated according to the parameters and the reference value signal when it is switched on.
Operation mode 651 Auto-start function

0- Off (factory setting) The drive starts when the controller enable S1IND and the starting command SW-Step 1+ or SW-Step
1- are connected.
1- On The drive is accelerated by the frequency inverter when the supply voltage is applied.
Tab. 65
DANGER
Automatic restart after a mains failure and voltage recovery

At this point, please pay particular attention to VDE regulations 0100, part 227, and 0113, particularly section 5.4
"Protection against automatic restart after a mains failure and voltage recovery", as well as section 5.5 "Under‐
214 716 44/200710
voltage protection". In addition, special regulations relevant to the individual application as well as national
regulations must be observed.
80
11.5 Search run
Synchronisation must be carried out with a rotating drive in applications which, due to their characteristics, drive the
motor or if the drive continues to rotate after a disconnection on fault. The motor is synchronised to the current motor
speed without the "overcurrent" error message by means of Operation mode 645. Subsequently the motor is
accelerated to the reference speed according to the set acceleration.
The synchronisation in operation modes 10 to 15 is made by short test pulses. Rotating frequencies up to 250 Hz
are determined within 100 ms to 300 ms. At higher frequencies a wrong frequency is determined and synchronisation
fails. A search run cannot determine whether an attempt to synchronise has failed in the "Quick Synchronisation"
operation modes.
Depending on the set configuration only certain operation modes can be selected.
Operation mode 645 Search run function

0- Off (factory setting) The synchronisation to a rotating drive is de-activated.
1- Search Dir. acc to Preset Val. The search direction is determined by the sign of the reference value. If a positive reference value
(clockwise rotating field) is specified, the search direction is positive (clockwise rotating field), with a
negative reference value (anti-clockwise rotating field) the search direction is negative.
2- First Clockw.,Then Anticl., DCB First synchronisation to the drive is attempted in positive direction (clockwise rotating field). If this at‐
tempt fails, synchronisation to the drive is attempted in negative direction (anti-clockwise rotating field).
3- First Anticl.,Then Clockw., DCB First synchronisation to the drive is attempted in negative direction (anti-clockwise rotating field). If this
attempt fails, synchronisation to the drive is attempted in positive direction (clockwise rotating field).
4- Clockwise Only, Synchronisation to the drive is only carried out in positive direction (clockwise rotating field).
DC-Brake
5- Anti-clockwise Only, Synchronisation to the drive is only carried out in negative direction (anti-clockwise rotating field).
DC-Brake
10 - Quick Synchronisation Synchronisation to the drive is attempted in the positive (clockwise rotating field) or negative direction
(anti-clockwise direction).
11 - Quick Synch. acc. to Preset Val‐ The search direction is determined by the sign of the reference value. If a positive reference value
ue (clockwise rotating field) is specified, the search direction is positive (clockwise rotating field), with a
negative reference value (anti-clockwise rotating field) the search direction is negative.
14 - Quick Synch., Clockwise Only Synchronisation to the drive is only carried out in the positive direction (clockwise rotating field).
15 - Quick Synch., Anti-clockwise Synchronisation to the drive is only carried out in negative direction (anti-clockwise rotating field).
Only
Tab. 66
Operation modes 1, 4 and 5 specify a direction of rotation for the search run and avoid a direction of rotation that
deviates from this. The search run can accelerate drives by checking the rotating frequency, if these drives have a
low moment of inertia or small load torque.
A search run may determine an incorrect direction of rotation in operation mode 10 to 15 during Quick Synchroni‐
sation. For example a frequency that is not equal to zero may be determined although the drive is at standstill. If no
overcurrent occurs, the drive is accelerated accordingly. A direction of rotation is specified in operation modes 11,
14 and 15.
The synchronisation changes the set start-up behaviour of the selected configuration. The start command first ac‐
tivates the search run to determine the rotating frequency of the drive. In operation modes 1 to 5, the
Current / rated motor current 647 is used for synchronisation as a percentage of the Rated current
371.
Parameters Setting
647 Current / rated motor current 1,00% 100,00% 70,00%
Tab. 67
For the search run the V/f characteristic is extended by a PI controller which controls the set
Current / rated motor current 647.
If the Operation mode 645 parameter is set to operation mode 1 to 5 (search run), Demagnetizing Time 633
must elapse before the search run is started.
Parameters Setting
214 716 44/200710

648 Amplification 0,00 10,00 1,00
Tab. 68
81
If it is not possible to synchronise to the drive, the Braking current 631 is applied to the motor in operation mode
1 to 5 for the duration of the Brak. time after search run 646 in den Motor eingeprägt. When a direct current
is applied as set in the parameters of the DC brake, the motor heats up. Therefore a direct current should only be
applied to self-ventilated motors for a short time.
Parameters Setting
646 Brak. time after search run 0,0 s 200,0 s 10,0 s
Tab. 69
11.6 Positioning
11.6.1 General
Positioning is effected by specifying the positioning distance in "Reference positioning" operation mode or by spec‐
ifying the positioning angle in "Axle positioning" operation mode.
Positioning from a reference point uses a digital reference signal from a signal source that can be selected for
positioning the drive independent of the speed.
Axle positioning uses a digital reference signal of a rotary encoder. The "Reference positioning" function is available
in configurations 110, 410 and 210 and is activated by selecting operation mode 1 for the Operation mode 458
parameter.
The "Axle positioning" function is available in configuration 210 and is activated by selecting operation mode 2 for
the Operation mode 458 parameter.
Operation mode 458 Positioning function

0- Off (factory setting) Positioning is switched off
1- Reference positioning Positioning from reference point by specifying the positioning distance (revolutions), the reference point
is detected via a Signal source 459.
2- Axle positioning Position from reference point by specifying the positioning angle, reference signal from the rotary en‐
coder.
Tab. 70
11.6.2 Reference positioning
The feedback of the current position is related to the revolutions of the motor relative to the time of the reference
signal. The positioning accuracy of the application to be implemented depends on the current
Actual frequency 241, Deceleration 421, the No. of pole pairs 373, the selected
Positioning distance 460 and the set control and regulation process.
The distance between the reference point and the desired position must be entered in motor revolutions. Calculation
of the distance covered must be carried out by means of the selected Positioning distance 460 according to
the application.
If Positioning distance 460 is set to 0,000 r, the drive is immediately shut down according to the selected
stopping behaviour for Operation mode 630.
Parameters Setting
460 Positioning distance 0,000 r 1000000,000 r 0,000 r
Tab. 71
The Rotations 470 actual value parameter facilitates the setting and optimisation of this function. The revolutions
of the motor displayed should correspond to Positioning distance 460.
The minimum number of revolutions required until the desired position is reached depends on
Actual frequency 241 and Deceleration 421 (or Deceleration anticlockwise 423) as well as the
No. of pole pairs 373 of the motor.
214 716 44/200710
82
Example: f = 20 Hz, a = 5 Hz/s, p = 2 ⇒ Umin = 20 Umin = Min. number of revolutions
f2 f = Actual frequency 241
Umin =
2∙a∙p a = Deceleration 421 (423)
p = No. of pole pairs 373 of the motor
Tab. 72
At least 20 revolutions are required to stop at the desired position at an actual frequency of 20 Hz and a deceleration
of 5 Hz/s. The is the minimum value which must not be lower for the Positioning distance 460. If the number
of revolutions up to the desired position is lower, the frequency must be reduced, the deceleration must be increased
or the reference point must be shifted.
The digital signal for detecting the reference point and the logic operation can be selected from a range of
Signal sources 459. The logic operation between digital inputs S2IND, S3IND and S6IND with further functions
must be checked according to the selected Configuration 030.
Signal source 459 Function

2- S2IND, neg. edge Positioning starts with the logic signal change from 1 (HIGH) to 0 (LOW) at the reference point.
(factory setting)
3- S3IND, falling edge
6- S6IND, falling edge
1x - SxIND, rising edge Positioning starts with the logic signal change from 0 (LOW) to 1 (HIGH).
2x - SxIND, rising/falling edge Positioning starts with the logic signal change.
Tab. 73
Detection of the reference position via a digital signal can be influenced by a variable dead time when the control
command is read and processed. The signal propagation delay is compensated by a positive value for
Signal correction 461. When a negative signal correction is set, the processing of the digital signal is delayed.
Parameters Setting
461 Signal correction -327,68 ms +327,67 ms 0,00 ms
Tab. 74
The influences on positioning which depend on the working point must be corrected empirically by means of the
Load correction 462 parameter. If the desired position is not reached, the delay is increased by means of a
positive value for the load correction. The distance between the reference point and the desired position is increased.
Negative values accelerate the braking operation and reduce the positioning distance. The limit of the negative signal
correction results from the application and from the Positioning distance 460.
Parameters Setting
462 Load correction -32768 +32767 0
Tab. 75
The behaviour of the positioning function after the desired position has been reached can be defined by the
Activity after positioning 463 parameter.
Activity after positioning 463 Function

0- End positioning The drive is stopped with the stopping behaviour of Operation mode 630.
(Factory setting)
1- Waiting for positioning signal The drive speed is kept up to the new signal edge; with a new edge of the positioning signal
the drive is accelerated in the previous direction of rotation.
2- Reversal by new edge The drive speed is kept up to the new signal edge; with a new edge of the positioning signal
the drive is accelerated in the opposite direction of rotation.
3- Positioning ; off The drive is shut down and the power output stage is switched off.
4- Start by time control The drive speed is kept for the Time to wait 464; after the time to wait the drive is accel‐
erated in the previous direction of rotation.
5- Reversal by time control The drive speed is kept for the Time to wait 464; after the time to wait the drive is accel‐
erated in the opposite direction of rotation.
Tab. 76
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The position reached can be maintained for the Time to wait 464, before the drive is accelerated according to
operation mode 4 or 5.
83
Parameters Setting
464 Time to wait 0 ms 3600000 ms 0 ms
Tab. 77
Examples for positioning from a reference point depending on the parameters selected for the factory setting.
Positioning 458 = 1
1 Actual value: Digital inputs 250

2 Actual value: Actual frequency 241
3 Deceleration 421
Tab. 78
Fig. 66
● The reference point is detected by a signal at digital input 6 according to the Signal sources 459 parameter
in operation mode 16-S6IND, neg. edge.
● Positioning distance 460 with parameter value 0,000 r defines an immediate shutdown of the drive ac‐
cording to the Operation mode 630 defined in the stopping behaviour.
● The Signal correction 461 of the signal propagation time from the measuring point to the frequency inverter
is not used due to the value of 0 ms.
● The Load correction 462 can compensate an incorrect positioning by the load characteristic. In the factory
setting the compensation is deactivated with the value 0.
● Activity after positioning 463 is defined by operation mode 0–End of positioning.
● Time to wait 464 is not taken into account in the above setting of the Activity after positioning
463 parameter.
● The actual value Rotations 470 enables direct comparison with the desired Positioning distance 460.
In the case of deviations a Signal correction 461 or a Load correction 462 can be carried out.
11.6.3 Axle positioning
An incremental encoder with a reference pulse is required for axle postioning in configuration 210. The signal of the
rotary enoder with reference pulse can be evaluated by means of an optional extension module and operation modes
1004 and 1104. Positioning is effected by a start signal and a drop below an adjustable frequency limit. The motor
stops at the entered positioning angle according to the set stopping behaviour.
For correct functioning of axle positioning, the speed controller should be optimised after guided set-up. This is
described in the "Speed controller" section.
The angle between the reference point and the desired position is entered via parameter
Reference orientation 469. If this value is modified while the motor is at standstill, positioning is carried out
again at the frequency of 0,5 Hz. For this, a stopping behaviour needs to be selected for Operation mode 630
which applies a starting current permanently during shutdown or during the holding time (described in the "Stopping
behaviour" chapter).
Parameters Setting
469 Reference orientation 0,0° 359,9° 0,0°
Tab. 79
DANGER
Change of the direction of rotation during positioning

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During positioning the direction of rotation of the drive may change, independent of whether the command start
clockwise or start anti-clockwise has been activated.
84
Positioning is started by means of a start command from a signal souce (e.g. digital input), which must be allocated
to parameter Start positioning of axle 37. The signal source can be selected from the operation modes
for digital inputs described in the "Digtal inputs" chapter, ⇒ "Digital inputs", Page 128
Positioning starts provided that the Actual frequency 241 of the output signal is lower than the value entered in
the Positioning frequency 471 parameter. The actual frequency falls below the positioning frequency due to
a stopping behaviour.
Parameters Setting
471 Positioning Frequency 1,00 Hz 50,00 Hz 50,00 Hz
Tab. 80
The max. permissible deviation from the value of the Reference orientation 469 can be set by the
Max positional error 472 parameter.
Parameters Setting
472 Max positional error 0,1° 90,0° 3,0°
Tab. 81
The time constant for compensating the positional error can be set via parameter
Time constant positioning contr. 479. The value for the time constant should be increased, if oscillations
of the drive occur during positioning around the reference orientation.
Parameters Setting
479 Time constant positioning contr. 1,00 ms 9999,99 ms 20,00 ms
Tab. 82
In order to ensure that the set position is held under the influence of a load torque, a stopping behaviour should be
selected for the Operation mode 630 parameter, which applies a starting current permanently during shutdown
or during the holding time.
The "60-Arrived at desired Position" status message that is output when the reference orientation has been reached
can be allocated to a digital output. The message is output under the following conditions:
● Operation mode 2 (axle positioning) has been selected for parameter Operation mode 458.
● The controller enable on digital input S1IND is switched on.
● The Start positioning of axle 37 is activated.
● Encoder monitoring is activated, i.e. operation mode 2 (error message) for the Operation mode 760 parameter
of encoder monitoring is selected.
● Operation mode 1004 or 1104 (quadruple evaluation with reference pulse) is selected for the rotary encoder input.
● The Actual frequency 241 is smaller than 1 Hz.
● The deviation of the current position from the reference orientation is smaller than the
Max. positional error 472.
The current position after Start positioning of axle 37 is detected by the frequency inverter as follows:
● During the set-up, after the frequency inverter has been switched on, a search run over 3 revolutions at a rotating
frequency of 1 Hz is carried out to detect the reference signal. After the reference signal has been detected two
times, positioning to the Reference orientation 469 is effected.
● If the motor was already rotating before axle positioning has been started, positioning to the
reference orientation 469 is effected without the search run, since the position of the reference point was
already detected by the frequency inverter.
If positioning is effected after the controller enable and starting command from standstill of the motor:
● The motor is positioned to the reference orientation at clockwise rotation, if the value for the reference orientation
is higher than the value set before.
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● The motor is positioned to the reference orientation at anti-clockwise rotation, if the value for the reference ori‐
entation is smaller than the value set before.
The direction of rotation during positioning is independent of whether start clockwise or start anti-clockwise has been
activated. 85
The time until reaching the reference orientation depends on:
● Actual frequency
● Frequency ramp for deceleration
● Angle of rotation up to reference orientation
● Max positional error
● Time constant positioning contr.
11.7 Brake control
11.7.1 General
t2 t3 A t4
t1 t5
42399144_xml.eps
Fig. 67
1 fref t1 Brake release delay 824

2 Release brake t2 Start delay 820
3 PWM t3 DC pre-magnetisation time 821
4 S2IND t4 DC post-magnetisation time 822
A Integrator operation t5 Brake application time 825
Tab. 83
Starting and stopping of the drive can be controlled by means of various functions. The diagram shows the curves
as a function of time.
The individual functions are described in the following sections.

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86
11.7.2 Start delay
This function delays the internal travel signal by the time set. During this time modulation is still being switched off.
Parameters Setting
820 Start delay 0 ms 1000 ms 0 ms
Tab. 84
11.7.3 DC pre-magnetisation time
With the field-oriented regulation the speed is set to 0 between start delay and integrator operation for the time set.
With the V/f characteristic a direct voltage is output between start delay and integrator operation for the time set,
⇒ "Start-up behaviour", Page 78.
Parameters Setting
821 DC pre-magnetisation time 0 ms 1000 ms 0 ms
Tab. 85
11.7.4 DC post-magnetization time
Fig. 68
1 Output frequency tB Brake application time

2 SW-Step 1+ tVZ Delay time
3 "Release brake" message tGS DC post-magnetization time
4 "Modulation on" message
Tab. 86
With the field-oriented regulation the speed is set to 0 after the integrator operation for the time set.
With the V/f characteristic a direct voltage is output after the integrator operation for the time set, ⇒ "DC magneti‐
sation", Page 79.
Parameters Setting
822 DC post-magnetization time 0,0 s 30,0 s 0,0 s
Tab. 87
The diagram shows the effect of the post-magnetization time. For the set time, the inverter supplies a DC voltage
to the amount of 1½ times the "Characteristic boost for f = 0" parameter when the deceleration phase is finished.
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This causes the motor to exhibit eddy-current braking characteristics. Calculation of the cut-off value on the basis
of the brake application time and deceleration time also considers the post-magnetization time. Therefore, the me‐
chanical brake is only applied at the end of the post-magnetization time.
87
11.7.5 Brake release delay
Brake release delay 824 is started when DC pre-magnetization time 821 is initiated. The digital "Release
brake" message can be delayed in this way.
Parameters Setting
824 Brake release delay 0 ms 5000 ms 0 ms
Tab. 88
11.7.6 Brake application time
The Brake application time 825 must be set to the actual response time of the brake.
Parameters Setting
825 Brake application time 0 ms 2000 ms 100 ms
Tab. 89
The inverter calculates an internal frequency cut-off value on the basis of the brake application time and the decel‐
eration ramp. This also considers a programmed DC post-magnetization time parameter. At the moment the setpoint
value is switched off, the inverter compares the actual output frequency with the calculated cut-off value. In principle,
there are 3 possibilities as shown in cases 1 to 3.
Case 1: The brake application time is shorter than the remaining deceleration time
Fig. 69 Case 1: The brake application time is shorter than the remaining deceleration time
1 Output frequency 4 "Modulation on" message tB Brake application time

2 SW-Step 1+ 5 Calculated cut-off value tVZ Delay time
3 "Release brake" message
Tab. 90
In case 1, the brake application time is shorter than the remaining deceleration time. The "Release brake" signal is
switched off as soon as the value drops below the cut-off value. The brake is no longer excited and the mechanical
brake starts to brake when its application time has elapsed. If the brake application time is correctly programmed,
the ramp is at zero at the same moment and modulation is switched off.
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88
Case 2: The brake application time is longer than the remaining deceleration time
Fig. 70 Case 2: The brake application time is longer than the remaining deceleration time

3 "Release brake" message tGS DC post-magnetization time
Tab. 91
In case 2, the brake application time is longer than the remaining deceleration time. The "Release brake" signal is
switched off immediately and the inverter calculates a DC post-magnetization time. The output frequency decreases
to zero at the ramp and the modulation then remains switched on. For the calculated DC post-magnetization time,
the inverter supplies a DC voltage to the amount of 1½ times the "Characteristic boost for f = 0" parameter. This
causes the motor to exhibit eddy-current braking characteristics until the mechanical brake engages.
Case 3: The brake application time is interrupted by an integrator stop, for example
Fig. 71 Case 3: The brake application time is interrupted by an integrator stop, for example

3 "Release brake" message 6 Integrator stop tGS DC post-magnetization time
Tab. 92
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Case 3 shows an interrupted brake application time. The cause of this may be another valid setpoint or an integrator
stop due to an overload. In both cases, the calculation is restarted as in case 2. The DC post-magnetization time is
extended correspondingly.
89
11.8 Brake release monitoring
11.8.1 General
The brake release monitoring function monitors an external brake that is controlled by the Dedrive Compact unit. A
contact on the brake is required for the monitoring function. This contact sends the "Brake feedback" signal to a
digital input which is evaluated by the Brake feedback 827 parameter.
The brake release monitoring function monitors and compares the internal logic signal and the brake feedback signal
with each other. If any difference occurs, brake release monitoring error message F0405 is output after
Error response time 899 elapses.

0- Off (factory setting) Brake release monitoring is switched off.
1- On Brake release monitoring is switched on.
Tab. 93
Parameters Setting
828 Brake release time 0 ms 5000 ms 400 ms
894 Brake application time 0 ms 5000 ms 200 ms
899 Error response time 0 ms 5000 ms 100 ms
Tab. 94
Special digital output functions are available for the brake release monitoring function. See ⇒ Tab. 173, Page 123
11.8.2 Watchdog N
The Watchdog N signal can be selected for the digital outputs. The signal is set provided the brake release monitoring
function has detected normal error-free operation.
11.8.3 Brake release monitoring warning
The Brake release monitoring warning signal can be selected for the digital outputs. The signal is set without any
delay as soon as the brake release monitoring function has detected a deviation. The signal is reset when the F0405
brake release monitoring function error message has been acknowledged.
11.9 Load spectrum calculation
11.9.1 General
Hoist units are classified corresponding to their planned mode of operation in groups of mechanisms according to
operating time and load spectra and dimensioned according to the resulting loads (DIN 15020; ISO4301/1; FEM
1.001; FEM 9.511; FEM 9.755).
Therefore, they are only rated for a limited duration of service.
Classification is carried out on the basis of

● the planned total duration of service of the hoist unit
● the load, loading and stress spectra that the hoist unit is exposed to.
When the total duration of service has expired, measures must be taken in which components are checked and
replaced as specified by the manufacturer. A new available duration of service is then specified.
The load spectrum calculation is designed to enable the actual duration of service to be calculated at all times and
displayed as a reference for the total duration of service. When 90% of the total duration of service has expired, the
frequency inverter displays a warning that is designed to remind the hoist operator of the corresponding maintenance
measures.

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● The hoist owner bears sole responsibility for ensuring that maintenance is carried out in good time.
● Before the load spectrum calculation is carried out, the Lifting correction factor and Lowering correction factor
parameters must be adjusted.
90
● This adjustment must be carried out when the motor is warmed up for operation.
● The following sections must be followed exactly.
Parameters 829, 830, 831, 832, 833, 835 and 839 are not changed if Load spectrum calculation (Para. 830 = 1) is
active when the default is set (via parameter 34 = 4444) see ⇒ "Programming", Page 73. This means that the Load
spectrum calculation is active with the previous settings when the unit is reset to the default settings. However, it
must be considered that the load spectrum calculation will no longer function correctly after the default values have
been set, as the motor data (P rated, n rated) may have changed.
If parameters are transferred to the Parcom Compact unit using the parameter copy function of the KP500 control
unit or by means of the "Load parameter values from file" function, the load spectrum calculation is activated if the
necessary conditions are satisfied.
11.9.2 Load spectrum calculation mode

0- Off (factory setting) Load spectrum calculation is switched off.
1- On Load spectrum calculation is switched on.
Tab. 95
Load spectrum calculation is switched off by default by means of Operation mode 830.
The function can only be activated when the Theoretical duration of service 831 is greater than 0.
When programming parameters via a PC with the Parcom Compact software, the "Read inverter information" func‐
tion must be called up to enable the "1– Activated" selection. Selection "1" can be selected at any time on the KP500
control unit if the given conditions are satisfied.
The "Read inverter information" function must be called up again following activation.
None of the load spectrum calculation function parameters can be changed after load spectrum calculation has been
activated by means of Operation mode 830. This means that the function itself cannot be deactivated.

● Therefore, the load spectrum parameters must be set and adjusted before the load spectrum calculation function
is activated.
● It can only be deactivated by the Demag Customer Service department.
The Actual duration of service 835 is calculated after the function is activated. The LOAD SPECTRUM
warning is displayed when the Actual duration of service 835 reaches 90% of the
Theoretical duration of service 831. This warning remains on until the
Actual duration of service 835 drops below 90% of the Theoretical duration of service 831
again.
When the specified maintenance work has been carried out, the Actual duration of service 835 can be set
to 0 by the Demag Customer Service department.
11.9.3 Theoretical duration of service
Provided the load spectrum calculation has not yet been activated, the number of full load hours can be specified
according to the FEM classification by means of the Theoretical duration of service 831 parameter.
The load spectrum calculation can only be activated (parameter 830 = 1) when the
Theoretical duration of service 831 is greater than 0. This prevents unintended activation.
Parameters Setting
831 Theoretical duration of service 0,0 hours 100000,0 hours 0,0 hours
Tab. 96
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91
11.9.4 Lifting correction factor
Lifting correction factor 832 is included in the calculation of the Actual duration of service
835. The Lifting correction factor 832 parameter can only be changed if the load spectrum calculation
has not yet been activated.
The "Lifting" direction of operation must be activated with the "SW-Step 1+" input.

● Lifting correction factor 832 must be adjusted when the motor is warmed up for operation before the
load spectrum calculation function is activated.
To do this, a defined load must be suspended from the hoist unit. This load should approximately correspond to the
rated load of the hoist unit. The ratio of this load to the rated load must be determined.
Lifting correction factor 832 must be set in such a way that the Relative torque 837 actual value
corresponds to the ratio determined during the lifting operation.
Parameters Setting
832 Lifting correction factor 30% 200% 100%
Tab. 97
11.9.5 Lowering correction factor
Lowering correction factor 833 is included in the calculation of the Actual duration of service
835. The Lowering correction factor 833 parameter can only be changed if the load spectrum calculation
has not yet been activated.
The "Lowering" direction of operation must be activated with the "SW-Step 1-" input.

● Lowering correction factor 833 must be adjusted when the motor is warmed up for operation before
the load spectrum calculation function is activated.
To do this, a defined load must be suspended from the hoist unit. This load should approximately correspond to the
rated load of the hoist unit. The ratio of this load to the rated load must be determined.
Lowering correction factor 833 must be set in such a way that the Relative torque 837 actual value
corresponds to the ratio determined during the lowering operation.
Parameters Setting
833 Lowering correction factor 30% 200% 100%
Tab. 98
11.9.6 Duration of service specification
The Actual duration of service 835 can be pre-set via the Duration of service specification
834 parameter. It may be necessary to specify the parameter for replacement or additional units or if an incorrect
value has been entered. Actual duration of service 835 can only be specified if the load spectrum calcu‐
lation has not yet been activated.
Parameters Setting
834 Duration of service specification 0,0 hours 100000,0 hours 0,0 hours
Tab. 99
11.9.7 Actual duration of service
Actual duration of service 835 is an actual value parameter and reflects the current duration of service in
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full load hours. The value of the Actual duration of service 835 is 0 before the load spectrum calculation
is activated.
92
The actual values can be read out and monitored in the VAL sub-menu of the operating unit.
A further "Absolute duration of service" value is calculated for monitoring. Calculation of the "Absolute duration of
service" corresponds to calculation of the Actual duration of service 835.
However, the "Absolute duration of service" cannot be reset or reduced. It can only be read by the DCC Customer
Service department under number 890. This makes it possible to establish whether the
Actual duration of service 835 has been reset by means of the
Duration of service specification 834 parameter, e.g. following maintenance of the hoist unit.
If the load spectrum calculation is activated, and the Duration of service specification 834 is larger than
the internal "Absolute duration of service", the "Absolute duration of service" is increased to the value of
Duration of service specification 834.
11.9.8 Remaining service life
Remaining service life 836 provides the owner of the hoist unit with information for a due maintenance
deadline. The inverter displays the "Load spectrum" warning at 10%. A general overhaul must be carried out at no
later than 0 %.
11.9.9 Relative torque
The Relative torque 837 actual value must be used to adjust the Lifting correction factor 832 and
Lowering correction factor 833 parameters. The read value must correspond to the ratio of hoist unit actual
load to rated load.
11.9.10 Ramp factor
During the acceleration and deceleration ramps a ramp factor 838 is applied to the calculated load spectrum.
The dynamic shares occurring with very steep ramps are only partially applied to the load spectrum, if the value set
is smaller than 1,00.
Parameters Setting
838 Ramp factor 0,30 1,00 1,00
Tab. 100
11.9.11 Frequency at rated hoist speed
Starting with device software version 4.2.4/050-7, the load spectrum value can also be calculated with a speed value
function. The ratio of the current actual frequency to the programmable Frequency at rated hoist speed
839 is used for this purpose. The speed evaluation function is deactivated if the
Frequency at rated hoist speed 839 parameter is set to 0,00 Hz.
Parameters Setting
839 Frequency at rated hoist speed 0,00 Hz 300,00 Hz 0,00 Hz
Tab. 101
11.9.12 Factor
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Starting with device software version 4.2.4/050-7, the internally calculated load spectrum value can also be calcu‐
lated with a Factor 829 in special cases.
93
Parameters Setting
829 Factor 0,50 2,00 1,00
Tab. 102
11.10 Limit switch functions
11.10.1 Reference value limitation
5
6
7
42399644_xml.eps
Fig. 72
1 (SOSP) acceleration 062 5 Minimum frequency 418

2 SW-Step 1+ 068 6 Setpoint val. limit 1+ 871
3 Fast to slow limit switch limitation 1+ 803 7 Direction of travel for positive frequency
4 Maximum frequency 419
Limitation of the setpoint value is activated when the relevant digital input is logically OFF when the fast-to-slow limit
switch is approached (input open).
If no fast-to-slow limit switches are wired, the input parameters

Fast to slow limit switch limitation 1+ 803, Fast to slow limit switch limitation 1-
804 and Fast to slow limit switch limitation 2 805 must be set to the value "6 - ON", ⇒ "Fast-to-slow
limit switch limitation", Page 131.
The diagram shows setpoint value limitation using an example of control with setpoint memory in the positive direction
and limit 1+.
11.10.2 Setpoint val. limit 1+ and setpoint val. limit 1-
The Fast to slow limit switch limitation 1+ 803 and

Fast to slow limit switch limitation 1- 804 input parameters can be programmed independently of
each other with 2 digital inputs, ⇒ "Fast-to-slow limit switch limitation 1+ and fast-to-slow limit switch limitation 1-",
214 716 44/200710
Page 131.
The limitation is always applied according to the sign, i.e. only the positive setpoint value is limited when the
Fast to slow limit switch limitation 1+ 803 input is logically OFF, and vice versa. The limitation
94 function is only effective if the current setpoint value is higher than the limitation value. In this case, a programmed
limitation value may also be lower than the value of the first setpoint step (e.g. SOST step 1 480). If the conditions
for the limitation are satisfied, the inverter will decelerate down the current ramp to the limitation value. If the limitation
function is switched off again and a higher setpoint value is required, the inverter will accelerate back up to the
specified setpoint value. However, only to the Minimum frequency 418 value for SOSP.
Parameters Setting
871 Setpoint val. limit 1+ -300,00 Hz 300,00 Hz 2,00 Hz
872 Setpoint val. limit 1- -300,00 Hz 300,00 Hz 2,00 Hz
Tab. 103
11.10.3 Setpoint val. limit 2+ and Setpoint val. limit 2-
The Fast to slow limit switch limitation 2 805 input function can be programmed with one digital
input ⇒ "Fast-to-slow limit switch limitation 2", Page 131.
If the fast-to-slow limit switch is approached with a frequency greater than 6.00 Hz, it is possible to travel in the
opposite direction out of the fast-to-slow limit switch range without any limitation, provided the inverter has not been
switched off in the meantime.
The limitation function is only effective if the current setpoint value is higher than the limitation value. In this case, a
programmed limitation value may also be lower than the value of the first setpoint step (e.g. SOST step 1 480). If
the conditions for the limitation are satisfied, the inverter will decelerate down the current ramp to the limitation value.
If the limitation function is switched off again and a higher setpoint value is required, the inverter will accelerate back
up to the specified setpoint value. However, only to the Minimum frequency 419 value for SOSP.
Parameters Setting
873 Setpoint val. limit 2+ -300,00 Hz 300,00 Hz 2,00 Hz
874 Setpoint val. limit 2- -300,00 Hz 300,00 Hz 2,00 Hz
Tab. 104
11.10.4 Limit switch monitoring frequency
The Operating limit switch + 806 and Operating limit switch - 807 input functions can be pro‐
grammed independently of each other with 2 digital inputs, ⇒ "Operating limit switches", Page 132.
If Operating limit switch + 806 is approached in the positive direction with a frequency higher than
Limit switch monitoring freq. + 875 or Operating limit switch- 807 is approached in the negative
direction with a frequency higher than Limit switch monitoring freq. - 876, error 1120 "Limit switch mon‐
itoring frequency exceeded" is generated.
Parameters Setting
875 Limit switch 0,00 Hz 300,00 Hz 2,00 Hz
monitoring frequency +
876 Limit switch 0,00 Hz 300,00 Hz 2,00 Hz
monitoring frequency -
Tab. 105
11.10.5 Limit switch status
The State 1 866 to State 4 869 parameters are only needed for system bus applications.
Therefore, for applications without a system bus, the factory setting
"814 – Limit switch status"
must remain unchanged.
11.11 External error / quick stop

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Programming the External error / quick stop function enables the Dedrive Compact unit to respond to external events,
e.g. faults in the installation for a further drive.
95
The logic signal or the digital input signal which is to be used to evaluate the external event is assigned to the
External error / quick stop 183 parameter. The function is activated as soon as the
External error / quick stop 183 is logically set to ON. Therefore, an inverted digtal input must be used for
failsafe evaluation.
The following variants are available as possible reponses by the Dedrive Compact unit which can be selected by
the Operation mode 535 parameter of the External error / quick stop function.

0- deactivated No reaction to the External error / quick stop 183 digital input.
1- Error Switch-Off If the logic signal or the digital input signal is applied for the External error / quick stop 183
parameter, the drive is switched off without any deceleration ramp, the brake is applied immediately and
the „F1454 External error“ error message is output. The error can only be acknowledged when the
External error / quick stop 183 parameter is logically set to OFF.
2- Shutdown, error If the logic signal or the digital input signal is applied for the External error / quick stop 183
parameter, the drive is switched off with the current deceleration ramp and the „F1454 External error“ error
message is then output. The ramp can be interrupted. The error can only be acknowledged when the
3- Quick stop, error If the logic signal or the digital input signal is applied for the External error / quick stop 183
parameter, the drive is switched off with the programmed Emergency Stop Clockwise 424 or
Emergency Stop Anticlockwise 425 quick stop ramp and the „F1454 External error“ error message
is then output. The ramp can be interrupted. The error can only be acknowledged when the
4- Quick stop, no error If the logic signal or the digital input signal is applied for the External error / quick stop 183
parameter, the drive is switched off with the programmed Emergency Stop Clockwise 424 or
Emergency Stop Anticlockwise 425 quick stop ramp. No error message is then output. The ramp
can be interrupted. A new travel command must be issued after the drive has come to a standstill.
Tab. 106
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96
12 Error and warning behaviour
12.1 General
The operation of the frequency inverter and the connected load is continuously monitored. The monitoring functions
and the associated limit values must be programmed specifically for the application. If the limits are set to values
below the cut-off limit of the frequency inverter, a disconnection on fault can be prevented by corresponding meas‐
ures in the case of a warning message. The warning message is indicated by the LEDs and can be read out via the
operating unit or by means of the Parcom Compact programming software via the Warnings 269 parameter or
output via one of the digital control outputs.
12.2 Overload Ixt

The admissible load characteristic depends on various technical data of the frequency inverters and on the ambient
conditions.
The selected Modulation frequency 400 determines the rated current and the overload being available for ten
or sixty seconds. The associated parameters Warning Limit Short Term Ixt 405 and
Warning Limit Long Term Ixt 406 must also be programmed.
Parameters Setting
405 Warning limit short term Ixt 6% 100% 80%
406 Warning limit long term Ixt 6% 100% 80%
Tab. 107
12.3 Temperature
The ambient conditions and the current working point heat up the frequency inverter. In order to avoid a disconnection
on fault of the frequency inverter, the Warning Limit Heat Sink Temp. 407, for the temperature limit of the
heat sink and the Warning Limit Inside Temp. 408, for the temperature limit inside the frequency inverter
housing can be programmed. The temperature value which is calculated from the limit value depending on the type
minus the set warning limit can be determined from the application data.
The cut-off limit of the frequency inverter is 60 °C - 70 °C inside the frequency inverter housing and 80 °C - 90 °C
for the heat sink.
Parameters Setting
407 Warning Limit Heat Sink Temp. -25 °C 0 °C -5 °C
408 Warning Limit Inside Temp. -25 °C 0 °C -5 °C
Tab. 108
12.4 Controller status

The selected control and regulation process and the associated monitoring functions prevent disconnection of the
frequency inverter. The effect of the function changes the operating behaviour of the application and can be displayed
via status messages by the Controller status 275 parameter. The limit values and events that lead to inter‐
vention by the corresponding controller are described in the corresponding sections. Behaviour resulting from
intervention by a controller is configured by the Controller status message 409 parameter.
Controller status message 409 Function

0- No message The controllers which influence the operating behaviour are indicated in the
Controller status 275 parameter.
1- Warning status (Factory setting) The limitation by a controller is indicated as a warning by the operating unit.
11 - Warning status and LED The limitation by a controller is indicated as a warning by the operating unit and by the LEDs.
Tab. 109
12.5 IDC compensation limit

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Due to asymmetries the output current of the frequency inverter may contain a DC percentage. This DC percentage
can be compensated by the frequency inverter. The maximum compensation output voltage is set by the
97
IDC compensation limit 415 parameter. Error "F1301 IDC-COMPENSATION" is triggered if a higher voltage
than the set limit is required to compensate the DC percentage.
If this error occurs, the load should be checked for being defective. Under certain circumstances the voltage limit
must be increased.
If the parameter IDC compensation limit 415 is set to zero, the DC compensation is deactivated.
Parameters Setting
415 IDC compensation limit 0,0 V 1,5 V 0,0 V
Tab. 110
12.6 Frequency switch-off limit

The maximum permissible output frequency of the frequency inverter must be set with the
Frequency switch-off limit 417 parameter. If this frequency limit is exceeded by Stator frequency
210, or Actual frequency 241, the frequency inverter switches off and outputs error message "F1100".
For configurations 110 "V/f- characteristic" and 410 "FOR control speed without encoder", encoder 1 can be activated
by the Operation mode 490 parameter or encoder 2 can be activated by the Operation mode 493 parameter
for additional monitoring of the measured actual frequency.
Parameters Setting
417 Frequency switch-off limit 0,00 Hz 999,99 Hz 100,00 Hz
Tab. 111
12.7 Motor temperature

The monitoring function can be programmed by the Motor-PTC Operation Mode 570 parameter. A thermal
contact is evaluated via a digital input in operation modes 1 … 5. Integration into the application can be improved
by an operation mode with delayed disconnection, ⇒ "Motor thermal contact", Page 130.

0- Off (factory setting) The monitoring of the motor temperature is not active.
1- Therm.-Cont.: Warning only The critical working point is indicated by the operating unit and the parameter Warnings 269.
2- Therm.-Cont.: Error Switch-Off The disconnection on fault is indicated by message F0400. The disconnection on fault can be ac‐
knowledged via the operating unit or digital input.
3- Therm.-Cont.: Err.Switch-Off 1 The disconnection on fault corresponding to operation mode 2 is delayed by one minute.
min delayed
4- Therm.-Cont.: Err.Switch-Off 5 The disconnection on fault corresponding to operation mode 2 is delayed by five minutes.
min delayed
5- Therm.-Cont.: Err.Switch-Off 10 The disconnection on fault corresponding to operation mode 2 is delayed by ten minutes.
min delayed
Tab. 112
If the EM extension module is plugged in, further operation modes for evaluating a PTC thermistor are available.
Refer to the EM – UNI-01 extension module operating instructions.
12.8 Phase failure

If one of the three phases of the motor or power supply fails, the frequency inverter, the motor and the mechanical
drive components may get damaged, if the phase failure is not noticed. Behaviour in the event of a phase failure
can be set by the Phase Supervision 576 parameter.

10 - Mains: Error switch-off In the case of a phase failure in the power supply, the disconnection is delayed by one minute
(Factory setting) indicating error F0703. During the delay warning message A0100 is displayed.
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11 - Mains & Motor: Error Switch-Off The phase supervision disconnects the frequency inverter after one minute indicating error mes‐
sage F0403 in the case of a motor phase failure and F0703 in the case of a phase failure in the
power supply.
98
20 - Mains: Shutdown The drive is shut down one minute after a phase failure in the power supply indicating error F0703.
21 - Mains & Motor: Shutdown This function shuts down the drive immediately in the case of a motor phase failure and after one
minute in the case of a phase failure in the power supply.
Tab. 113
12.9 Automatic error acknowledgement

Automatic error acknowledgement makes it possible to acknowledge the Overcurrent F0500, Overcurrent F0507
and Overvoltage F0700 errors without any intervention by a higher-level control system or a user. If one of the above-
mentioned errors occurs, the frequency inverter cuts off the power semiconductors and waits for the time set with
the Restart Delay 579 parameter. If the error has to be acknowledged, the motor speed is determined by means
of the Quick Synchronisation function and synchronised with the rotating machine. Automatic error acknowledge‐
ment uses the Quick Synchronisation operation mode independent of the Operation mode 645 parameter setting.
Please note the information on the search run function. The number of errors to be acknowledged within ten minutes
is set by the Allowed no. of auto-acknowl. 578 parameter. The above-mentioned errors have a separate
counter so that a new acknowledgement above the admissible number within ten minutes leads to the direct dis‐
connection of the frequency inverter.
Parameters Setting
578 Allowed no. of auto-acknowl. 0 20 0
579 Restart delay 0 ms 1000 ms 20 ms
Tab. 114
12.10 Frequency monitoring

The Frequency monitoring 468 parameter determines the reaction of the frequency inverter to differences
between the output of the ramp and the actual frequency.
Frequency monitoring 468 Function

1- Max. frequency deviation When the value of parameter Max. frequency deviation 429 is exceeded, an error is signalled,
Factory setting for configuration ⇒ „Max. frequency deviation“, Page 99
210
2- Max. leading The difference is limited by the Maximum Leading 426, ⇒ „Frequency ramps“, Page 107 parameter
Factory setting for all other configu‐
rations
Tab. 115
12.11 Max. frequency deviation

The function is only activated for configuration 210 as factory setting.
A tolerance range is established around the current output frequency of the ramp (integrator) by the
Max. frequency deviation 429 parameter. If the difference between the integrator and the current actual
frequency of the motor exceeds the max. frequency deviation, this will result in disconnection on fault F1102 = "Max.
frequency deviation".
This function is only active, when the rotary encoder is de-activated and modulation is switched on.
This function is also active, when the rotary encoder is activated and modulation is switched off.
If one of the rotary encoders is activated in configurations without encoder, the rotary encoder frequency is evaluated
as actual frequency instead of the rotor frequency calculated internally.
Parameters Setting
429 Max. frequency deviation 0,01 Hz 15,00 Hz 10,00 Hz
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Tab. 116
99
13 Reference values
13.1 General
Dedrive Compact frequency inverters can be configured specifically to the application and allow to adapt the modular
hardware and software structure to the requirements of the customer.
13.2 Frequency limits

The speed range and, therefore, the output frequency of the frequency inverter is defined by the
Minimum frequency 418 and Maximum frequency 419 parameters. The corresponding control and regulation
processes use the two limit values for scaling and limiting the frequency.
Parameters Setting
Tab. 117
The torque-forming current component and thus the slip frequency of the asynchronous machine depend on the
required torque. The field-oriented regulating processes additionally include the parameter Slip limit 719 for
limiting the torque in the calculation of the machine model. The rated slip calculated from the rated motor data is
limited according to the percentage set by the Slip limit 719 parameter.
Parameters Setting
719 Slip limit 0% 10000% 330%
Tab. 118
13.3 Percentage limits

Percentage limits only apply to configurations with torque regulation.
The control range of the percentages is defined by the Minimum reference percentage 518 and
Maximum reference percentage 519 parameters. The corresponding control and regulation processes use
the two limit values for scaling and limiting the percentages.
Parameters Setting
518 Minimum reference percentage 0,00% 300,00% 0,00%
519 Maximum reference percentage 0,00% 300,00% 100,00%
Tab. 119
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100
13.4 Reference frequency channel
13.4.1 General
The various functions for specifying the reference frequency in the speed-controlled configurations are combined in
the reference frequency channel. Drive control 475 determines the additive linkage of the available reference
value sources depending on the hardware installed.
Control 475 Function

1 to 21 Operation modes with absolute value function
1- Analogue MFI1A The reference value source is the multi-function input 1 in Operation mode 452 - voltage
input.
⇒ „Analogue input MFI1A“, Page 118
10 - SOST Absolute value of reference value steps according to the input functions (SOST) Step 2
066 and (SOST) Step 3/4 067
⇒ „SOST reference value steps“, Page 105
11 - SOST + Analogue MFI1A Adds operation modes 10 and 1
20 - SOSP The setpoint source is the function setpoint memory (SOSP) Acceleration 62
⇒ „SOSP reference value memory“, Page 110
21 - SOSP + Analogue MFI1A Adds operation modes 20 and 1
101 - 111 As operation mode 1 to 11, however with sign
Tab. 120
Further selections are possible when an EM – UNI-01 extension module is installed. See operating instructions of
the extension modules.
13.4.2 Table of switch positions
The following table describes the software switches shown in the block diagram depending on the selected
Drive control 475.
Switch position in the block diagram

Operation mode MFI1A FF MP EM-S1INA F3 Sign
1 1 Absolute value
2 1 Absolute value
4 1 1 Absolute value
10 1 Absolute value
14 1 1 1 Absolute value
20 1 Absolute value
24 1 1 1 Absolute value
32 1 Absolute value11)
101 1 +/-
110 1 +/-
111 1 1 +/-
Tab. 121
EM-S1INA only with extension module

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11) only in the manual mode 101

13.4.3 Block diagram
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Fig. 73 Block diagram of the reference frequency channel
102
13.5 Reference percentage channel
13.5.1 General
The reference percentage channel only applies to configurations with torque regulation.
The reference percentage channel combines different signal sources to specify the reference values. The scaling
in percent facilitates the integration into the application taking different process variables into account.
Reference percentage source 476 determines the additive linkage of the available reference value sources
depending on the hardware installed.

1- Abs. Analogue Value MFI1A The reference value source is multi-function input 1 in Operation mode 452 - analogue signal.
10 - Abs. Fix. Perc. Val. (FP) The percentage according to the Fixed percent change-over 1 75,
Fixed percent change-over 2 76 and the current data set, ⇒ „Fixed percentage values“,
Page 106
11 - Abs. Value MFI1A + FP Combination of operation modes 10 and 1
20 - Abs. Val. Motorpoti (MP) The reference value source is the function Percent motorpoti up 72 und
Percent motorpoti down 73
21 - Abs. Value MFI1A + MP Combination of operation modes 20 and 1
32 - Abs. Val. Rep. Freq. Input (F3) The frequency signal on the digital input acc. to Operation mode 496
101 - 132 Operation modes with sign (+/-)
Tab. 122
Further selections are possible when an EM – UNI-01 extension module is installed. See operating instructions of
the extension modules.
13.5.2 Operation mode 476
The following table describes the software switches shown in the block diagram depending on the selected
Reference percentage source 476.
Switch position in the block diagram

Operation mode MFI1A FP MP F3 Sign
1 1 Absolute value
10 1 Absolute value
20 1 Absolute value
32 1 Absolute value
101 1 +/-
110 1 +/-
111 1 1 +/-
120 1 +/-
121 1 1 +/-
132 1 +/-
Tab. 123
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103
104
13.5.3
Prozentsollwertkanal
Block diagram
Prozentsollwertquelle 476
Folgefrequenz
0 F3
S2IND % 0
Jrel.
S3IND
f
S6IND
1
Betriebsart 496
Teiler 497
Motorpoti
Prozent-Motorpoti MP
AUF 72 0
Fig. 74 Block diagram of the reference percentage channel

Max. Betrag Start / Stop /
Drehrichtungsauswahl
Min. 1 Prozentsollwert 229
Prozent-Motorpoti Prozentwertgrenzen
0
AB 73 %max
MFI1A + Prozentsollwert
0 -1
Multifunktion %min
analog Min. Prozentwert 518

Max. Prozentwert 519 SW-Stufe 1+ 68
1 SW-Stufe 1- 69
MFI1
digital
Betriebsart 452
FP
Festprozentwert
0
Festprozentwert 1 520
Festprozentwert 3 522 1
Umschaltung 1 75
Umschaltung 2 76
42399844DE_xml.eps
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13.6 Fixed reference values
13.6.1 General
Fixed reference values can be programmed as reference value steps or fixed percentages according to the config‐
uration and function.
The signs of the fixed reference values determine the direction of rotation. A positive sign means a clockwise rotating
field and a negative sign means an anti-clockwise rotating field. The direction of rotation can only be reversed by
means of the sign, if the Drive control 475, or Reference percentage source 476 is set to an operation
mode with sign (+/-). The direction of rotation can additionally be specified by means of the digital signal sources
linked with the parameters SW-Step 1+ 68 and SW-Step 1- 69.
Fixed reference values can be programmed in four data sets and are linked with further sources via the reference
value channel. Thus the functions Data Set Change-Over 1 70 and Data Set Change-Over 2 71 can be
used for setting 16 fixed reference values.
13.6.2 SOST reference value steps
The four reference value steps define reference values which are selected via SW-Step 1+ 68 or SW-Step 1-
69 , as well as (SOST) Step 2 66 and (SOST) Step 3/4 67, ⇒ "SOST reference value step change-over",
Page 129
Operating principle: General information
All reference step functions are activated when current flows through the relevant input. The input signals are filtered
by the hardware and software.
An edge from "off" to "on" must be created following the ready for operation signal in order to obtain a valid setpoint
value.
Edge evaluation is only possible if the inverter is ready for operation. Edge signals given too early will not be detected
and have to be repeated.
Reference value step function
2, 3 or 4 reference value steps can be selected. Depending on the number selected, various inputs are available for
other functions.
The steps do not work on the basis of summation. A lower value may be programmed to a higher step than for a
lower one. The current reference value is always specified by the highest step that is switched on.
When the first step SW-Step 1+ 68 is applied, the inverter accelerates up the Acceleration 420 ramp to the
frequency value programmed for SOST step 1 480. If a further step is applied to the SW-Step 1+ 68 input, the
inverter will accelerate or decelerate to the corresponding programmed speed. The signal must remain applied to
the SW-Step 1+ 68 input for activating higher steps.
If no signal is applied to the SW-Step 1+ 68 input any longer, the inverter will decelerate down the current ramp to
0 and will switch off the output stage.
If a signal is applied for the opposite direction SW-step 1– 69 before zero is reached, the inverter will accelerate
in the opposite direction after reaching 0 without switching off the "Release brake" signal.
The setpoint value step function works in the "–" direction in the same way.
If both SW-Step 1+ 68 and SW-Step 1– 69 inputs are activated simultaneously, the inverter will evaluate this
status as an invalid reference value. The reaction is determined by the Operation mode 630 parameter of the
stopping behaviour function.
SOST-Parameters
Parameters Setting
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68 SW-Step 1+ 71 – S2IND
69 SW-Step 1 - 72 – S3IND
66 (SOST) Step 2 75 – S6IND
67 (SOST) Step 3/4 7 - Off
105
Parameters Setting
480 SOST step 1 -300,00 Hz 300,00 Hz 5,00 Hz
481 SOST step 2 -300,00 Hz 300,00 Hz 50,00 Hz
482 SOST step 3 -300,00 Hz 300,00 Hz 5,00 Hz
483 SOST step 4 -300,00 Hz 300,00 Hz 5,00 Hz
Tab. 124
See also ⇒ "SOST reference value step change-over", Page 129
13.6.3 JOG frequency
The JOG function forms part of the functions for controlling the drive via the KP500 operating unit. The JOG frequency
can be modified within the function by means of the arrow keys. The drive starts and the motor rotates at the set
JOG-Frequency 489. If the JOG frequency has been modified by means of the arrow keys, this value is saved,
⇒ "Controlling the motor via the operating unit", Page 59
Parameters Setting
489 JOG frequency -300,00 Hz 300,00 Hz 5,00 Hz
Tab. 125
13.6.4 Fixed percentage values
Fixed percentages only apply to configurations with torque regulation. The four percentages define reference values
which are selected via the Fixed Percent Change-Over 1 75 and Fixed Percent Change-Over 2 76.
The Reference percentage source 476 defines the addition of the different sources in the reference percent‐
age channel.
Parameters Setting
520 Fixed percentage 1 -300,00% 300,00% 0,00%
Tab. 126
⇒ "Fixed percentage value change-over", Page 130
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106
13.7 Frequency ramps
Frequency ramp
Fig. 75
1 Clockwise rotation
2 Anti-clockwise rotation
The internal reference value from the reference frequency channel and the line reference value of a bus control can
be applied to the ramp as individual values or as a summated variable. The setting is programmed via the
Ramp setpoint 434 parameter.
Ramp setpoint 434 Function

1- Internal Setpoint The source is the frequency reference value generated internally.
2- Line Setpoint The source is the reference value specified by a bus control.
3- Internal + line setpoint (Factory Addition of the internal reference value and the line reference value.
setting)
Tab. 127
The ramps determine how fast the frequency value is modified after a reference value has been changed or after a
start, stop or brake command. The maximum permissible ramp steepness must be selected corresponding to the
application and the motor power consumption.
Programming by means of the Acceleration 420 and Deceleration 421 parameters is sufficient if the frequency
ramp settings are the same for both directions of rotation. The values of the frequency ramps
Acceleration anticlockwise 422 and Deceleration anticlockwise 423 are taken over, if these are
programmed to the factory setting of -0,01 Hz/s.
The parameter value 0,00 Hz/s for the acceleration blocks the corresponding direction of rotation.
Parameters Setting
420 Acceleration 0,00 Hz/s 999,99 Hz/s 10,00 Hz/s
421 Deceleration 0,01 Hz/s 999,99 Hz/s 10,00 Hz/s
422 Acceleration anticlockwise - 0,01 Hz/s 999,99 Hz/s - 0,01 Hz/s
423 Deceleration anticlockwise - 0,01 Hz/s 999,99 Hz/s - 0,01 Hz/s
Tab. 128
The ramps for the Emergency stop clockwise 424 and Emergency stop anticlockwise 425 of the drive
which must be activated via the Operation mode 630 must be selected according to the application. The non-
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linear (S-shaped) curve of the ramps is not active in the case of an emergency stop of the drive.
107
Parameters Setting
424 Emergency stop clockwise 0,01 Hz/s 999,99 Hz/s 30,00 Hz/s
425 Emergency stop anticlockwise 0,01 Hz/s 999,99 Hz/s 30,00 Hz/s
Tab. 129
The Maximum Leading 426 parameter limits the difference between the output of the ramp and the current actual
value of the drive. The set maximum difference is a dead time for the regulation process and should be selected as
low as possible.
Parameters Setting
426 Maximum leading 0,01 Hz/s 999,99 Hz/s 5,00 Hz/s
Tab. 130
The load occurring with a linear acceleration of the drive is reduced by the speeds of change to be set (S-shaped
curve). The non-linear frequency curve is defined as a ramp rise or fall and specifies in which time range the fre‐
quency is lead to the set ramp. The values set by parameters 420 to 423 are maintained independent on the selected
ramp rise or fall times.
If the ramp rise or fall time is set to 0 ms, the S-shaped curve function is deactivated and enables the linear ramps
to be used. The data set change-over of the parameters during one acceleration phase of the drive requires the
defined transfer of values. The control calculates the values necessary for reaching the reference values from the
ratio of the acceleration to the ramp rise or fall time and uses these values until the acceleration phase is completed.
This procedure avoids the reference values being exceeded and makes it possible to switch between data sets with
extremely different values.
Parameters Setting
430 Ramp rise time clockwise 0 ms 65000 ms 0 ms
431 Ramp fall time clockwise 0 ms 65000 ms 0 ms
432 Ramp rise time anticlockwise 0 ms 65000 ms 0 ms
433 Ramp fall time anticlockwise 0 ms 65000 ms 0 ms
Tab. 131
Fig. 76
1 Clockwise rotation 2 Anti-clockwise rotation

3 Frequency reference value = 0,00 Hz
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Example:Calculation of the acceleration time for a clockwise rotating field with an acceleration from 20 Hz to 50 Hz
(fmax) and an Acceleration ramp 420 of 2 Hz/s. The Ramp rise time clockwise 430 is set to 100 ms.
108
Δf 50 Hz - 20 Hz tauftr Acceleration time clockwise rotating field
taufr = = = 15 sec
RACCR 2 Hz/s ∆f Frequency change acceleration ramp
RACCR Acceleration
tauf = taufr + RRTR = 15 s + 100 ms = 15.1 sec RRTR Ramp rise time clockwise
Tab. 132
13.8 Percentage ramps

Fixed percentage ramps only apply to configurations with torque regulation.
The percentage ramps scale the change of reference values in percent for the corresponding input function. The
acceleration and deceleration of the drive are programmed via the frequency ramps.
The characteristic Gradient percentage ramp 477 corresponds to a function which takes the time response of
the drive system into account. When the parameter is set to 0 %/s, this function is deactivated, which leads to a
direct change of the reference value for the following function.
The factory-set value depends on Configuration 30.
Parameters Setting
477 Gradient percentage ramp 0%/s 60,000%/s 10%/s
Tab. 133
13.9 Blocking frequencies
Fig. 77
1 Reference value output 2 Internal reference value

3 Hysteresis
In certain applications it is necessary to block reference frequencies, which avoids that points of resonance of the
installation are used as stationary working points. The 1st blocking frequency 447 and
2nd blocking frequency 448 parameters with the Frequency hysteresis 449 parameter define two points
of resonance.
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A blocking frequency is active when the parameter values of the blocking frequency and the frequency hysteresis
are not equal to 0,00 Hz.
109
The area blocked by the hysteresis as stationary working point is passed as quickly as possible according to the set
ramp. If the selected setting of the controller parameters results in a limitation of the output frequency, e.g. by
reaching the current limit, the hysteresis is passed with a delay. The behaviour of the reference value can be de‐
termined from its direction of movement in the diagram shown above.
Parameters Setting
447 1. blocking frequency 0,00 Hz 999,99 Hz 0,00 Hz
448 2. blocking frequency 0,00 Hz 999,99 Hz 0,00 Hz
449 Frequency hysteresis 0,00 Hz 100,00 Hz 0,00 Hz
Tab. 134
13.10 SOSP reference value memory
13.10.1 Operating principle: General information
All reference value memory functions are activated when current flows through the relevant input. The input signals
are filtered by the hardware and software.
An edge from "off" to "on" must be created following the ready for operation signal in order to obtain a valid setpoint
value.
Edge evaluation is only possible if the inverter is ready for operation. Edge signals given too early will not be detected
and have to be repeated.
Reference value memory function
This reference value creation function is specially designed for use with 2-stage pushbuttons. A 2-stage pushbutton
is required for each direction of rotation. The first step actuates the SW-step 1+ 68 or SW-step 1– 69 input. The
second step actuates the relevant (SOSP) Acceleration 62 input.
When the first SW-Step 1+ 68 step is applied, the inverter accelerates up Acceleration 420 ramp to the value
of the Minimum frequency 418 parameter. If a signal is applied to the (SOSP) Accelerate 682 input in addition
to the SW-Step 1+ 62 input, the inverter will continue to accelerate up the acceleration 420 ramp. Acceleration
can be interrupted by switching off the signal at the (SOSP) Acceleration 62 input. If the signal remains applied
to the SW-Step 1+ 68 input, the inverter will save the current frequency reference value to memory. The acceleration
operation can be continued at any time until the Max. frequency 419 parameter value is reached.
The signal applied to the SW-Step 1+ 68 input must be switched off to start decelerating. The inverter will then
reduce its frequency down the Deceleration 421 ramp. If the SW-Step 1+ 68 input is activated once more, the
inverter will save the current frequency to memory, but only if it is still higher than the Minimum frequency 48
parameter value. If the current value is lower than the Minimum frequency 418 parameter value, the inverter will
accelerate to the Minimum frequency 418 parameter value. Frequency values between 0 and
Minimum frequency 418 cannot be achieved with this reference value control when stationary.
If the SW-Step 1+ 68 signal remains switched off, the inverter will reach zero and switch off the output stage.
If a signal is applied for the opposite direction SW-step 1– 69 before zero is reached, the inverter will accelerate
in the opposite direction after reaching 0 without switching off the "Release brake" signal.
The "–" direction of rotation works in the same way.
If both SW-step 1+ 68 and SW-step 1– 69 inputs are activated simultaneously, the inverter will evaluate this
status as an invalid setpoint value. The reaction is determined by the Operation mode 630 parameter of the
stopping behaviour function.
13.10.2 SOSP parameter
Parameters Setting
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68 SW-Step 1+ 71 – S2IND
69 SW-Step 1 - 72 – S3IND
62 (SOSP) Acceleration 75 – S6IND
Tab. 135
110
13.10.3 Reference value memory diagram
Fig. 78
1 Minimum frequency 418 3 "SW-Step 1 +" input

2 Maximum frequency 419 4 "(SOSP) Acceleration" input
The SOSP function 474 parameter defines the behaviour of the function in relation to different working points of
the frequency inverter. The reference values are limited by the corresponding limit values Minimum frequency
418, Maximum frequency 419 or Minimum reference percentage 518,
Maximum reference percentage 519.

0- Not Latching The drive runs up to the minimum frequency at each start.
1- Latching When started via the „Auto-start“ function, the drive will run up to the reference value selected
before the controller enable signal S1IND was deactivated. This reference value is saved even
when the unit is switched off.
2- Taking Over Taking Over operation mode is to be used for the change-over of data sets of the reference
value channel. The current reference value is used on change-over to SOSP control.
3- Taking Over and Latching This operation mode combines the behaviour in operation mode 1 and 2.
Tab. 136
13.11 Keypad motor potentiometer

The operating unit includes the motor potentiometer function by means of different keys. The change of the reference
value is limited by the Ramp Keypad-Motorpoti 473 parameter, ⇒ "Controlling the motor via the operating unit",
Page 59.
Parameters Setting
473 Ramp Keypad-Motorpoti 0,00 Hz/s 999,99 Hz/s 2,00 Hz/s
Tab. 137
13.12 Repetition frequency input

The use of a frequency signal completes the many possibilities of reference value specification. The signal on one
of the available digital inputs is evaluated according to the selected Operation mode 496.
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111
0- Off (factory setting) The repetition frequency is zero.
21 - S2IND single evaluation pos. One edge of the frequency signal on terminal X210A.4 is evaluated with a positive sign.
22 - S2IND double evaluation pos. Both edges of the frequency signal on terminal X210A.4 are evaluated with a positive sign.
31 - S3IND single evaluation pos. One edge of the frequency signal on terminal X210A.5 is evaluated with a positive sign.
32 - S3IND double evaluation pos. Both edges of the frequency signal on terminal X210A.5 are evaluated with a positive sign.
61 - S6IND single evaluation pos. One edge of the frequency signal on terminal X210B.1 is evaluated with a positive sign.
62 - S6IND double evaluation pos. Both edges of the frequency signal on terminal X210B.1 are evaluated with a positive sign.
121 to 162 The operation modes 21 to 62 with evaluation of the frequency signal, but with a negative sign.
Tab. 138
The signal frequency on the selected repetition rate input must be scaled by means of the Divider 497 parameter.
The parameter value is comparable with the pulse number per revolution of a rotary encoder. The limit frequency of
the programmed digital input must be taken into account for the frequency of the input signal.
Parameters Setting
497 Divider 1 8192 1024
Tab. 139
The many possibilities of reference value specification within the different functions allow to use the repetition
frequency input as percentage. The signal frequency of 100 Hz on the repetition frequency input corresponds to
100% or 1 Hz corresponds to 1%. The Divider 497 parameter can be used in the same way as for rotary encoder
simulation.
13.13 ProHub function
13.13.1 General
If a drive operating at rated speed is subjected to a load less than its rated torque, the speed of the drive may be
increased beyond the rated speed in the field weakening range. For hoist units, the hoist speed may be increased
above the rated value with low loads and, therefore, process times may be reduced.
With the ProHub function, the torque is measured and used to calculate the Valid max. frequency 861 to which
the unit may accelerate.
This Valid max. frequency 861 is saved until the unit drops below a programmable frequency at which the
torque is also measured.
Up to 4 different hoist units can be operated by one frequency inverter by switching between data sets.
The ProHub function is only available in the 210 = "FOR speed control with encoder" setting of the Configuration 30
parameter.
Reference value step SW-Step 1+ must be used for the lifting motion. Reference value step SW-Step 1- must be
used for the lowering motion.
The ProHub function is activated by means of the Operation mode 850 parameter with selection 1 (On).
The torque is then measured, the Valid max. frequency 861 value is determined and the corresponding output
frequency of the relevant hoist unit with the load is limited.
Before field weakening is enabled, the Lifting correction value 853 and
Lowering correction value 854 parameters must be adjusted while the motor is warmed up and the ProHub
function is active. To do this, a defined load must be suspended from the hoist unit. This load should approximately
correspond to half of the rated load of the hoist unit. The exact ratio of this load to the rated load must be determined.
Lifting correction value 853 or Lowering correction value 854 must be set in such a way that the
Current measuring value 860 actual value corresponds to the ratio during the lifting or lowering operation.
If the ProHub function operation mode is switched off, the output frequency is only limited by the
214 716 44/200710
Maximum frequency 419 parameter.
The Maximum frequency 419 parameter must be set in such a way that the drive is not operated in field weak‐
ening mode when the ProHub function is switched off in hoist applications.
112
The field weakening range of a motor usually begins at the rated frequency of the motor. However, the start of field
weakening may differ for drives with frequency inverters. On the one hand, a lower output voltage (e.g. due to a low
line voltage) results in a shift in the field weakening range; on the other hand, the output frequency is higher than
the rated frequency specified on the motor rating plate due to the automatic slip compensation of the field-oriented
control.
The start of field weakening is defined by the product of Rated frequency 375 with the
Field weakening start 852 parameter.
The frequency calculated in this way is the limit frequency when the ProHub function is activated if field weakening
operation is not enabled.
Case 1:
Field weakening operation is not enabled when the ProHub function is activated
Field weakening operation is not enabled if the Field weakening enable 851 input function is not set or is 0 or
if measurement of the torque has not been completed.
The reference frequency is limited to the product of the Rated frequency 375 with the
Field weakening start 852 parameter and to the Maximum frequency 419 parameter.
The lower of the two frequency limits applies.
Case 2:
Field weakening operation is enabled when the ProHub function is activated
Field weakening operation is enabled if the Field weakening enable 851 input function is set or is 1 or if
measurement of the torque has been completed.
The reference frequency is limited to the calculated Valid max. frequency 861 parameter of the ProHub function
and to the Maximum frequency 419 parameter.
Torque measurement
Dedrive Compact units measure the torque in order to determine the Valid max. frequency 861 value of the
ProHub function. The torque is determined while the drive is in operation. Start of the measurement is specified by
the Start of measurement 855 parameter.
The lower of the two frequency limits applies.
13.13.2 ProHub function operation mode

0- Off (factory setting) The ProHub function is switched off.
1- On The ProHub function is switched on.
Tab. 140
It can only be activated when the modulation is switched off.
13.13.3 Field weakening enable
The link to the logic signals, e.g. to the digital inputs, is established with the Field weakening enable 851
parameter, ⇒ "Digital inputs", Page 128.
The Field weakening enable 851 input function has to be set, the ProHub function has to be activated and
measurement of the torque has to be completed in order to enable field weakening operation. Completion of the
measurement can be reported via the digital outputs, ⇒ "Digital outputs", Page 123.
13.13.4 Field weakening start
The Field weakening start 852 parameter refers to the Rated frequency 375 of the motor. If field weak‐
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ening operation is not enabled when the ProHub function is activated, the output frequency is limited to the product
of these two parameters.
113
The Field weakening start 852 parameter must be set in such a way that the product of
Rated frequency 375 with the Field weakening start 852 parameter is higher by at least approx. 0,1 Hz
than the Start of measurement 855 parameter, as the measurement cannot otherwise be carried out.
Parameters Setting
852 Field weakening start 50% 200% 100%
Tab. 141
13.13.5 Lifting correction value
Lifting correction value 853 refers to the rated torque of the motor.
Lifting correction value 853 must be set during a lifting motion at constant speed in such a way that the
value shown for the Current measuring value 860 parameter corresponds to the actual load on the hoist.
This adjustment should be carried out at approximately half of the rated load of the hoist unit.
Parameters Setting
853 Lifting correction value 0% 50% 10%
Tab. 142
13.13.6 Lowering correction value
Lowering correction value 854 refers to the rated torque of the motor.
Lowering correction value 854 must be set during a lowering motion at constant speed in such a way that
the value shown for the Current measuring value 860 parameter corresponds to the actual load on the hoist.
This adjustment should be carried out at approximately half of the rated load of the hoist unit.
Parameters Setting
854 Lowering correction value 0% 50% 1%
Tab. 143
13.13.7 Start of measurement
The Start of measurement 855 parameter determines the frequency at which the torque is measured.
The value has to be approx. 0,1 Hz lower than the product of the Rated frequency 375 and
Field weakening start 852 parameters, as otherwise the measurement cannot be carried out.
When measurement has been completed, the "60 – End of ProHub measurement" internal logic signal is activated,
which can be programmed to a digital output, for example.
Parameters Setting
855 Start of measurement 5,00 Hz 999,99 Hz 49,90 Hz
Tab. 144
13.13.8 Field weakening factor
The Field weakening factor 856 parameter is included in calculation of the Valid max. frequency 861
parameter.
If the value of the Field weakening factor 856 parameter is equal to 1,00, the motor is operated in the field
weakening range with constant output.
A correspondingly smaller factor must be selected for motors whose breakdown torque is much lower in the field
214 716 44/200710
weakening range.
If the value of the Field weakening factor 856 parameter is equal to 0,50, the motor must provide half of the
114 output in the field weakening range.
Parameters Setting
856 Field weakening factor 0,50 1,00 0,50
Tab. 145
13.13.9 Current measuring value
The Current measuring value 860 actual value parameter indicates the measured load in percent with refer‐
ence to the rated load of the hoist unit.
The torque is measured, Valid max. frequency 861 is determined and the Current measuring value
860 is also calculated if field weakening operation is not enabled.
The Current measuring value is specified as 100,00 if the measurement has not yet been completed.
The Current measuring value is specified as 100,00 if the ProHub function is switched off by means of
Operation mode 850.
13.13.10 Valid maximum frequency
The Valid max. frequency 861 actual value parameter specifies the maximum reference frequency of the
ProHub function.
If measurement of the torque has not yet been completed, the Valid max. frequency 861 parameter is set to
the product of the Rated frequency 375 and Field weakening start 852.
13.13.11 Hoist rating factor
Starting with device software version 4.2.4/050-7, internal calculation of Valid max. frequency 861 can be
influenced with Hoist rating factor 849. This is necessary for hoist units that are fitted with over-dimensioned
motors. Unacceptably high speeds are avoided in this way. The Hoist rating factor 849 parameter must be
set to the manually calculated ratio of the motor rated output to the output at rated load before adjusting the
Lifting correction value 853 and Lowering correction value 854 parameters.
Parameters Setting
849 Hoist rating factor 1,00 3,00 1,00
Tab. 146
13.14 Additional setpoint value
13.14.1 General
Certain applications, e.g. load-sway damping systems or synchronous operation control systems, work with a sep‐
arate control device, which supplies the frequency inverter with an additional setpoint value. This additional setpoint
value is added to the ramp output of the basic setpoint value via a separate ramp in the Dedrive Compact unit.
The default value for the additional setpoint value can be provided by an analogue signal, field bus or a three-step
controller with 2 digital inputs.
The additional setpoint value function can be activated or deactivated by the Operation mode 840 parameter. In
addition, the function must be released via the Additional setpoint value release 802 digital input function,
⇒ "Additional setpoint value release", Page 131.
13.14.2 Additional setpoint value operation mode

0- Off (factory setting) The additional setpoint value function is switched off.
1- On The additional setpoint value function is switched on.
214 716 44/200710
Tab. 147
115
13.14.3 Additional control
The Additional setpoint value source 841 parameter determines the additional setpoint value input. The
value selected here should not already be used for the regular Drive control 475.

0- Zero Additional setpoint value is zero
50 - Reference analogue value MFI1A Additional setpoint value via analogue input MFI1A
53 - Reference analogue value EM- Additional setpoint value via analogue input EM-S1INA
S1INA
480 - Bus operation P.846 Additional setpoint value is written into parameter 846 via field bus
481 - Additional fixed frequencies Additional setpoint value via fixed frequencies
708
- RxPDO Control via system bus
729
Tab. 148
13.14.4 Additional setpoint value frequency limits
The frequency range of the additional setpoint value is defined by the

Max. additional frequency negative 842 and Max. additional frequency positive 843 param‐
eters.
Parameters Setting
842 Max. additional frequency negative -300,00 Hz 0,00 Hz 0,00 Hz
843 Max. additional frequency positive 0,00 Hz 300,00 Hz 0,00 Hz
Tab. 149
13.14.5 Additional setpoint value frequency ramps
The Acceleration additional setpoint value 844 and

Deceleration additional setpoint value 845 frequency ramps define how quickly the output frequency
changes when the additional setpoint value is changed. The maximum permissible ramp steepness must be selected
corresponding to the application and the motor power consumption.
The additional setpoint value frequency ramps must be set much steeper than the Acceleration 420 and
Deceleration 421 parameters.
Parameters Setting
844 Acceleration additional setpoint 0,01 Hz/s 999,99 Hz/s 25,00 Hz/s
value
845 Deceleration additional setpoint 0,01 Hz/s 999,99 Hz/s 25,00 Hz/s
value
Tab. 150
13.14.6 Additional setpoint value bus operation
The Additional setpoint value bus operation 846 frequency can be described by means of a field bus
application. In this case, the value is only saved in the temporary RAM memory, but not in the EEPROM of the
frequency inverter. The initial value when the frequency inverter is switched on is 0,00 Hz.
The Additional setpoint value source 841 parameter must be set to 480 in order to use this frequency.
For Profibus applications, the value is specified via the PZD3 in PPO type 2. The notation is identical to the regular
setpoint value in the PZD2.
(See also section "PZD2, reference value/actual value" of the CM – PDP-24 operating instructions 214 770 44)
For CAN-Bus applications, the value is specified via the RxPDO1.

214 716 44/200710
116
Parameters Setting
846 Additional setpoint value bus oper‐ -300,00 Hz 300,00 Hz 0,00 Hz
ation
Tab. 151
13.14.7 Additional fixed frequencies
The Additional fixed frequency 1 847 and Additional fixed frequency 2 848 frequencies can be
used like a three-step controller with the help of the Additional fixed frequency selection 1 800 and
Additional fixed frequency selection 2 801 digital input functions.
The Additional setpoint value source 841 parameter must be set to 481 in order to use these frequencies.
Additional fixed frequency 1 847 is added as an additional setpoint value when the
Additional fixed frequency selection 1 800 digital input is applied.
Additional fixed frequency 2 848 is added as an additional reference value when the
Additional fixed frequency selection 2 801 digital input is applied, ⇒ "Additional fixed frequency se‐
lection", Page 130.
Parameters Setting
847 Additional fixed frequency 1 -300,00 Hz 300,00 Hz 0,00 Hz
848 Additional fixed frequency 2 -300,00 Hz 300,00 Hz 0,00 Hz
Tab. 152
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117
14 Control inputs and outputs
14.1 General
The modular structure of the frequency inverters offers a wide range of applications on the basis of the available
hardware and software functions. The control inputs and outputs described in the following are to be used via con‐
nection terminals X210A and X210B and to be freely combined with software modules by means of the described
parameters.
14.2 Multi-function input MFI1
14.2.1 General
The multi-function input MFI1 can optionally be configured as voltage or current input or as digital input. Depending
on the Operation mode 452 selected, a combination with different software functions is possible. The operation
modes which are not used are connected to the signal value zero (LOW).

1- Voltage input (factory setting) Voltage signal (MFI1A), 0 V … 10 V
2- Current input Current signal (MFI1A), 0 mA … 20 mA
3- Digital input Digital signal (MFI1D), 0 V / 24 V
Tab. 153
14.2.2 Analogue input MFI1A
14.2.2.1 General
The multi-function input MFI1 is factory-set for an analogue reference value source with a voltage signal from 0 V
to 10 V.
Alternatively, the operation mode analogue current signal must be programmed from 0 mA to 20 mA. The current
signal is continuously monitored and if the maximum value is exceeded, error message "F1407" is displayed.
14.2.2.2 Characteristic curve
The analogue input signals can be converted into a frequency or percentage reference value to meet various re‐
quirements. The parameters must be set via two points of the linear characteristic of the reference value channel.
Characteristic point 1, with the coordinates X1 and Y1, and characteristic point 2, with the coordinates X2 and Y2
must be set in the four data sets.
Parameters Setting
454 Point X1 0,00% 100,00% 2,00%
455 Point Y1 -100,00% 100,00% 0,00%
456 Point X2 0,00% 100,00% 98,00%
457 Point Y2 -100,00% 100,00% 100,00%
Tab. 154
The coordinates of the characteristic points are a percentage of the analogue signal of 10 V or 20 mA and the
parameter Maximum frequency 419 or Maximum Reference Percentage 519. The direction of rotation can
be reversed via the digital inputs or by selecting the characteristic points.
The Point X1 454 parameter must be checked to monitor the analogue input signal by means of the
Error/warning Behaviour 453 parameter.
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118
Factory setting of the characteristic curve
(1) pos. maximum
(2) neg. maximum
Point 1:
X1 = 2,00% ∙ 10V = 0,20V
Y1 = 0,00% ∙ 50,00Hz = 0,00Hz
Point 2:
X2 = 98,00% ∙ 10V = 9,80V
Y2 = 100,00% ∙ 50,00Hz = 50,00Hz
Tab. 155
Fig. 79
The characteristic curve shown above is set in the factory and can be adapted to the application by means of the
above-mentioned parameters.
Example: Freely configured characteristic curve for inverse reference value specification
(1) pos. maximum
Point 1:
X1 = 2,00% ∙ 10V = 0,20V
Y1 = 100,00% ∙ 50,00Hz = 50,00Hz
Point 2:
X2 = 98,00% ∙ 10V = 9,80V
Y2 = -80,00% ∙ 50,00Hz = -40,00Hz
Tab. 156
Fig. 80
The characteristic curve which can be freely configured makes it possible to set a tolerance at the ends as well as
to define two directions of rotation. The example above shows an inverse reference value specification with an
additional reversal of the direction of rotation.
In this example the direction of rotation is reversed at an analogue input signal of 5.5V.
The definition of the analogue input characteristic can be calculated by means of the two-point form of the line
equation. Speed Y of the drive is controlled according to the analogue control signal X.
Y2 - Y1
Y= (X - X1) + Y1
X2 - X1
Tab. 157
Additionally the characteristic curve of the analogue input can be set by means of the Characteristic type
870 parameter. Thus the drive at lower frequencies can be set to smoother characteristics.
Characteristic type 870 Function

1- Linear (factory setting) Linear characteristic as shown above.
2- Square Square characteristic. At lower frequencies voltage changes result in low frequency changes.
3- Cubic Cubic characteristic. At lower frequencies voltage changes result in very low frequency
changes.
Tab. 158
14.2.2.3 Scaling
The analogue input signal is mapped to the characteristic curve which can be freely configured. The maximum
admissible control range of the drive must be set by means of the frequency or percentage limits depending on the
configuration selected. When a bipolar characteristic is programmed, the minimum and the maximum limit are taken
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over for both directions of rotation. The percentages of the characteristic points are related to the limits selected.
119
Parameters Setting
Tab. 159
The control uses the maximum value of the output frequency which is calculated from the Maximum frequency
419 and the compensated slip of the drive. The frequency limits define the speed range of the drive and the per‐
centage limits supplement scaling of the analogue input characteristic depending on the functions configured.
Parameters Setting
518 Minimum reference percentage 0,00% 300,00% 0,00%
519 Maximum reference percentage 0,00% 300,00% 100,00%
Tab. 160
14.2.2.4 Tolerance range and hysteresis
The analogue input characteristic with a change of the reference value sign can be adapted to the application by
means of the Tolerance band 450 parameter. The tolerance band to be defined extends the zero crossing of the
speed related to the analogue control signal. The percentage parameter value is related to the maximum current or
voltage signal.
Parameters Setting
450 Tolerance band 0,00% 25,00% 2,00%
Tab. 161
Without tolerance band

(1) pos. maximum
(2) neg. maximum
Tab. 162
Fig. 81 Without tolerance band
With tolerance band

(1) pos. maximum
(2) neg. maximum
(3) Zero point tolerance band
Tab. 163
Fig. 82 With tolerance band

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120
Tolerance band with set minimum frequency
(1) pos. maximum
(2) neg. maximum
(3) Zero point tolerance band
(4) pos. minimum
(5) neg. minimum
Tab. 164
Fig. 83 Tolerance band with set minimum fre‐

quency
The Minimum frequency 418 or the Minimum reference percentage 518 extend the programmed tolerance
band to form a hysteresis.
Thus resulting from positive input signals, the output variable is kept on the positive minimum value, until the input
signal becomes lower than the value for the tolerance band in negative direction. Only then operation follows the
set characteristic curve.
14.2.2.5 Error and warning behaviour
For monitoring the analogue input signal as required for the application, multi-function input MFI1 must be configured
by means of the Error/warning behaviour 453 parameter.
Error/warning behaviour 453 Function

0- Off (factory setting) The input signal is not monitored.
1- Warning < 1V/2 mA If the input signal is lower than 1 V or 2 mA, warning A0800 is displayed.
2- Shutdown < 1V/2 mA If the input signal is lower than 1 V or 2 mA, warning A0800 is displayed.
The drive decelerates until it comes to standstill.
3- Error-Switch-Off < 1V/2 mA If the input signal is lower than 1 V or 2 mA, warning A0800 and error F1401 are displayed.
The drive coasts to a stop. The brake is applied.
Tab. 165
The monitoring function of the analogue input signal is active independent of the release of the frequency inverter
according to the operation mode selected.
In operation mode 2 the drive is decelerated down the current ramp. Subsequently error message F1401 is displayed.
The drive can be restarted after the error has been acknowledged.
Operation mode 3 defines the cut-off of the modulation and the deactivation of the "Release brake" message.
The Point X1 454 parameter must be checked to monitor the analogue input signal by means of the
Error/warning Behaviour 453 parameter.
14.3 Multi-function output MFO1
14.3.1 General
Multi-function output MFO1 can optionally be configured as digital output, analogue output or as an output for the
repetition frequency. Depending on the Operation mode MFO1 550 selected, a combination with different software
functions is possible. The operation modes which are not in use are deactivated internally.
Operation Mode MFO1 550 Function

0- Off The output has the logic signal LOW.
1- Digital, (factory setting) Digital output 0 / 24 V
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2- Analogue Analogue output, 0 … 24 V

3- Repetition frequency Repetition frequency output, 0 / 24 V, fmax = 150 kHz
Tab. 166
121
14.3.2 Operation mode analogue MFO1A
14.3.2.1 General
The actual values to be selected by means of the Operation mode analogue MFO1A 553 parameter depend
on the configuration selected.
Operation mode analogue MFO1A 553 Function

0- Off Operation mode analogue MFO1A switched off
1- Abs. Fs Absolute stator frequency, 0,00 Hz … Maximum frequency 419
2- Abs. Fs betw. fmin/fmax Absolute stator frequency, Minimum frequency 418 … Maximum frequency 419
3- Abs. Speed Sensor 1 Absolute value of rotary encoder signal 1, 0,00 Hz … Maximum frequency 419
4- Abs. Speed Sensor 2 Absolute value of rotary encoder signal 2, 0,00 Hz … Maximum frequency 419
7- Abs. Actual Frequency Absolute actual frequency value, 0,00 Hz … Maximum frequency 419
(Factory setting)
10 - Abs. Ref. Percentage Value Absolute reference percentage value, 0,00 Hz … Maximum frequency 419
11 - Abs. Ref. Percent. betw. %min/% Absolute reference percentage, 0,00% … Maximum Reference Percentage 519
max
20 - Abs. Iactive Absolute actual active current IACT, 0,0 A … FI rated current
21 - Abs. Isd Absolute flux-forming current component, 0,0 A … FI rated current
22 - Abs. Isq Absolute torque-forming current component, 0,0 A … FI rated current
30 - Abs. Pactive Absolute value of the actual active output PACT, 0,0 kW ... Rated mech. power 376
31 - Abs. M Absolute calculated torque M, 0,0 Nm … Rated torque
32 - Abs. Inside Temperature Absolute inside temperature measured, 0 °C … 100 °C
33 - Abs. Heat Sink Temperature Absolute heat sink temperature measured, 0 °C … 100 °C
40 - Abs. Analogue Input MFI1A Absolute signal on the analogue input MFI1A, 0,0 V … 10,0 V
41 - Abs. Analogue Input EM-S1INA Absolute signal on the analogue input EM-S1INA, 0,0 V … 10,0 V
only with EM – UNI-01 extension module
50 - Abs. I Absolute output currents measured, 0,0 A … FI rated current
51 - DC-Link Voltage Link voltage Ud, 0,0 V … 1000,0 V
52 - Voltage Output voltage U, 0,0 V … 1000,0 V
53 - Volume Flow Absolute volumetric flow calculated 0,0 m3/h … Nominal volumetric flow 397
54 - Pressure Absolute pressure calculated 0,0 kPa … Nominal Pressure 398
101 to 141 Operation modes in analogue operation with sign
Tab. 167
14.3.2.2 Output characteristic
Fig. 84
Operation mode analogue MFO1A 553 absolute actual val‐

A B Operation mode analogue MFO1A 553 with sign
ue
Tab. 168
Parameters Setting
551 Voltage 100% 0,0 V 24,0 V 10,0 V
214 716 44/200710
553 Voltage 0% 0,0 V 24,0 V 0,0 V

Tab. 169
Application of the analogue output signal to the programmed Operation mode analog MFO1A 553 is possible
for different applications via Voltage 100% 551 and Voltage 0% 552.
122
The voltage range is set to 100% or 0% of the variable to be output by the Voltage 100% 551 and Voltage 0%
552 parameters. If the output value exceeds the reference value, the output voltage also exceeds the value of the
Voltage 100% 551 parameter up to the maximum value of 24V.
14.3.3 Operation mode repetition frequency MFO1F
Multi-function output MFO1 can be used as frequency output depending on the selected
Operation mode MFO1 550. The 24V output signal is allocated to the absolute speed or frequency by means of
the Operation Mode Repetition Freq. MFO1F 555 parameter.
Operation Mode Repetition Freq. MFO1F 555 Function

0- Off Operation mode repetition rate MFO1F switched off
1- Actual Frequency (factory setting) Absolute Actual frequency 241
2- Stator Frequency Absolute Stator frequency 210
3- Frequency speed sensor 1 Absolute Encoder 1 frequency 217
5- Repetition frequency input Absolute Repetition frequency input 252
Tab. 170
Scaling
The mapping of the programmed Operation mode repetition freq. MFO1F 555 corresponds to an incre‐
mental encoder. The Division marks 556 parameter must be programmed to consider the output frequency.
Parameters Setting
556 Division marks 30 8192 1024
Tab. 171
The limit frequency of fmax=150kHz must not be exceeded when calculating the Division marks 556.
150000 Hz
S max = l f l = Absolute frequency
IfI
Tab. 172
14.4 Digital outputs
14.4.1 General
Digital output 1 S1OUT with the parameter Op. mode digital output 1 S1OUT 530 and relay output S3OUT
with the Op. Mode Digital Output 3 S3OUT 532 parameter combine the digital outputs with different functions.
When multi-function output MFO1 is used as a digital output, Operation Mode MFO1 550 must be set to "1 –
Digital" and linked to Operation mode digital MFO1D 554.
Operation mode Function

0- Off Digital output is switched off
1- Ready The frequency inverter is initialized, ready and the controller enable is activated.
S1OUT (Factory setting)
2- Modulation on Signal controller enable and a start command are applied, output voltage applied
3- Error The message is displayed via the Current error 259 or Warnings 269 parameter
MFO1D (Factory setting)
4- Setting frequency Stator Frequency 210 is higher than the set Setting Frequency 510
5- Reference Frequency reached Actual frequency 241 of the drive has reached Internal reference frequency 228
6- Reference Percentage reached The Actual percentage value 230 has reached the
Reference percentage value 229
7- Ixt-Warning Warning limit short term Ixt 405 or Warning limit long term Ixt 406 has
been reached
8- Warning Heat Sink Temperature The max. heat sink temperature TK of 80 °C minus the
Warning limit heat sink temp. 407 has been reached
214 716 44/200710
9- Warning Inside Temperature The max. inside temperature TK of 65 °C minus the Warning limit inside temp. 408
has been reached
10 - Warning Motor Temperature Warning after programmed Motor-PTC operation mode 570 at max. motor temperature
TPTC
123
11 - Warning, General The message is displayed via the Warnings 269 parameter
12 - Warning Overtemperature The selected Warning limit heat sink temp. 407,
Warning limit inside temp. 408 or the max. motor temperature limit values have been
exceeded.
13 - Mains Failure Failure of the line voltage and back-up active according to Operation mode 670
14 - Warning Motor Protect. Switch Programmed Operation mode 571 has been actuated
15 - Warning Current Limitation A controller or Operation mode 573 limit the output current
16 - Controller Current Limit. The overload reserve for 60 s has been used and the output current is limited.
Long Term Ixt
17 - Controller Current Limit. The overload reserve for 10 s has been used and the output current is limited.
Short Term Ixt
18 - Controller Current Limit. Max. heat sink temperature TK reached, Operation mode 573 active
Tc
19 - Controller Current Limit. M-PTC Max. motor temperature TPTC reached, Operation mode 573 active
20 - Comparator 1 The comparison according to the selected Op. Mode Comparator 1 540 is true
21 - Comparator 2 The comparison according to the selected Op. Mode Comparator 2 543 is true
22 - Warning Fieldbus-Toggle-Bit-OFF Field bus monitoring reports failure of the bus system. See operating instructions for the ex‐
tension modules.
23 - Timer 1 The selected Operation mode timer 1 790 creates an output signal of the function
24 - Timer 1 The selected Operation mode timer 2 793 creates an output signal of the function
25 - Warning mask Message of the configurable Actual Warning Mask 537
30 - Flux-forming finished Magnetic field has been applied.
41 - Release brake Control of an electrical brake
S3OUT (Factory setting)
43 - External fan Switch-on temperature 39 has been reached
45 - Watchdog N See ⇒ „Watchdog N“, Page 90
46 - Brake release monitoring warning See ⇒ „Brake release monitoring warning“, Page 90
60 - End of ProHub measurement Torque measurement for the ProHub function is completed.
See ⇒ „Field weakening enable“, Page 113
70 - Logic Function 1 Output of Operation mode 198
… … …
79 - Logic Function 10 Output of Operation mode 891
80 - Warning Load Spectrum The load spectrum function signals that 90% of the safe working period of the hoist unit has
elapsed.
See ⇒ „Load spectrum calculation“, Page 90
100 to 180 Operation modes inverted (LOW active)
Tab. 173
14.4.2 Setting frequency
If Operation mode 4 is selected, the corresponding output becomes active when Stator frequency 210 has
exceeded the value set under the Setting frequency 510 parameter.
The corresponding output is deactivated as soon as the Stator frequency 210 falls below the set value.
Parameters Setting
510 Setting frequency 0,00 Hz 999,99 Hz 3,00 Hz
Tab. 174
14.4.3 Reference value reached
In Operation mode 5 or 6 a message is sent via the corresponding output when the actual frequency or percentage
value has reached the reference value. The maximum deviation of the adjustable range (max. - min.) in percent can
be set via the Max. control deviation 549 parameter.
Parameters Setting
214 716 44/200710

549 Max. control deviation 0,01% 20,00% 5,00%
Tab. 175
124
14.4.4 Flux-forming finished
When Operation mode 30 is selected, the corresponding output becomes active when the flux-forming is finished.
The flux-forming time results from the operating status of the motor and the parameters programmed for magneti‐
sation of the motor. The magnetisation must be defined via the starting behaviour and is influenced by the
programmed starting current level.
14.4.5 Release brake
The "Release brake" function in Operation mode 41 makes it possible to control an electrical brake via a digital
control output.
See ⇒ "Brake control", Page 86
14.4.6 Current limitation
Operation modes 15 to 19 link the digital outputs and the relay output with the functions of the intelligent current
limits. The reduction of the output by the value set in percent of the rated current depends on the selected operation
mode. Correspondingly, the event that leads to activation of the current limitation can be output by means of the
operation mode of the digital outputs. If the function of the intelligent current limits is deactivated within the control
without encoders, Operation modes16 to19 are also switched off.
14.4.7 Comparator
Different comparisons of actual values with fixed percentage values can be carried out by means of the software
functions comparator 1 and 2. The actual values to be compared can be selected by means of the
Op. Mode Comparator 1 540 and Op. Mode Comparator 2 543 parameters according to the following table.

0- Off The comparator is switched off
1- Absolute Current Motor current 211 (100% ≙ rated current 371)
2- Ab. Active Current Active current 214 (100% ≙ rated current 371)
3- Abs. Stator Frequency Stator frequency 210 (100% ≙ Maximum frequency 419)
4- Abs. Actual Speed 1 Encoder 1 Speed 218 (100% ≙ Maximum speed, calculated from Maximum frequency
419 and No. of pole pairs 373)
5- Abs. Actual Repetition Freq. Repetition frequency input 252 (100% ≙ Maximum frequency 419)
6- Winding Temp. Winding temperature 226 (100% ≙ temperature 100 °C)
7- Abs. Actual Frequency Actual frequency 241 (100% ≙ Maximum frequency 419)
8- Abs. Actual Speed 2 only with EM – UNI-01.
Encoder 2 Speed 220 (100% ≙ Maximum speed, calculated from Maximum frequency
419 and No. of pole pairs 373)
9- DC-Link Voltage Link voltage 222 (100% ≙ DC 1000 V)
10 - Abs. Isq Torque current share Isq 216 (100% ≙ rated current 371)
11 - Abs. Filtered Active Current Filtered Active current 214 (100% ≙ rated current 371)
12 - Abs. Internal Ref. Frequency Internal reference frequency 228 (100% ≙ Maximum frequency 419)
13 - Abs. Ref. Percentage Value Reference percentage value 229 (100% ≙ Maximum reference percentage 519)
14 - Abs. Actual Percentage Value Actual percentage value 230 (100% ≙ Maximum reference percentage 519)
15 - Abs. Analogue Input MFI1A Analogue input MFI1A 251 (100% ≙ input signal 10 V or 20 mA)
16 - Abs. Analog Input EM-S1INA only with EM – UNI-01.
Analog input EM-S1INA 253 (100% ≙ input signal 10 V or 20 mA)
100 to 116 Operation modes with sign (+/-)
Tab. 176
The thresholds for switching on and off comparators 1 are set by means of the Comparator 1 on above 541 and
Comparator 1 off below 542 parameters.
The thresholds for switching on and off comparators 2 are set by means of the Comparator 2 on above 544 and
Comparator 2 off below 545 parameters.
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The percentage limits are specified for the corresponding reference values.
125
Parameters Setting
541 Comparator 1 on above - 300,00% 300,00% 100,00%
542 Comparator 1 off below - 300,00% 300,00% 50,00%
544 Comparator 2 on above - 300,00% 300,00% 100,00%
545 Comparator 2 off below - 300,00% 300,00% 50,00%
Tab. 177
Setting of the comparator percentage limits enables the following logic operations. A comparison with sign is possible
in the corresponding operation modes of the comparators.
Logic operations
Fig. 85
1 off below
2 on above
14.4.8 Warning mask
The logic signals of different monitoring and control functions can be set in the configurable
Create Warning Mask 536. Depending on the application any number of warnings and controller status mes‐
sages can be combined enabling the internal or external control with a common output signal.

0- No Change The configured warning mask is not changed.
1- Activate everything The warnings and controller status messages listed are combined in the warning
mask.
2- Activate all Warnings The warnings listed are combined in the warning mask.
3- Activate all Controller States The controller status messages listed are combined in the warning mask.
10 - Warning Ixt The frequency inverter is overloaded.
11 - Warning Short Term Ixt Overload reserve for 10 s minus Warning limit short term Ixt 405 has been
reached.
12 - Warning Long Term Ixt Overload reserve for 60 s minus Warning limit long term Ixt 406 has been
reached.
13 - Warning Heat Sink Temperature The max. heat sink temperature TK of 80 °C minus the
Warning limit heat sink temp. 407 has been reached
14 - Warning Inside Temperature The max. inside temperature TK of 65 °C minus the
Warning limit inside temp. 408 has been reached
15 - Warning Limit The controller listed in the Controller Status 355 limits the reference value.
16 - Warning Load Spectrum The load spectrum function signals that 90% of the safe working period of the hoist
unit has elapsed.
⇒ „Load spectrum calculation“, Page 90
17 - Warning Motor Temperature Warning after programmed Motor-PTC operation mode 570 at max. motor tem‐
perature TPTC
18 - Warning Mains Failure The Phase supervision 576 signals a phase failure in the power supply.
19 - Warning Motor Protective Switch Programmed Operation Mode 571 has been actuated.
20 - Warning Fmax The Maximum frequency 419 has been exceeded. The frequency limitation is ac‐
214 716 44/200710
tive.
21 - Warning Analogue Input MFI1A The input signal is lower than 1V / 2 mA depending on the operation mode
Error/Warning behaviour 453
126
22 - Warning Analogue Input EM-S1INA The input signal is lower than 1V / 2 mA depending on the operation mode
Only with an extension module.
23 - Warning Systembus A slave on the system bus signals an error, warning only relevant with EM – UNI-01
option.
24 - Warning Udc The link voltage has reached the minimum value which depends on the type.
25 - Warning Fieldbus-Toggle-Bit-OFF Field bus monitoring reports a failure of the bus connection.
30 - Controller Udc Dynamic Operation The controller is active depending on the Operation Mode 670
31 - Controller Shutdown The output frequency at power failure is below the Shutdown threshold 675.
32 - Controller Mains Failure Failure of the line voltage and back-up active according to Operation mode 670
33 - Controller Udc Limitation The link voltage has exceeded the Reference DC link limitation 680.
34 - Controller Voltage Pre-Control Dyn. voltage pre-control 605 accelerates the control behaviour.
35 - Controller I abs. The output current is limited.
36 - Controller Torque Limitation The output power or the torque is limited on the speed controller.
37 - Controller Torque Control Change-over of the FOR between speed and torque control
38 - Ramp Stop The Operation Mode 620 selected in the starting behaviour limits the output current.
39 - Contr. Intel. Curr. Lim. LT-Ixt The overload limit of the long term Ixt (60 s) is reached, intelligent current limits active.
40 - Contr. Intel. Curr. Lim. ST-Ixt The overload limit of the short term Ixt (10 s) is reached, intelligent current limits active.
41 - Contr. Intel. Curr. Lim. Tc Max. heat sink temperature TK reached, Operation mode 573 active
42 - Control. Intel. Curr. Lim. M-PTC Max. motor temperature TPTC reached, Operation mode 573 active
43 - Controller Freq. Limitation The reference frequency has reached the Maximum frequency 419. The frequency
limitation is active.
101 to 143 Removing or deactivating the operation mode within the warning mask
Tab. 178
The selected warning mask can be read out via the Actual warning mask 537. The operation modes above,
which are set in the configurable Create Warning Mask 536, are coded in the Actual warning mask 537.
The code results from the hexadecimal addition of the individual operation modes and the associated acronym.
Warning code Operation mode 536

A FFFF FFFF - 1- Activate everything
A 0000 FFFF - 2- Activate all Warnings
A FFFF 0000 - 3- Activate all Controller States
A 0000 0001 Ixt 10 Warning Ixt
A 0000 0002 IxtSt 11 - Warning Short Term Ixt
A 0000 0004 IxtLt 12 - Warning Long Term Ixt
A 0000 0008 Tc 13 - Warning Heat Sink Temperature
A 0000 0010 Ti 14 - Warning Inside Temperature
A 0000 0020 Lim 15 - Warning Limit
A 0000 0040 LK 16 - Warning Load Spectrum
A 0000 0080 PTC 17 - Warning Motor Temperature
A 0000 0100 Mains 18 - Warning Mains Failure
A 0000 0200 PMS 19 - Warning Motor Protective Switch
A 0000 0400 Flim 20 - Warning Fmax
A 0000 0800 A1 21 - Warning Analogue Input MFI1A
A 0000 1000 A2 22 - Warning Analogue Input EM-S1INA
A 0000 2000 Sysbus 23 - Warning Systembus
A 0000 4000 UDC 24 - Warning Udc
A 0000 8000 Toggle bit 25 - Warning fieldbus-toggle-bit
A 0001 0000 UDdyn 30 - Controller Udc Dynamic Operation
A 0002 0000 UDstop 31 - Controller Shutdown
A 0004 0000 UDctr 32 - Controller Mains Failure
A 0008 0000 UDlim 33 - Controller Udc Limitation
A 0010 0000 Boost 34 - Controller Voltage Pre-Control
A 0020 0000 Ilim 35 - Controller I abs.
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A 0040 0000 Tlim 36 - Controller Torque Limitation

A 0080 0000 Tctr 37 - Controller Torque Control
A 0100 0000 Rstp 38 - Ramp Stop
A 0200 0000 IxtLtlim 39 - Contr. Intel. Curr. Lim. LT-Ixt
127
Warning code Operation mode 536
A 0400 0000 IxtStlim 40 - Contr. Intel. Curr. Lim. ST-Ixt
A 0800 0000 Tclim 41 - Contr. Intel. Curr. Lim. Tc
A 1000 0000 PTClim 42 - Control. Intel. Curr. Lim. M-PTC
A 2000 0000 PTClim Flim 43 - Controller Freq. Limitation
Tab. 179
⇒ "Warning status", Page 170
14.5 Digital inputs
14.5.1 Assignment
The allocation of the control signals to the available software functions can be adapted to the corresponding appli‐
cation. The allocation set in the factory or the selected operation mode is different depending on the
Configuration 30. In addition to the digital control inputs available, further internal logic signals can be used as
sources. The individual software functions are allocated to the different signal sources via programmable inputs.
This provides for a flexible and versatile use of the digital control signals.

6- On The signal input is switched on.
7- Off The signal input is switched off.
61 - Error Signal Output An error has occurred.
70 - S1IND Digital signal on contact input 1 (X210A.3);
invariably linked with the controller enable
71 - S2IND Signal on digital input 2 (X210A.4)
75 - S6IND Signal on digital input 6 (X210B.1)
76 - MFI1D Signal on multi-function input 1 (X210A.3) in Operation Mode 452 = 3 - Digital input
157 - Warning mask The defined Actual Warning Mask 537 signals a critical working point.
158 - Timer 1 Output signal of the timer function corresponding to input link Timer 1 83
159 - Timer 2 Output signal of the timer function corresponding to input link Timer 2 84
160 - Ready message Signal when Ready message is active
161 - Message Modulation on Signal when ”Modulation on” message is active
162 - Message Error Signal when ”Error” message is active
163 - Reference Frequency reached Signal, when the Actual frequency 241 has reached the frequency reference value.
164 - Setting frequency Signal, when the Setting Frequency 510 is smaller than or equal to the Actual frequency 241
165 - Warning Ixt The monitoring functions signal frequency inverter overload
166 - Warning Heat Sink Temperature The max. heat sink temperature TK of 80 °C minus the Warning limit heat sink temp. 407 has
been reached
167 - Warning Inside Temperature The max. inside temperature TK of 65 °C minus the Warning limit inside temp. 408 has been
reached
168 - Warning Motor Temperature Warning after programmed Motor-PTC operation mode 570 at max. motor temperature TPTC
169 - General Warning Signal, when Warnings 269 are displayed in the event of a critical working point
170 - Warning Overtemperature The selected Warning limit heat sink temp. 407, Warning limit inside temp. 408 or
the max. motor temperature limit values have been exceeded.
171 - Output Comparator 1 The comparison according to the selected Op. Mode Comparator 1 540 is true
172 - Negated Output Operation mode 171 with inverted logic
Comparator 1 (LOW active)
173 - Output Comparator 2 The comparison according to the selected Op. Mode Comparator 2 543 is true
174 - Negated Output Operation mode 173 with inverted logic
Comparator 2 (LOW active)
175 - Digital Signal 1 Signal corresponding to the programmed Op. mode digital output 1 S1OUT 530
176 - Digital Signal 2 Signal corresponding to the programmed Operation mode digital MFO1D 554
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177 - Digital Signal 3 Signal corresponding to the programmed Op. mode digital output 3 S3OUT 532
178 - Reference Percentage reached Signal, when the Actual percentage value 230 has reached the reference percentage value
180 - Warning Motor Protective Switch Programmed Operation mode 571 has been actuated
220 - Logic Function 1 Output signal of logic function 1
128
221 - Logic Function 1 inverted Inverted output signal of logic function 1
270 to 276 Operation modes 70 to 76 of the digital inputs inverted
(LOW active)
700 - RxPDO1 Boolean1 Signal with optional extension module with system bus
710 to 713 Operation modes 700 to 703 for RxPDO2 with extension module with system bus
720 to 723 Operation modes 700 to 703 for RxPDO3 with extension module with system bus
730 - Sysbus Emergency Signal with optional extension module with system bus
… … …
Further functions are available when an extension module is installed.
Tab. 180
14.5.2 Starting command
The SW-Step 1+ 68 and SW-Step 1- 69 parameters must be linked with the available digital control inputs or with
the internal logic signals. The drive is only accelerated according to the control and regulation process after a starting
command. The logic functions are used for specifying the direction of rotation as well as for making use of the
programmed Operation Mode 620 and Operation Mode 630 verwendet.
14.5.3 Data set change-over
The different software parameters must be saved in four different data sets as permitted by the function. This allows
the use of different parameter values depending on the current working point of the frequency inverter. The change‐
over between the four data records is carried out via the logic signals allocated with the parameter
Data set change-over1 70 and Data set change-over 2 71.
The actual value parameter Active data set 249 shows the selected data set.
Data set change-over

Data set change-over 1 Data set change-over 2 Function / active data set
0 0 Data set 1 (DS1)
Tab. 181
0 = Contact open
1 = Contact closed
14.5.4 SOST reference value step change-over
In configurations with variable speed control the reference values are specified by the allocation of the
Drive control 475. A changeover between reference value steps is possible by linking the logic signals with the
parameters (SOST) Step 2 66 or (SOST) Step 3/4 67.
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SOST
(SOST) Step 2 (SOST) Step 3/4 Function / active reference value step
0 0 SOST Step 1 480
1 0 SOST Step 2 481 129
SOST
(SOST) Step 2 (SOST) Step 3/4 Function / active reference value step
1 1 SOST Step 3 482
0 1 SOST Step 4 483
Tab. 182
0 = Contact open
1 = Contact closed
14.5.5 Fixed percentage value change-over
In configurations with torque control the reference values are specified by the allocation of the
Reference percentage source 476. A changeover between fixed percentage values is possible by linking the
logic signals with the parameters Fixed percent change-over 1 75 or Fixed percent change-over 2
76.
Fixed percent change-over

Fixed percent change-over 1 Fixed percent change-over 2 Function / active fixed value
0 0 Fixed percentage 1 520
Tab. 183
0 = Contact open
1 = Contact closed
14.5.6 SOSP reference value memory function
The Drive control 475 parameter includes the operation mode SOSP reference value memory. The
SOSP function 474 parameter defines the behaviour of the reference value memory function and the
(SOSP) Acceleration 62 parameter defines the link with the available logic signals, ⇒ "SOSP reference value
memory", Page 110.
14.5.7 Motor thermal contact
The monitoring of the motor temperature forms part of the error and warning behaviour which is freely configurable.
The Motor thermal contact 204 parameter links the digital input signal with the defined
Motor-PTC operation mode 570, ⇒ "Motor temperature", Page 98.
The temperature is monitored via a digital input in the inverter without extension module. Therefore a thermal
contact or, if a thermistor is used, an additional circuit must be used.
If an EM – UNI-01 extension module is used, a PTC thermistor can also be evaluated.
14.5.8 Timers
The timer functions must be programmed by the Operation mode timer 1 790 and
Operation mode timer 2 793 parameters. The sources of the logic signals are selected with the parameters
Timer 1 83 and Timer 2 84 and processed according to the timer function selected.
14.5.9 Additional fixed frequency selection
With the help of the digital input functions Additional fixed frequency selection 1 800 and
Additional fixed frequency selection 2 801, the additional reference value function can be operated
like a three-step controller, ⇒ "Additional fixed frequencies", Page 117.
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Additional fixed frequency selection

Additional fixed frequency selec‐ Additional fixed frequency selection Active additional fixed frequency
tion 1 2
0 0 Additional reference value = 0 Hz
130
Additional fixed frequency selection
1 0 Additional fixed frequency 1 847
0 1 Additional fixed frequency 2 848
1 1 Additional reference value = 0 Hz
Tab. 184
0 = input parameter logically OFF
1 = input parameter logically ON
14.5.10 Additional setpoint value release
The additional setpoint value function must be released by means of the

Additional setpoint value release 802 digital input function. The function must additionally be activated
by means of the Operation mode 840 parameter, ⇒ "Additional setpoint value", Page 115.
14.5.11 Fast-to-slow limit switch limitation
14.5.11.1 General
Limitation of the reference value is activated when the relevant digital input is logically OFF when the fast-to-slow
limit switch is approached.
If no fast-to-slow limit switches are wired, the input parameters

Fast to slow limit switch limitation 1+ 803, Fast to slow limit switch limitation 1-
804 and Fast to slow limit switch limitation 2 805 must be set to the value "6 - ON", ⇒ "Limit switch
functions", Page 94.
14.5.11.2 Fast-to-slow limit switch limitation 1+ and fast-to-slow limit switch limitation 1-
The Fast-to-slow limit switch limitation 1+ 803 and

Fast-to-slow limit switch limitation 1-804 input parameters can be programmed independently of
each other with two different digital inputs, ⇒ "Setpoint val. limit 1+ and setpoint val. limit 1-", Page 94.
Reference value limitation

Fast-to-slow limit switch Fast-to-slow limit switch Active limitation on
Reference value limitation 1+ Reference value limitation 1-
0 0 Limitation
1 0 Limitation 1- 872
0 1 Limitation 1+ 871
1 1 No limitation
Tab. 185
14.5.11.3 Fast-to-slow limit switch limitation 2
The Fast to slow limit switch limitation 2 805 input function can be programmed with one digital
input ⇒ "Setpoint val. limit 2+ and Setpoint val. limit 2-", Page 95.
Reference value limitation

Setpoint value limitation 2 Active limitation
0 Limitation 2+ 873
Limitation 2- 874
1 No limitation
Tab. 186

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131
14.5.11.4 Operating limit switches
The Operating limit switch + 806 and Operating limit switch - 807 input parameters can be pro‐
grammed independently of each other with two digital inputs.
The drive is brought to standstill when the relevant digital input is logically OFF when the fast-to-slow limit switch is
approached (input open).
If no operating limit switches are connected, the Operating limit switch + 806 and
Operating limit switch- 807 input parameters must be set to "6 – ON".
The frequency is monitored when the operating limit switches are approached. Error 1120 "Limit switch monitoring
frequency exceeded" is generated when the limits are exceeded, ⇒ "Limit switch monitoring frequency", Page 95.
14.5.12 Error Acknowledgment
Frequency inverters have certain monitoring functions which can be adapted via the error and warning behaviour.
Setting parameters depending on the application should avoid that the frequency inverter is switched off at the
different working points.
In the case of a disconnection on fault, the following possibilities of error acknowledgement are available:
– Briefly de-activating the digital input S1IND (factory setting of parameter 103))
– Disconnect and restore the line power supply. The waiting time depends on the type of unit. If power is restored
too soon, the error will not be acknowledged. When the power is restored, the unit will re-initialize. Dedrive
Compact inverters may only be connected to the line supply every 60 seconds.
– Actuating the stop key on the operating unit
– Setting the Program 34 parameter to value 123
14.5.13 n-/M-control change-over
The field-oriented regulation processes include functions for controlling the drive depending on the speed or torque.
The change-over can be carried out during operation of the drive, since the transfer between the two control modes
is monitored by an additional function. Corresponding to the n-/M-control change-over 164 the speed con‐
troller or the torque controller is active.
14.5.14 Percent motor potentiometer
The Reference percentage source 476 parameter includes operation modes with percent motor potentiom‐
eter. The SOSP function 474 parameter defines the behaviour of the percent motor potentiometer function and
the Percent motorpoti up 72 and Percent motorpoti down 73 parameters define the link with the available
logic signals.
Drive control
Motorpoti up Motorpoti down Function
0 0 Output signal does not change
1 0 Output value increases with set ramp
0 1 Output value decreases with set ramp
1 1 Output value reset to initial value
Tab. 187
0 = Contact open
1 = Contact closed
14.6 Timer function
14.6.1 General
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The timer function can be linked with different functions for the sequence control of digital signals as a function of
time.
The Timer 1 083 and Timer 2 084 parameters define the link with the available logic signals to start the timers.
132
The Operation mode timer 1 790 and Operation mode timer 2 793 parameters define evaluation of the
digital input signals and the unit of time of the timer function.

0- Off The signal output is switched off.
1- Normal, Rising Edge, Sec. Positive signal edge starts timer (trigger),
time 1 delays the output signal,
time 2 defines the signal duration
2- Retrigger, Rising Edge, Sec. Positive signal edge starts timer (trigger),
new positive signal edge within time 1 starts the time delay again (retrigger),
time 2 defines the signal duration
3- AND operation, pos. edge, sec. Positive signal edge starts timer (trigger),
(factory setting) no input signal within time 1 starts the time delay again (retrigger),
no input signal within time 2 finishes the signal duration
11 to 13 Negative signal edge starts timer
101 to 113 Operation mode with unit of time in minutes
201 to 213 Operation mode with unit of time in hours
Tab. 188
The output signal of the timer function is available as a logic operation for the digital inputs and outputs.
14.6.2 Timer time constant
The logic sequence of input and output signal can be set separately by the time constants for both timer functions.
The parameter values set in the factory lead to a direct link of input and output signal without a time delay.
Parameters Setting
791 Time 1 Timer 1, signal delay 0,00 s/m/h 650,00 s/m/h 0,00 s/m/h
792 Time 2 Timer 1, signal duration 0,00 s/m/h 650,00 s/m/h 0,00 s/m/h
793 Time 1 Timer 2, signal delay 0,00 s/m/h 650,00 s/m/h 0,00 s/m/h
794 Time 2 Timer 2, signal duration 0,00 s/m/h 650,00 s/m/h 0,00 s/m/h
Tab. 189
Examples of the timer function depending on the selected operation mode and on the input signal.
Example 1
Fig. 86 Normal, Rising Edge
1 Input
2 Output
Parameter Operation mode timer = 1
Time 1 starts with the positive signal edge applied to the input. After the time delay has elapsed, the output signal
is applied for signal duration time 2.
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133
Example 2
Fig. 87 Retrigger, Rising Edge
1 Input
2 Output
Time 1 starts with the positive signal edge applied to the input. If a positive signal edge is detected within the time
delay, time 1 starts again. After the time delay has elapsed, the output signal is applied for signal duration time 2.
Example 3
Fig. 88 AND-Connect., Rising Edge
1 Input
2 Output
Time 1 starts with the positive signal edge applied to the input. If a positive signal edge is detected within the time
delay, time 1 starts again. After the time delay has elapsed, the output signal is applied for signal duration time 2.
The output with the input signal is switched off within signal duration time 2.
14.7 Logic function

A logic function can be used for binary logic operations between digital signals. Ten logic functions are available.
Each function has two logic inputs.
The following table shows the assignment of parameters to the logic functions.
Logic function Operation mode Input 1 Input 2

1 198 199 200
2 201 202 203
3 205 206 207
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4 503 504 505

5 817 818 819
6 857 858 859
7 877 878 879
134 8 882 883 884

Logic function Operation mode Input 1 Input 2
9 885 886 887
10 891 892 893
Tab. 190
The operation mode of the logic functions parameter define the type of logic operation between the two logic inputs
Input 1 and Input 2.
The logic functions are processed by the software of the unit in the sequence logic function 1 to logic function 10.

0- Off (factory setting) Logic function is switched off.
1- AND AND operation between input 1 and input 2
2- OR OR operation between input 1 and input 2
3- XOR Exclusive OR operation between input 1 and input 2
10 - RS-Flip-Flop Input 1 (set) sets the output of the logic function to HIGH. Input 2 (reset) resets the output to LOW.
20 - Toggle-Flip-Flop The first positive edge on input 1 sets the output of the logic function to HIGH. The next positive edge
on input 2 resets the output to LOW.
30 - D-Flip-Flop A positive edge on input 2 (clock) leads to the transfer of the signal from input 1 (D) to the output.
Tab. 191
The output signal of the logic function is available as a logic operation for the digital inputs and outputs.
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135
15 V/f characteristic
15.1 General
The V/f characteristic in configurations 110 and 111 is based on the proportional change of the output voltage in
relation to the output frequency according to the characteristic configured.
The voltage of the asynchronous motor connected is frequency-controlled by means of the V/f characteristic set.
The torque to be built up in the corresponding working point of the motor requires that the output voltage is controlled
in proportion to the frequency. At a constant ratio between the output voltage and the output frequency of the fre‐
quency inverter, the magnetisation in the nominal range of the asynchronous motor is constant. The rated working
point of the motor or vertex of the V/f characteristic is set by the Cut-off voltage 603 and
Cut-off frequency 604 parameters.
The lower frequency range is critical, since an increased voltage is required for starting the drive. The voltage at an
output frequency = zero is set by the Boost for f=0 600 parameter. A voltage boost deviating from the linear V/
f characteristic can be defined by the Voltage Rise 601 and Rise frequency 602 parameters. The parameter
value in percent is calculated from the linear V/f characteristic. The working range of the motor or the V/f characteristic
is determined by the Minimum frequency 418 and Maximum frequency 419 parameters.
V/f characteristic
Fig. 89
1 Area
Parameters Setting
600 Boost for f=0 0,0 V 100,0 V 5,0 V
601 Voltage rise -100% 200% 10%
602 Rise frequency 0% 100% 20%
603 Cut-Off Voltage 60,0 V 560,0 V 400,0 V
604 Cut-Off Frequency 0,00 Hz 999,99 Hz 50,00 Hz
Tab. 192
The rated motor parameters and the rated data of the frequency inverter are taken into account when the V/f
characteristic is pre-set during guided set-up. The rated speed of asynchronous motors can be increased at a
constant torque, if the motor winding can be switched over from star connection to delta connection. If the data for
the delta connection from the type plate of the asynchronous motor have been entered, the cut-off frequency is
automatically increased by the square root of three.
Cut-off voltage 603 (UC) and Cut-off frequency 604 (FC) set in the factory are derived from the motor
data Rated voltage 370 or Rated frequency 375. The line equation of the V/f characteristic results from the
set Boost for f=0 600 (US).
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Line equation of the V/f characteristic
UC - US 400,0 V - 5,0 V
U= ∙ f + US = ∙ f + 5,0 V
FC - 0 50,00 Hz - 0,00 Hz
Tab. 193
136
Rise frequency 602 (FK) is entered as a percentage of the Cut-off frequency 604 (FC) and is set in the
factory to f = 10Hz. The output voltage is calculated as U = 92,4 V when the Voltage rise 601 (UK) is set in the
factory.
Calculation of the voltage rise
UC - US 400,0 V - 5,0 V
U=( ∙ FK ∙ FC + US ) ∙ ( 1 + UK ) = ( ∙ 0,2 ∙ 50 Hz + 5,0 V ) ∙ 1,1 = 92,4 V
FC - 0 50,00 Hz - 0,00 Hz
Tab. 194
15.2 Dynamic voltage pre-control

Dynamic voltage pre-control 605 accelerates the regulation process of Operation mode 610 and
Operation mode 670. The value of the output voltage resulting from the V/f characteristic is changed by adding
the calculated voltage pre-control.
Parameters Setting
605 Dynamic voltage pre-control 0% 200% 100%
Tab. 195
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137
16 Control functions
16.1 General
Frequency inverters offer a variety of established control and regulation processes in different Configurations
30. The selected controller structure is freely programmable and can be optimised for the application by means of
further functions.
16.2 Intelligent current limits

The current limits to be set depending on the application avoid the impermissible loading of the load connected and
the disconnection on fault of the frequency inverter. This function extends the current controller available in the
control process. The overload reserve specified for the frequency inverter can be used optimally by means of the
intelligent current limits, particularly for applications with dynamic load changes. The criterion to be selected by the
Operation mode 573 parameter defines the threshold to activate the intelligent current limit. The programmed
rated motor current or rated current of the frequency inverter is followed up as a limit value by the intelligent current
limits.

0- Off (factory setting) The function is switched off.
1- Ixt Limitation to the overload of the frequency inverter (Ixt)
10 - Tc Limitation to the max. heat sink temperature (TK)
11 - Ixt + Tc Operation modes 1 and 10 (Ixt + TK)
20 - PTC Limitation to the motor temperature (TPTC)
21 - PTC + Ixt Operation modes 20 and 1 (TPTC + Ixt)
30 - Tc + PTC Operation modes 10 and 20 (TK + TPTC)
31 - Tc + PTC + Ixt Operation modes10, 20 and 1 (TK + TPTC + Ixt)
Tab. 196
The threshold selected by the Operation mode 573 parameter is monitored by the intelligent current limits. In the
operation modes with monitoring of the motor and the heat sink temperature, the derating selected with the
Power limit 574 parameter is applied when the limit value is reached. In motor operation this is achieved by
reducing the output current and the speed. For a useful application of the intelligent current limits, the load charac‐
teristic of the machine connected must depend on the speed. In addition to the cooling time the total time of derating
due to an increased motor or heat sink temperature also includes the defined Limitation Time 575.
The power limit should be defined as low as possible in order to give the motor sufficient time to cool down. The
reference value is the rated power of the frequency inverter or the rated power set for the motor.
Parameters Setting
574 Power limit 40,00% 95,00% 80,00%
575 Limitation Time 5 min 300 min 15 min
Tab. 197
The output current is reduced when the threshold is exceeded in the operation modes with an overload reserve (Ixt).
Here a distinction is made between long-term and short-term overload reserve. After the short-term overload (10 s)
has been used, the output current is reduced to the long-term overload current depending on the current switching
frequency. After the long-term overload (60 s) has been used, the output current is reduced to the rated current
which also depends on the switching frequency. If the output current has already been reduced, since the long-term
overload has been used, the short-term overload is no longer available, even if it has not been used before. The
defined overload reserve (Ixt) of the frequency inverter is again available after a derating of 10 minutes.
16.3 Voltage controller
16.3.1 General
The voltage controller includes the necessary functions for monitoring the link voltage.
● The voltage controller adjusts the link voltage which rises during regenerative operation or braking of the asyn‐
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chronous motor to the set limit value.

● The mains support uses the rotational energy of the drive for buffering short-term mains failures.
The voltage controller is adjusted according to the application by means of the Operation mode 670 parameter.
138
0- Off The function is switched off.
1- Udc-Llimitation active Overvoltage controller switched on
2- Mains Support active Mains support switched on
3- Udc-Limit & Mains Supp. active Overvoltage controller and mains support switched on
Tab. 198
16.3.2 Operation mode overvoltage controller
Fig. 90 Parameter Operation mode 670 (UDSEL) = 1
1 Overvoltage controller active

2 421 or 423
The overvoltage control prevents the frequency inverter from being switched off in regenerative operation. An over‐
voltage may occur in the link when the drive speed is reduced by a ramp gradient selected by the Deceleration
421 or Deceleration anticlockwise 423 parameters. If the voltage exceeds the value set by the
Reference DC link limitation 680 parameter, deceleration is reduced in such a way that the link voltage is
adjusted to the set value. If the link voltage cannot be adjusted to the set reference value by reducing the deceleration,
deceleration is stopped and the output frequency is increased. The output frequency is calculated by adding the
parameter Max. frequency rise 681 to the frequency at the working point of controller action.
Parameters Setting
680 Reference DC link limitation Udmin+25 V Udmax-25 V Ud
681 Max. frequency rise 0,00 Hz 999,99 Hz 10,00 Hz
Tab. 199
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139
16.3.3 Operation mode mains support
Short-term mains failure
Fig. 91 Short-term mains failure, Parameter Operation mode 670 = 2
1 Line voltage 4 Steepness limited by 673 or 683

2 Mains Failure 5 Standard ramp or 674
3 Mains resumption
The mains support can be used for buffering short-term mains failures. A mains failure is detected when the link
voltage drops below the value set for the Mains failure threshold 671 parameter. If a mains failure is detected,
the controller tries to adjust the link voltage to the value set with the Reference mains support value 672
parameter. For this purpose, the output frequency is continuously reduced and the motor and its rotating masses is
transferred to regenerative operation. Maximum reduction of the output frequency according to the configuration is
achieved by the current set by the Gen. ref. current limit 683 parameter or by the
Mains support deceleration 673 ramp.
The threshold values of the voltage controller are calculated with the Mains failure threshold 671 and
Reference mains support value 672 parameters on the basis of the current link voltage.
If the mains voltage returns before disconnection on mains undervoltage, the drive is accelerated to its reference
frequency with the set acceleration or according to the parameter Acceleration on mains resumption 674.
Parameters Setting
671 Mains failure threshold -200,0 V -50,0 V -100,0 V
672 Reference mains support value -200,0 V -10,0 V -40,0 V
Tab. 200
When the mains support is activated, the frequency inverter reacts to the signals applied to the control inputs as
during normal operation. The application of externally supplied control signals is only possible with an uninterrup‐
tible power system. As an alternative the supply via the frequency inverter must be used.
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140
Mains Failure
Fig. 92 Mains failure, Parameter Operation mode 670 = 2
1 Line voltage 3 Off

2 Mains Failure 4 673 or 683
The link voltage available in the case of a mains failure is supplied by the motor. The output frequency is continuously
reduced and the motor with its rotating masses is set to regenerative operation. Maximum reduction of the output
frequency is achieved by the current set by the Gen. ref. current limit 683 parameter or by the
Mains Support Deceleration 673 ramp up to the Shutdown threshold 675 frequency limit. If the energy
in the system is not sufficient to overcome the mains failure, deceleration is carried out at maximum ramp gradient
from Shutdown threshold 675. The period until the motor comes to a standstill results from the regenerative
energy of the system, which increases the link voltage. The link voltage set by the
Reference shutdown value 676 parameter is used as a controlled variable and kept constant by the voltage
controller. The voltage boost can be used to optimise the braking behaviour and the time until shutdown. The control
behaviour is comparable to stopping behaviour 2 (shutdown + holding), since the voltage controller shuts down the
drive with the maximum deceleration ramp and supplies the remaining link voltage to the drive.
In the case of mains resumption, after the drive has been shut down, however the disconnection on undervoltage
has not yet been reached, the frequency inverter signals an error. The operating unit displays error message "F0702".
If the mains failure without shutdown (Shutdown threshold 675 = 0 Hz) lasts for as long as the frequency has
been lowered to 0 Hz, the drive is accelerated to the reference frequency when the mains supply resumes.
If the mains failure with or without activated shutdown lasts as long as the frequency inverter is totally switched off
(LEDs = OFF), the frequency inverter will be in the "Ready" state when the mains supply resumes. When the enable
signal is sent again, the drive starts up. If the enable signal is permanently applied and the drive is to start automat‐
ically after mains resumption, Auto-start 651 must be switched on.
Parameters Setting
675 Shutdown Threshold 0,00 Hz 999,99 Hz 0,00 Hz
676 Reference Shutdown Value Udmin Udmax Ud
Tab. 201
The voltage controller uses the limit values of the link voltage for controlling. The frequency change necessary for
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this purpose is programmed by means of the regenerative reference current to be set or by means of the ramp. The
Gen. ref. current limit 683 or the ramp Mains support deceleration 673 defines the maximum
deceleration of the drive which is necessary to reach the Reference mains support value 672. The
Acceleration on mains resumption 674 replaces the set values of the ramp parameters Acceleration
141
420 or Acceleration anticlockwise 422. The voltage control on mains failure changes off the frequency limit
Shutdown Threshold 675 from Reference mains support value 672 to the
Reference shutdown value 676.
Parameters Setting
683 Gen. Ref. Current Limit 0,0 A ü·IFUN IFUN
673 Mains support deceleration 0,01 Hz/s 9999,99 Hz/s 50,00 Hz/s
674 Acceleration on Mains Resumption 0,00 Hz/s 9999,99 Hz/s 0,00 Hz/s
Tab. 202
The proportional as well as the integrating part of the voltage controller must be set by the Amplification 677
and Integral time 678 parameters. The control functions can be deactivated by setting the parameter to zero.
Depending on the setting, the controller is either a proportional-action controller or an integral-action controller.
Parameters Setting
677 Amplification 0,00 30,00 1,00
Tab. 203
16.4 Control functions of the V/f characteristic
16.4.1 General
The configurations of the V/f characteristic include the additional functions described in the following which supple‐
ment the behaviour according to the programmed V/f characteristic.
16.4.2 Slip compensation
The slip is defined as the load-dependent difference between the reference and the actual speed of the asynchronous
motor . This dependency can be compensated by measuring the current in the output phases of the frequency
inverter. Operation Mode 660 makes it possible to control the speed without any feedback. The stator frequency
or speed is corrected depending on the load.

0- Off The slip compensation is switched off.
1- On The load-dependent slip speed is compensated.
Tab. 204
The slip compensation regulation process can only be optimised by means of the parameters in special applications.
The Amplification 661 parameter determines the correction of the speed or the effect of slip compensation in
proportion to the load change. The Max. slip ramp 662 defines the max. frequency change per second, in order
to avoid an overcurrent in the case of a load change.
The Minimum frequency 663 parameter determines the minimum frequency at which slip compensation will
become active.
Parameters Setting
661 Amplification 0,0% 300,0% 100,0%
662 Max. slip ramp 0,01 Hz/s 650,00 Hz/s 5,00 Hz/s
663 Minimum Frequency 0,01 Hz 999,99 Hz 0,01 Hz
Tab. 205
16.4.3 Current limit controller
The current limit controller avoids any impermissible load on the drive system by means of load-dependent speed
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control. This is extended by the intelligent current limits described in the previous chapter. The current limit controller
reduces, for example, the load on the drive during acceleration by stopping the acceleration ramp. This prevents
disconnection of the frequency inverter if the acceleration ramp is too steep. The current limit controller is switched
on and off by means of the Operation mode 610 parameter.
142
0- Off The functions of the current limit controller and the intelligent current limits are deactivated.
1- On The current limit controller is active.
Tab. 206
Behaviour during motor operation:
When the current set by means of the Current limit 613 parameter is exceeded, the activated current limit
controller will reduce the output frequency until the current limit is no longer exceeded. The output frequency is
maximally reduced down to the frequency set by means of the Frequency limit 614 parameter. When the current
falls below the Current limit 613, the output frequency is increased to the reference value again.
Behaviour during regenerative operation:
When the current set by means of the Current limit 613 parameter is exceeded, the current limit controller will
increase the output frequency until the current limit is no longer exceeded. The output frequency is maximally in‐
creased up to the set Maximum frequency 419. When the current falls below the Current limit 613, the output
frequency is reduced to the reference value again.
Parameters Setting
613 Current Limit 0,0 A ü·IFUN ü·IFUN
614 Frequency limit 0,00 Hz 999,99 Hz 0,00 Hz
Tab. 207
The control behaviour of the current limit controller must be set via the proportional part, i.e. the Amplification
611 parameter and the integrating part, i.e. the Integral time 612 parameter. If, in exceptional cases, the con‐
troller parameters need to be optimised, a large adjustment of the Current limit 613 parameter should be carried
out.
Parameters Setting
611 Amplification 0,01 30,00 1,00
Tab. 208
The dynamic response of the current limit controller and of the voltage controller is influenced by the setting of the
Dyn. voltage pre-control 605 parameter.
16.4.4 Technology controller
16.4.4.1 General
Structure diagram: Technology controller

1 Reference percentage source 476
2 Actual percentage source 478
3 Actual values: Actual percentage value 230;
Reference percentage value 229
Tab. 209
Fig. 93
The technology controller the behaviour of which corresponds to a proportional-plus-integral controller is available
as an additional function in configuration 111. The combination of reference and actual value of the application with
the frequency inverter functions provides for the process control without any further components. Therefore, appli‐
cations, such as the control of pressure, volumetric flow or speed, can be implemented with ease.
Particular attention must be paid to the configuration of the reference percentage source and to the link of the actual
percentage source.
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143
Apart from the reference value, the technology controller requires a link to an analogue application variable with the
Actual percentage source 478 parameter. The technology controller uses the difference between the refer‐
ence and the actual value for controlling the drive system. The actual value measured is mapped to the input signal
of the actual percentage source via a measuring transducer.

1- Analogue input MFI1A The analogue signal on the multi-function input 1 in the Operation mode 452 -
analogue operation.
32 - Repetition frequency input (F3) The frequency signal on the digital input acc. to the selected Operation mode 496
Tab. 210
The function selected by the Operation mode 440 parameter defines the behaviour of the technology controller.

0- Off The technology controller is switched off, the reference value is specified via the ref‐
erence percentage channel.
1- Standard For controlling the pressure and volumetric flow with linear operating characteristic
and actual value monitoring
2- Liquid Level 1 Level control with defined motor speed when the actual value is not available
3- Liquid Level 2 Level control with defined behaviour when the actual value is not available or the
system deviation is high
4- Speed controller Speed control with analogue feedback of the actual speed
5- Indirect Volume Flow Control Controlling the pressure or volumetric flow with reduced actual value
Tab. 211
CAUTION
Particular attention must be paid to the factory-set link between the parameter SW-Step 1+ 68 and the logic signal
of the technology controller.
Risk of injury or material damage.
The technology controller is activated by the controller enable on digital input S1IND.
The behaviour of the technology controller corresponds to a proportional-plus-integral controller. The proportional
part is optimised by means of the Amplification 444 parameter and the integral part by means of the
Integral time 445 parameter. The sign of the amplification determines the direction of control, i.e. the output
frequency is decreased with rising actual value and positive sign of the amplification (e.g. when controlling the
pressure). The output frequency is increased with rising actual value and negative sign of the amplification (e.g. with
temperature control, refrigerating machines, evaporators). The Max. P-component 442 parameter limits the fre‐
quency change at the controller output. This prevents system vibration when large acceleration ramps have been
selected. Hysteresis 443 limits deviation of the output variable of the technology controller from the motor current
stator frequency in the Standard and Level 2 operation modes.
Parameters Setting
441 Fixed Frequency -999,99 Hz +999,99 Hz 0,00 Hz
442 Max. P-component 0,01 Hz 999,99 Hz 50,00 Hz
443 Hysteresis 0,01% 100,00% 10,00%
444 Amplification -15,00 +15,00 1,00
446 Ind. volume flow control factor 0,10 2,00 1,00
Tab. 212
Programming the technology controller in the individual data sets makes it possible to adapt the system to different
working points of the application by means of the data set change-over via control contacts.
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144
16.4.4.2 Operation mode standard
Parameter Operation mode 440 = 1
This operation mode is, for example, suitable for controlling pressure or volumetric flow with a linear operating
characteristic. If the actual value is not available (less than 0,5 %), the output frequency is set to the frequency
programmed with the Minimum frequency 418 parameter by means of the programmed Deceleration 421
parameter.
This function prevents that the drive starts up when the actual value is not available. When the actual value is
restored, the controller will automatically continue to operate. By means of the Hysteresis 443 parameter, an
overswing of the technology controller can be prevented by limiting its output value in relation to the stator frequency.
This means that the output value of the controller cannot be higher or lower than the current actual value plus the
limit values of the set hysteresis.
16.4.4.3 Operation mode level 1
This operation mode is suitable for controlling a fill level, for example. If the actual value is not available (less than
0,5 %), the output frequency is set to the frequency programmed with the Fixed frequency 441 parameter by
means of the programmed Deceleration 421 parameter. The Fixed frequency 441 must be programmed to
a value higher than or equal to the set Minimum frequency 418, otherwise the frequency is limited to 418.
If the actual value is not available, this function sets the drive to an adjustable frequency which may be in the control
range between the Minimum frequency 418 and the Maximum frequency 419 (FMAX).
When the actual value is restored, the controller will automatically continue to operate.
16.4.4.4 Operation mode level 2
This operation mode is suitable for controlling a fill level, for example. If the actual value is not available (less than
0,5%), the output frequency is set to the Fixed frequency 441 as for fill level 1. If the system deviation becomes
zero or negative, the output frequency is set to the Minimum frequency 418 with the set Deceleration 421.
This function prevents that the drive starts up when the actual value is not available. If the system deviation becomes
zero or negative and the Minimum frequency 418 is set to 0 Hz, the drive is shut down. The power section is
switched off, i.e. no current is supplied to the motor, until the actual value is restored or the system deviation exceeds
the positive hysteresis 443.
16.4.4.5 Operation mode speed control
This operation mode, for example, is suitable for controlling the speed with an analogue actual value encoder (e.g.
analogue tachometer). If the actual value is not available (less than 0,5 %), the output frequency is set to the
Maximum frequency 419 with the programmed Acceleration 420. When the actual value is restored, the con‐
troller will automatically continue to operate.
16.4.4.6 Operation mode indirect volumetric flow control
This operation mode extends the functions of pressure and volumetric flow control in operation mode 1. The root-
extracted actual value in operation mode 5 makes it possible, for example, to measure the differential pressure
directly in the installation via the intake nozzle of the fan. The differential pressure has a square-law ratio to the
volumetric flow and is thus the controlled variable of the volumetric flow control. The calculation corresponds to the
"proportionality law", which generally applies to gyroscopic machines.
The adaptation to the individual application and the measurement are made via the
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Ind. volume flow control factor 446. The actual values are calculated from the installation data rated
pressure and volumetric flow to be set according to the worst point process.
145
Structure diagram volumetric flow control
1 Reference percentage source 476
2 Ind. volume flow control factor 446
3 Actual percentage source 478
4 Actual values: Volumetric flow 285; Pressure 286
Tab. 213
Fig. 94
16.5 Functions of field-oriented regulation
16.5.1 General
The field-oriented regulating processes are based on a cascade control and on the calculation of a complex machine
model. An image of the machine is created by parameter identification and is transferred to various parameters
during guided set-up. These parameters are partially visible and can be optimised for different working points.
16.5.2 Current controller
The internal control loop of the field-oriented regulation consists of two current controllers. Thus the field-oriented
regulation applies the motor current to the machine via two components to be controlled. This is done by controlling
the flux-forming current component Isd and by controlling the torque-forming current component Isq.
By the separate control of these two components, the system is de-coupled equivalent to a DC machine with external
excitation.
The structure of the two current controllers is identical and makes it possible to set the amplification and the integral
time for both controllers together. For this purpose the parameters Amplification 700 and Integral time
701 are available. The integrating and the proportional part of the current controllers can be de-activated by setting
the parameter to zero.
Parameters Setting
700 Amplification 0,00 2,00 0,13
701 Integral time 0,00 ms 10,00 ms 10,00 ms
Tab. 214
Guided set-up selects the parameters of the current controller in such a way that they can be used for most appli‐
cations without any modifications.
If, in exceptional cases, the current controller characteristics must be optimised, the reference value step change
during the flux-forming phase can be used for this purpose. If programmed appropriately, the reference value of the
flux-forming component rises in a step to the Current during Flux-Formation 781 value and after the
Maximum flux build-up time 780 has elapsed, it is regulated to the magnetisation current. The working point
necessary for an adjustment requires the Minimum frequency 418 parameter to be set to frequency value 0,00
Hz, since the drive is accelerated after magnetisation. The sudden response, which is defined by the ratio of the
currents mentioned above, should be measured in the motor supply line by means of a measuring current transformer
with a suitable range.
The output of the actual value calculated internally for the flux-forming current component via the analogue output
cannot be used for this measurement, since the time resolution of the measurement is not sufficient.
For setting the parameters of the PI controller first the Amplification 700 is increased until the actual value shows
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a clear overswing during the control process. Subsequently the amplification is reduced to half and the
Integral time 701 is followed up until the actual value shows a slight overswing during the regulation process.
146
The setting of the current controller should not be too dynamical, in order to ensure a sufficient control reserve. If
the control reserve is reduced, the control tends to increased vibration.
The dimensioning of the current controller parameters by calculating the time constant must be made for a modulation
frequency of 2 kHz. For all other modulation frequencies the values are adapted internally so that the setting may
remain unchanged for all modulation frequencies. The dynamic properties of the current controller improve with
increasing modulation and scanning frequency.
The following scanning frequencies of the current controller result from the fixed time interval for modulation via the
Modulation frequency 400 parameter.
Setting
Modulation frequency Scanning frequency
4 kHz 4 kHz
8 kHz 8 kHz
12 kHz 8 kHz
16 kHz 8 kHz
Tab. 215
16.5.3 Torque controller
The torque-controlled configurations frequently require that the speed is limited in the working points without load
torque. The control increases the speed for reaching the reference torque value until the
Frequency upper limit 767 or Frequency lower limit 768 is reached. From the limit value the speed is
set to the maximum, which corresponds to the behaviour of a speed controller. Thus the controller is limited to the
Maximum frequency 419.
Parameters Setting
767 Frequency upper limit -999,99 Hz 999,99 Hz 999,99 Hz
768 Frequency lower limit -999,99 Hz 999,99 Hz 999,99 Hz
Tab. 216
16.5.4 Limit value sources
Apart from fixed values, the frequency can also be limited by linking it to an analogue input variable. The analogue
value is limited by the Minimum reference percentage 518, Maximum reference percentage 519 pa‐
rameters, however it does not take the Gradient percentage ramp 477 of the reference percentage channel
into account. The allocation for the torque controller is effected by the Frequency upper limit source 769
and Frequency lower limit source 770 parameters.

101 - Analogue Input MFI1A The source is multi-function input 1 in an analogue Operation mode 452
110 - Fixed Limit The selected parameter values are taken into account for limiting the speed controller.
201 - Inv. Analogue Input MFI1A Inverted operation mode 101
210 - Inv. Fixed Limit Inverted operation mode 110
Tab. 217
16.5.5 Speed controller
16.5.5.1 General
The torque-forming current component is controlled by the speed controller in the external control loop. The speed
controller must be used in different operation modes specifically for the application which are selected by the
Operation mode 720 parameter. The setting of the operation mode defines the use of the limits to be set in relation
to the direction of rotation or to the direction of the torque depending on the configuration selected.
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147
0- Speed Controller Off The controller is deactivated or the torque-forming current component is equal to zero.
1- Limits The limitation of the speed controller assigns the upper limit to motor operation of the drive.
for Motor/Generator Op. (factory The same limit is used independent of the direction of rotation. The same applies to the lower
setting) limit for regenerative operation.
2- Limits for pos./neg. Torque The limit is allocated by the sign of the variable to be limited. The positive limitation of the upper
limit is made independent of the working points of the drive at motor or regenerative operation.
The lower limit is considered as negative limit.
Tab. 218
Fig. 95
A Operation mode 1 2 Generator

B Operation mode 2 3 Motor current limit 728
a Counter-clockwise rotation 4 Generative current limit 729
b Clockwise rotation
1 Motor
The properties of the speed controller can be adapted for adjusting and optimising the control. The amplification and
the integral-action time of the speed controller must be set by means of the Amplification 721,
Integral time 722 parameters and for the second speed range by means of the Amplification f > f um
723, Integral time f > f um 724 parameters. A distinction between the speed ranges is made by means of
the value selected with the Switch-over frequency f um 738 parameter. The Amplification f > f um
723 and Integral time f > f um 724 parameters are taken into account for frequencies which are higher than
the selected Switch-over frequency f um 738 parameter.
The amplification set for the current working point can be additionally evaluated depending on the control deviation
via the Backlash damping 748 parameter. Particularly the behaviour of low-level signals in applications with a
gearbox can be improved by a value above zero.
Parameters Setting
721 Amplification 0,00 200,00 Depending on config.
722 Integral time 0 ms 60000 ms Depending on type
723 Amplification f > f um 0,00 200,00 5,00
724 Integral time f > f um 0 ms 60000 ms Depending on type
738 Switch-over frequency f um 0,00 Hz 999,99 Hz Depending on motor
748 Backlash damping 0% 300 % 0%
Tab. 219
The Amplification 721 parameter is automatically set to the following values after parameter identification:
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Configuration 2xx : 10,00
Configuration 4xx : 5,00
Therefore, any previously set values that deviate must be set again.
148
The factory-set integral-action time is related to the set machine data. This provides for a first function test in many
applications. The parameters for the current frequency range are distinguished by the software according to the limit
value selected.
The speed controller can be optimised by means of a reference value step change. The level of the step change is
defined by the set ramp or limitation. The PI controller should be optimised with the maximum permissible reference
value change. First the amplification is increased until the actual value shows a clear overswing during the control
process. This is perceptible from a strong speed vibration or from running noise. In the next step, the amplification
is reduced (1/2 … 3/4 etc) and subsequently the integral time is also reduced (higher I share), until the actual value
only shows a slight overswing during the control process.
If required, the speed control adjustment for dynamic processes, i.e. accelerating and decelerating, is checked in a
second step. The frequency at which the controller parameters are switched over can be set by means of the
Switch-over frequency f um 738 parameter.
16.5.5.2 Limitation of the speed controller
The output signal of the speed controller is the torque-forming current component Isq. The output and the I share of
the speed controller are limited by the Motor current limit 728, Generative current limit 729,
Motor torque limitation 730, Generative torque limitation 731 or
Power limit motor operation 739, Power limit generator operation 740 parameters. The limits of
the proportional share are set by means of the P share motor torque limitation 732 and
P share generative torque limitation 733 parameters.
● The output value of the controller is limited by an upper and a lower current limit by the
Motor current limit 728 and Generative current limit 729 parameter. The limit values are specified
in amps. Apart from the fixed limits, the current limits of the controller also must be linked to analogue input
variables. The allocation is made by means of the Isq limit source motor operation 734 and
Isq limit source generator op. 735.
● The output value of the controller is limited by an upper and a lower torque limit by the
Motor torque limitation 730 and Generative torque limitation 731 parameters. The limit values
are specified as a percentage of the motor rated torque. The allocation of fixed values or analogue limit values
is made by means of the Torque limit source motor op. 736 and
Torque limit source gen. op. 737 parameters.
● The output value of the proportional share is set by means of the P share motor torque limitation
732 and P share generative torque limitation 733 parameters. The limit values are specified as
torque limits in percent of the motor rated torque.
● The motor output power is proportional to the product of speed and torque. This output power can be limited by
means of a Power limit motor operation 739 and Power limit generator operation 740. The
power limits are specified in kilowatts.
Parameters Setting
728 Motor current limit 0,0 A ü·IFUN ü·IFUN
729 Generative current limit 0,1 A ü·IFUN ü·IFUN
730 Motor torque limitation 0,00% 650,00% 650,00%
731 Generative torque limitation 0,00% 650,00% 650,00%
732 P share motor torque limitation 0,00% 650,00% 100,00%
733 P share generative torque limita‐ 0,00% 650,00% 100,00%
tion
739 Power Limit Motor Operation 0,00 kW 2·ü·PFUN 2·ü·PFUN
740 Power limit generator operation 0,00 kW 2·ü·PFUN 2·ü·PFUN
Tab. 220
16.5.5.3 Limit value sources
As an alternative to limitation of output values by a fixed value, a link to an analogue input variable is also possible.
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The analogue value is limited by the Minimum reference percentage 518,

Maximum reference percentage 519 parameters, however it does not take the
Gradient percentage ramp 477 of the reference percentage channel into account. The allocation is made by
149
means of the Isq limit source motor operation 734 and Isq limit source generator op. 735
parameters.
The sources for the torque limits are specified in the same way by means of the
Torque limit source motor op. 736 and Torque limit source gen. op 737 parameters.
Source 734 … 737 Function

101 - Analogue input MFI1A The source is multi-function input 1 in an analogue Operation mode 452
105 - Repetition frequency input (F3) The frequency signal on the repetition rate input acc. to the Operation mode 496
110 - Fixed limit source (Factory setting) The selected parameter values are taken into account for limiting the speed controller.
Tab. 221
The data sets for the selected limit values and links with different limit source values can be changed. If the data
set change-over is used, the corresponding parameters must be checked.
16.5.6 Acceleration pre-control
The acceleration pre-control is active in the speed-controlled configurations and can be activated by means of the
Operation mode 725 parameter.

0- Off (factory setting) The control behaviour is not influenced.
1- On Depending on the limit values the acceleration pre-control is active.
Tab. 222
The acceleration pre-control controlled in parallel to the speed controller reduces the response time of the drive in
the case of a reference value change. The minimum acceleration time defines the speed of change of the speed
reference value from which a torque necessary for accelerating the drive is pre-controlled. The acceleration of the
mass depends on the Mech. time constant 727 of the system. The value calculated from the gradient of the
reference value and the multiplier of the required torque is added to the output signal of the speed controller.
Parameters Setting
726 Minimum Acceleration 0,1 Hz/s 6500,0 Hz/s 0,1 Hz/s
727 Mech. time constant 1 ms 60000 ms 10 ms
Tab. 223
For an optimum setting the acceleration pre-control is switched on and the mechanical time constant is set to the
minimum value. During the acceleration processes the output value of the speed controller is compared to the
minimum acceleration time. The frequency ramp must be set to the highest value occurring during operation at which
the output value of the speed controller is not yet limited. Subsequently the value of the
Minimum acceleration 726 is set to half the set acceleration ramp, in order to ensure that the acceleration pre-
control becomes active. Acceleration pre-control is increased by increasing the Mech. time constant 727 until
the output value corresponds to the time change of the drive during the acceleration processes.
16.5.7 Field controller
16.5.7.1 General
The flux-forming current component is controlled by the field controller in the external control loop. Guided set-up
optimises the parameters of the field controller by measuring the time constant and magnetisation curve of the
asynchronous machine connected to the unit. The field controller parameters are selected in such a way that they
can be used without any modifications in most applications. The proportional as well as the integrating part of the
field controller must be set by means of the Amplification 741 and Integral time 742 parameters.
Parameters Setting
717 Flow correction factor 0,01% 300,00% 100,00%
741 Amplification 0,0 100,0 5,0
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Tab. 224
The control parameters of the field controller should be optimised in the basic speed range. The frequency to be set
150 should be shortly before the limit of the modulation controller selected by means of the
Reference modulation 750 parameter so that is does not become active. Flow correction factor 717
should only be optimised in exceptional cases. The adjusted percentage value changes the flux-forming current
component as a ratio of the torque-forming current component. Therefore, correction of the magnetisation current
by means of the Flow correction factor 717 changes the torque of the drive. If the
Flow correction factor 717 parameter is decreased in a step (switching over from 100% to 50%), the con‐
trolled variable Isd can be measured by means of an oscillograph. After one oscillation the signal curve of the flux-
forming current Isd should reach the stationary value without oscillations. The integral time of the field controller
should be selected according to half the rotor time constant calculated by the software. The actual value to be read
out via the Current rotor time constant 227 parameter divided by two must be used for the
Integral time 742 in a first approach. If the application requires a faster transfer into field-weakening, the integral
time should be reduced. In order to obtain a good dynamic performance of the controller, a relatively high amplifi‐
cation should be selected. Please note that controlling a load with low-pass behaviour as in the case of an
asynchronous motor requires an increased overswing to obtain good control behaviour.
CAUTION
Brake does not release:

Increased brake wear
KB motor brakes must be checked to ensure that they are reliably released. If required, the parameter
Flow correction factor 717 must be increased.
16.5.7.2 Limitation of the field controller
The output signal of the field controller, consisting of the integrating and the proportional component, is limited by
the Ref. Isd upper limit 743 and Ref. Isd lower limit 744 parameters. Guided set-up sets the
Ref. Isd upper limit 743 parameter according to the Rated current 371 parameter.
Parameters Setting
743 Ref. Isd upper limit 0,1·IFUN ü·IFUN IFUN
744 Ref. Isd lower limit - IFUN IFUN 0,0
Tab. 225
Apart from the maximum current which occurs, the limits of the field controller define the dynamic performance of
the controller. The upper and the lower limit limit the speed of change of the motor flux and the torque resulting from
it. Particularly the speed range above the rated frequency must be taken into account for the change of the flux-
forming component. The upper limit must be estimated from the product of the set magnetisation current and the
Flow correction factor 717, however, the limit must not exceed the overload current of the drive.
16.5.7.3 KB de-magnetization time
For cylindrical rotor motors, e.g. Demag Z motors, the KB de-magnetisation time must be set to 0.
Owing to the design, the Demag KB brake motor starts to run on when it is stopped. Run-on is reduced by means
of the KB de-magnetization feature. It becomes effective when the KB motor brake is applied. This function maintains
the torque for the duration of the KB de-magnetisation time 813 which, however, reduces magnetisation of
the motor as a consequence of which the rotor slides into the brake.
To optimise, increase the KB de-magnetisation time 813 from 0 ms in 20 ms increments until run-on is sig‐
nificantly reduced. Then increase in 5 ms increments until no further reduction of the run-on is achieved.
Parameters Setting
813 KB de-magnetization time 0 ms 200 ms 0 ms
Tab. 226
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151
16.5.8 Modulation controller
16.5.8.1 General
The modulation controller designed as an integral-action controller automatically adapts the output value of the
frequency inverter to the machine behaviour in the basic speed range and in the field-weakening range. The flux-
forming current component and, therefore, the flux in the machine are reduced if the modulation exceeds the value
set by the Reference modulation 750 parameter.
The variable selected by the Operation mode 753 parameter is set as a ratio of the link voltage to utilise the
available voltage as effectively as possible. This means that a high output voltage is available for a high line voltage
and the drive reaches the field-weakening range later and produces a higher torque.

0- Usq-Control The output voltage ratio is calculated from the ratio of the torque-building voltage component
Usq and the link voltage.
1- V-Absolute Value Control The modulation is calculated from the ratio of the absolute voltage value and the link voltage.
Tab. 227
The integrating part of the modulation controller can be set by the Integral time 752 parameter.
Parameters Setting
750 Reference modulation 3,00% 105,00% Conf. 1xx : 104,50 %
Conf. 2xx : 102,00 %
Conf. 4xx : 98,00 %
Tab. 228
The percentage setting of the Reference modulation 750 mainly depends on the leakage inductance of the
motor. The default value is selected so that in most cases the remaining difference of 5% is sufficient as control
reserve for the current controller. In order to optimise the controller parameters, the drive is accelerated into the field-
weakening range along a flat ramp, so that the modulation controller is engaged. The limit is set by the
Reference modulation 750 parameter. Subsequently the control loop can be activated with a jump function
(switching between 95% and 50%) by changing the reference modulation. The control process of the modulation
controller can be evaluated by measuring the flux-forming current component by means of an oscillograph at the
analogue output of the frequency inverter. After one oscillation the signal curve of the flux-forming current Isd should
reach the stationary value without oscillations. Oscillations in the current curve must be dampened by increasing
the integral time. The Integral time 752 parameter should approximatively correspond to the
Current rotor time constant 227 actual value.
16.5.8.2 Limitation of the modulation controller
The output signal of the modulation controller is the internal flux reference value. The controller output and the
integrating part are limited by means of the Reference Imr lower limit 755 parameter or by the product of
Idle current 716 and Flow correction factor 717. The magnetising current parameter building the upper
limit must be set to the rated value of the motor. For the lower limit a value must be selected which builds up a
sufficient flux in the motor also in the field-weakening range. The limitation of the control deviation at the input of the
modulation controller prevents possible vibration of the control loop in the case of load impulses. The
Control deviation limitation 756 parameter is specified as an absolute value and acts as a positive as
well as a negative limit value.
Parameters Setting
755 Reference Imr lower limit 0,01·IFUN ü·IFUN 0,01·IFUN
756 Control deviation limitation 0,00% 100,00% 10,00%
Tab. 229
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152
17 Special functions
17.1 General
The different software configurations provide for a wide range of applications of the frequency inverter, since the
functions in the individual control and regulating processes are freely configurable. Additional application-specific
functions facilitate the integration into the application.
17.2 Pulse width modulation

Motor noise can be reduced by switching over the parameter Modulation frequency 400. The modulation fre‐
quency should be reduced up to a ratio of max. 1:10 of the frequency of the sinusoidal output signal. The maximum
modulation frequency depends on the drive output and on the ambient conditions. The necessary technical data can
be seen from the table and the diagrams for the corresponding type.
Parameters Setting
400 Modulation frequency 2 kHz 16 kHz 4 kHz
Tab. 230
In configuration 410 only modulation frequencies from 4 kHz on can be used.
See ⇒ "Configuration", Page 62
Heat loss increases in proportion to the load point of the frequency inverter and to the modulation frequency. The
automatic reduction adapts the modulation frequency to the current operating status of the frequency inverter, in
order to make available the output power required for the drive application at maximum dynamic performance and
minimum noise.
The modulation frequency is adapted between the limits which can be set by means of the
Modulation frequency 400 and Min. modulation frequency 401 parameters. Automatic reduction is de‐
activated if the Min. modulation frequency 401 is higher than or equal to the Modulation frequency
400.
Parameters Setting
401 Min. modulation frequency 2 kHz 16 kHz 4 kHz
Tab. 231
The modulation frequency is changed depending on the cut-off limit of the heat sink temperature and the output
current. The temperature limit, which if exceeded reduces the modulation frequency, can be set by the
Reduction limit Ti/Tc 580 parameter. The modulation frequency is increased in steps if the heat sink tem‐
perature falls by more than 5°C below the threshold set by the Reduction limit Ti/Tc 580 parameter.
Parameters Setting
580 Reduction limit Ti/Tc -25 °C 0 °C -4 °C
Tab. 232
The limit value for the reduction of the modulation frequency is influenced by the intelligent current limits depending
on the selected Operation mode 573 and on the output current. If these are switched off or make available the
full overload current, the modulation frequency is reduced, when the output current exceeds the limit value of 87.5%
of the long-term overload current (60 s). The modulation frequency is increased, when the output current falls below
the rated current of the next higher modulation frequency.
17.3 Fan
The switch-on temperature of the heat sink fan can be set by the Switch-on temperature 39 parameter.
When the temperatur is set to 0 °C, the fan is permanently switched on.
When the heat sink temperature exceeds the set temperature value in the "Ready" status of the frequency inverter
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(green LED flashes), the fan is switched on.
When the heat sink temperature falls by more than 5 °C below the set temperature value, the fan is switched off
after a delay of one minute.
153
If the warnings TC or TI are applied or the modulation is switched on, the fan is switched on and switched off again
after a delay of one minute.
This "43 – External fan" function can be additionally linked to a digital output to control an external fan. See
⇒ "Digital outputs", Page 123
Parameters Setting
39 Switch-on temperature 0 °C 60 °C 20 °C
Tab. 233
17.4 Brake chopper

Frequency inverters are supplied ex works with an integrated brake chopper transistor. The external braking resistor
is connected to terminals Rb1 and Rb2. The Trigger threshold 506 parameter defines the switch-on threshold
of the brake chopper. The regenerative output of the drive resulting in an increase of the link voltage is converted
into heat by the external braking resistor from the trigger threshold on. The monitoring of the resistor temperature
must be integrated in the safety circuit.
Parameters Setting
506 Trigger threshold Ud-min+25V 1000,0 V UdBC = 780,0 V
Tab. 234
The resistors mentioned in section ⇒ "Braking resistors", Page 192 are rated for a voltage of 780 V. the
Trigger threshold 506 parameter can remain unchanged For these resistors.
If a deviating trigger threshold is required for resistors rated otherwise, the parameter must be set so that it is between
the maximum link voltage which the mains supply can produce and the maximum admissible link voltage of the
frequency inverter.
UAC ∙ 1,1 ∙ √2 < UdBC < 800,0 V

Tab. 235
If the Trigger threshold 506 parameter is set higher than the maximum admissible link voltage, the brake
chopper cannot become active and is switched off.
The brake chopper only operates if the digital input function is logically set to ON by the
Brake Chopper Release 095 parameter.
17.5 Motor chopper

Field-oriented regulation includes the function for appropriately converting a part of the regenerative energy into heat
in the asynchronous machine connected. This allows the implementation of a dynamic speed change at minimum
system cost. The torque and speed characteristics of the drive system are not influenced by the programmed type
of braking. The Trigger threshold 507 parameter of the link voltage defines the switch-on threshold of the motor
chopper function.
Parameters Setting
507 Trigger threshold Udmin+25 V 1000,0 V UdMC
Tab. 236
The Trigger threshold 507 parameter must be set so that it is between the maximum link voltage which the
mains supply can produce and the maximum admissible link voltage of the frequency inverter.
UAC ∙ 1,1 ∙ √2 < UdMC < 800,0 V

Tab. 237
When the parameter Trigger threshold 507 is set higher than the maximum admissible link voltage, the motor
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chopper cannot become active, it is switched off.
154
17.6 Motor protective switch
2h
100
40
1 10
1
40
20
2 10
5
2
1
200
G
R L K
U
50
3
20
2
1,5 2 3 5 10 30
4
43203244_xml.eps
Fig. 96
1 minutes
2 seconds
3 mill. seconds
4 x rated current
Motor circuit-breakers are used to protect the motor and its supply line against overheating due to overload. De‐
pending on the amount of overload, their instantaneous tripping is used as a protection against short circuits and
their slow tripping as overload protection.
Conventional motor circuit breakers are commercially available for different applications with different tripping char‐
acteristics (L, G/U, R and K) according to the diagram on the right. Since frequency inverters are mostly used for
supplying motors which are classified as equipment with very high starting currents, the K characteristic is exclusively
used for this function.
In contrast to the mode of operation of a conventional motor circuit breaker, which immediately isolates the equipment
to be protected when reaching the tripping threshold, this function provides for the possibility of sending a warning
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message, instead of immediately isolating the motor.
The rated current of the motor circuit-breaker is related to the rated current of the motor which is specified by means
of the Rated current 371 parameter of the corresponding data set. The rated values of the frequency inverter
must be taken into account when dimensioning the application. 155
The function of the motor circuit breaker can be switched over to different data sets. Thus different motors can be
operated at one frequency inverter. Each motor can be equipped with its own motor circuit-breaker.
If the frequency inverter is operated with a motor for which some variables, such as the minimum and the maximum
frequency, are changed via the data set change-over, only one motor circuit-breaker may be used. This function can
be specified for single-motor or multi-motor operation by selecting the parameter Operation mode 571.

0- Off The function is de-activated.
1- K-Char.,Mul.Motor Op.,Err.Sw.Off The rated values are monitored in each of the four data sets. Overload of the drive is
avoided by disconnection on fault „F0401“.
2- K-Char.,Sing.Motor,Err.Sw.-Off The rated values of the first data set are used independent of the active data set.
Overload of the drive is avoided by disconnection on fault „F0401“.
11 - K-Char.,Multi-Motor Op., Wwarning The rated values are monitored in each of the four data sets. Overload of the drive is
signalled by warning message „A0200“.
22 - K-Char.,Single-Motor,Warning The rated values of the first data set are used independent of the active data set.
Overload of the drive is signalled by warning message „A0200“.
Tab. 238
Multi-motor operation:
Parameter Operation mode 571 = 1 or 11
In multi-motor operation it is assumed that an associated motor is used for each data set. For this purpose a motor
and a motor circuit-breaker are assigned to each data set. In this operation mode the rated values of the active data
set are monitored. The current output current of the frequency inverter is only taken into account for the motor circuit-
breaker activated by the data set. The currents in the motor circuit-breakers of the other data sets are calculated as
zero, thus taking the thermal decay into account. In connection with the data set changeover, the function of the
motor circuit-breakers equals the behaviour of motors with their own circuit-breakers which are alternately connected
to the mains supply.
Single-motor operation:
Parameter Operation mode 571 = 2 or 22
In single motor operation only one motor circuit breaker is active monitoring the output current of the frequency
inverter. With a data set changeover only the cut-off limits resulting from the rated machine data are switched over.
Accumulated thermal values are further used after the change-over. When changing over data sets it must be en‐
sured that the motor data are specified identically for all data sets. In connection with the data set changeover, the
function of the motor circuit-breakers equals the behaviour of motors with a common circuit-breaker which are al‐
ternately connected to the mains supply.
Motor protection particularly of non-ventilated motors is improved by the Frequency limit 572. The output current
measured in working points below the frequency limit is evaluated higher by factor 2 when calculating the tripping
characteristic.
Parameters Setting
572 Frequency limit 0% 300% 0%
Tab. 239
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156
17.7 Bus controller
Frequency inverters can be extended with various options for data communication and can thus be integrated into
an automation and control system. Programming and set-up can be made via the optional communication interface
board , the operating unit or the interface adapter. The serial communication protocols are set to a transmission rate
of 9600 Baud. The Local/Remote 412 parameter defines the operating behaviour and a change between the
control via contacts or operating unit and the interface.
Local/Remote 412 Function

0- Control via Contacts The start and stop command and the specification of the direction of rotation are
(factory setting) transmitted via digital signals.
1- Control via Statemachine The start and stop command and the specification of the direction of rotation are
transmitted via the DRIVECOM state machine of the communication interface.
2- Control via Remote-Contacts The start and stop command and the specification of the direction of rotation are
transmitted via logic signals through the communication protocol.
3- Ctrl. KP, direction contacts The start and stop command is specified via the operating unit and the direction of
rotation is specified via digital signals.
4- Ctrl. KP or Cont., direction cont. The start and stop command is specified via the operating unit or via digital signals.
The direction of rotation is only specified via digital signals.
13 - Control via KP, Direction KP The start and stop command and the direction of rotation are specified via the oper‐
ating unit.
14 - Control KP+Cont., Direction KP The start and stop command is specified via the operating unit or via digital signals.
The direction of rotation is only specified via the operating unit.
20 - Control Contacts, Clockw. The start and stop command is transmitted via digital signals. The direction of rotation
is set to clockwise rotation only.
23 - Control Keypad, Clockw. The start and stop command is specified via the operating unit. The direction of rota‐
tion is set to clockwise rotation only.
24 - Control Cont. + KP, Clockw. The start and stop command is specified via the operating unit or via digital signals.
The direction of rotation is set to clockwise rotation only.
30 to 34 Operation mode 20 to 24, only anti-clockwise rotation
43 - Crtl. KP, Dir. Cont. + KP The start and stop command is specified via the operating unit. The direction of rota‐
tion is specified via the operating unit or via digital signals.
44 - Ctrl. Cont.+KP, Dir. Cont.+KP The start and stop command and the direction of rotation are specified via the oper‐
ating unit or via digital signals.
Tab. 240
17.8 Temperature adjustment

Only for field-oriented regulation, configuration 2xx and 4xx
Field-oriented regulation processes are based on the calculation of a machine model which must be as precise as
possible. The rotor time constant is an important machine variable for the calculation. The value to be read out by
the Current rotor time constant 227 parameter is calculated from the inductance of the rotor circuit and the
rotor resistance. In the case of a very large temperature range or very demanding requirements regarding accuracy,
the dependency of the rotor time constant from the motor temperature can be taken into account by a suitable
measurement. Different methods and actual value sources for temperature measurement can be selected via the
Operation mode 465 parameter.

1- Temp. measurement on MFI1A Temperature correction (0 … 200 °C => 0/2 … 10 V),
actual temperature value on multi-function input 1
2- Temp. measurement on EM-S1INA This selection cannot be used.
actual temperature value on the analogue input of the extension module
4- Temp. measurement when starting Temperature measurement by calculating the winding resistance when starting the
drive
Tab. 241
Operating mode 1 requires external measurement of the temperature to evaluate the temperature sensor (e.g.
PT100) and supply an image of the temperature range from 0 … 200 °C in the form of an analogue voltage signal.
In operation mode 4 – only available in configurations 210 and 230 – the winding resistance is measured when the
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controller enable is applied to input S1IND and a travel signal is applied to input SW-Step1+ or SW-Step 1- and thus
the Winding temperature 226 and the Current rotor time constant 227 are corrected. The measure‐
ment is only carried out, when no current was applied to the motor before the travel command for a period of 5 times
the Current rotor time constant 227.
157
The Temperature coefficient 466 parameter is used to allow for the material used for the rotor winding of the
motor. This value defines the change of the rotor resistance as a function of the temperature for a certain material
of the rotor winding. Typical temperature coefficients are 39%/100 °C for copper and 36%/100 °C for aluminium at
a temperature of 20 °C.
The temperature characteristic is calculated by the software by means of the above-mentioned temperature coeffi‐
cient and the Adjusting temperature 467 parameter. Apart from the parameter
Rotor time constant correction factor 718 the adjusting temperature is an additional means for opti‐
mising the rotor time constant.
Parameters Setting
466 Temperature coefficient 0,00%/100 °C 300,00%/100 °C 39,00%/100 °C
467 Adjusting temperature -50 °C 300 °C 100 °C
Tab. 242
The correction of the rotor time constant depending on the winding temperature can be adjusted. Normally the values
set in the factory should be sufficiently accurate that neither any adjustment of the rotor time constant via the
Rotor time constant correction factor 718 nor any adjustment of the temperature correction by means
of the Temperature coefficient 466 are necessary. For any adjustment, it must be taken into consideration
that the rotor time constant is calculated on the basis of the motor data during guided set-up. The
Adjusting temperature 467 must be set to the temperature at which the parameter identification has been
carried out. The temperature must be read out via the actual value parameter Winding temperature 226 and
can be used for the parameter during optimisation.
17.9 Rotary encoder monitoring

Only for field-oriented regulation, configuration 210 and 230
Malfunctions of the rotary encoder will lead to drive faults, since the control process is based on the measured speed.
Encoder monitoring continuously monitors the rotary encoder signal, the channel signals and the division marks
(pulse number per revolution). When the frequency inverter is released and a faulty signal longer than the time-out
is detected, this will result in a disconnection on fault. The monitoring function is deactivated if the
Operation mode 760 parameter is set to zero.

2- Error An error message is displayed depending on the set time-out.
Tab. 243
The parameters for the partial functions of encoder monitoring must be set accordding to the application. The mon‐
itoring function becomes active with the release of the frequency inverter and the starting command being applied.
The time-out defines the monitoring time during which the condition for a disconnection on fault must be continuously
fulfilled. If one time-out is set to zero, the monitoring function is deactivated.
Parameters Setting
761 Timeout: Signal fault 0 ms 65000 ms 150 ms
762 Timeout: Channel fault 0 ms 65000 ms 150 ms
763 Timeout: Direction fault 0 ms 65000 ms 500 ms
Tab. 244
Timeout: Signal fault
The actual speed value measured is compared to the output value of the speed controller. If the actual speed value
is exactly zero for the time set by the Timeout: Signal fault 761 parameter, even if a reference value is applied,
the error is displayed with the "F1430" message.
Timeout: Channel fault
The actual speed value determination monitors the time sequence of the signals in the operation mode quadruple
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evaluation. If the rotary encoder signal is defective for the time set by the Timeout: Channel fault 762 pa‐
rameter, the error is displayed with the "F1431" message.
158 Timeout: Direction fault

The actual speed value measured is continuously compared to the speed reference value. If the sign between the
reference value and the actual value is different for the time set by the Timeout: Direction fault 763 pa‐
rameter, the error is displayed with the "F1432" message. The monitoring function is reset as soon as the drive has
turned by a quarter of a revolution in the direction of the reference value.
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159
18 Actual values
18.1 General
The different control and regulating processes include controlled electrical variables and different calculated actual
values of the motor or installation. The various actual values can be used for operation and error diagnosis via a
communication interface or in the VAL sub-menu of the operating unit.
18.2 Actual frequency inverter values

Depending on the selected configuration and the extension cards installed, only certain actual values can be dis‐
played.
Actual frequency inverter values

No. Description Function
222 Link voltage DC voltage in the link
223 Output voltage ratio Output voltage of the frequency inverter related to the mains voltage (100% = UFUN)
228 Internal reference frequency Sum of Drive controls 475 as reference value from the frequency reference
channel
229 Reference percentage value Sum of Reference percentage source 476 as the reference value from the ref‐
erence percentage channel
230 Actual percentage value Actual value signal at the Actual percentage source 478
244 Working hours counter Working hours in which the power output stage is active
245 Operation hours counter Operation hours of the frequency inverter in which the supply voltage is applied
249 Active data set Depending on the Data set change-over 1 70 and
Data set change-over 2 71 the active data set used
250 Digital inputs Decimal-coded status of the six digital inputs and of multi-function input 1 in
Operation mode 452 „3 – digital input“
251 Analogue input MFI1A Input signal on multi-function input 1 in Operation mode 452 „1 – voltage input“ or
„2 – current input“
252 Repetition frequency input Signal on the repetition frequency input acc. to Operation mode 496
253 Analogue input EM-S1INA Signal on analogue input EM-S1INA of the EM extension module
254 Digital outputs Decimal-coded status of the two digital outputs and of the multi-function output 1 in
Operation mode 550 - digital
255 Heat sink temperature Measured heat sink temperature
256 Interior temperature Temperature measured inside housing
257 Analogue output MFO1A Output signal on multi-function output 1 in Operation mode 550 „2 – Analogue“
259 Current Error Error message with error code and acronym
266 Analogue output EM-S1OUTA Signal on analogue output EM-S1OUTA of the EM extension module
269 Warnings Warning message with warning code and acronym
275 Controller status The reference value signal is limited by the controllers coded in the controller status.
278 Frequency MFO1F Output frequency on multi-function output MFO1 in Operation mode 550 „3 – rep‐
etition frequency“
282 Reference bus frequency Internal reference frequency
283 Reference Ramp Frequency Internal reference frequency
Tab. 245
18.3 Actual machine values

The frequency inverter controls the behaviour of the machine in different working points. Depending on the selected
configuration and the extension cards installed, controlled variables and further actual value parameters of the motor
can be displayed.
Actual machine values

210 Stator frequency The output frequency (motor frequency) of the frequency inverter
211 Motor current Calculated root-mean-square output current (motor current) of the frequency inverter
212 Motor voltage Calculated root-mean-square value of the phase-to-phase output voltage (motor volt‐
age) of the frequency inverter.
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213 Active power Active power calculated from voltage, current and controlled variables
214 Active current Active power calculated from the rated motor parameters, current and controlled var‐
iables
215 Flow current share Isd The magnetic flux-forming current component of the field-oriented regulation
160
Actual machine values
216 Torque current share Isq The torque-forming current component of the field-oriented regulation
217 Encoder 1 frequency Calculated from the data of rotary encoder 1, the No. of pole pairs 373 and the
rotary encoder signal
218 Encoder 1 speed Calculated from the encoder 1 frequency
Only with an EM extension module.
220 Encoder 2 speed Calculated from the encoder 2 frequency
Only with an EM extension module.
221 Slip frequency Difference to the synchronous frequency calculated from the rated motor parameters,
controlled variables and current
224 Torque Torque calculated from voltage, current and controlled variables at the current output
frequency
225 Rotor flux Current magnetic flux related to the rated motor parameters
226 Winding temperature Temperature of the motor winding measured according to Operation mode 465 of
the temperature adjustment
227 Current rotor time constant Time constant calculated from the rated motor parameters and the measured and
controlled variables for the working point of the motor
235 Flux-forming voltage The magnetic flux-forming voltage component of the field-oriented regulation
236 Torque-forming voltage The torque-forming voltage component of the field-oriented regulation
238 Flux value Magnetic flux calculated according to the rated values and the working point of the
motor
239 Reactive current Reactive current calculated from the rated motor parameters, the controlled variables
and the current
240 Actual speed Measured or calculated speed of the drive
241 Actual frequency Measured or calculated frequency of the drive
Tab. 246
18.4 Actual system values

Certain actual value parameters are converted into system data in the Dedrive Compact
Actual system values

242 Actual value system Product of actual frequency and parameter Factor actual value system 389
Tab. 247
18.5 Actual value memory

The evaluation and maintenance of the frequency inverter in the corresponding application is facilitated by the saving
of different actual values. The actual value memory ensures the monitoring of the individual variables over a defined
period of time. The parameters of the actual value memory can be read out via a communication interface and
displayed via the operating unit. The peak and mean values can be additionally monitored in the VAL sub-menu of
the operating unit.
Actual value memory

231 Peak value long term Ixt The utilisation of the overload of 60 s depending on the unit
232 Peak value short term Ixt The utilisation of the overload of 10 s depending on the unit
287 Peak Value Vdc The max. link voltage measured
288 Average Value Vdc The average link voltage calculated for the specified period of time
289 Peak value heat sink temp. The highest heat sink temperature measured on the frequency inverter
290 Average value heat sink temp. The average heat sink temperature calculated for the specified period of time
291 Peak value inside temperature The max. inside temperature measured on the frequency inverter
292 Average value inside temperature The average inside temperature calculated for the specified period of time
293 Peak value Irms The highest absolute current value calculated from the measured motor phases
214 716 44/200710
294 Average value Irms The average absolute current value calculated for the specified period of time
295 Peak value active power pos. The highest active power calculated in motor operation
296 Peak value active power neg. Max. active power in generator operation calculated from voltage, current and con‐
trolled variables
297 Average value active power The average active power calculated for the specified period of time 161
Actual value memory
301 Energy, positive The energy calculated for the motor in motor operation
302 Energy, negative The energy calculated for the motor in generator operation
Tab. 248
The Reset memory 237 parameter that can be selected in the PARA sub-menu of the operating unit makes it
possible to reset the specific individual average and peak values. The peak value and average value with the values
saved over the specified period of time are overwritten with the parameter value zero.
Reset memory 237 Function

0- No Reset Values of the actual value memory remain unchanged
1- Peak value long term Ixt Reset Peak value long term Ixt 231
2- Peak value short term Ixt Reset Peak value short term Ixt 232
3- Peak Value Vdc Peak Value Vdc 287 reset
4- Average Value Vdc Average Value Vdc 288 delete
5- Peak value Tc Peak value heat sink temp. 289 reset
6- Average value Tc Average value heat sink temp. 290 delete
7- Peak value Ti Peak value inside temperature 291 reset
8- Average value Ti Average value inside temperature 292 delete
9- Peak Value Iabs. Reset Peak value Irms 293
10 - Average Value Iabs. Delete Average value Irms 294
11 - Peak value Pactive pos. Peak value active power pos. 295 reset
12 - Peak value Pactive neg. Peak value active power neg. 296 reset
13 - Average value Pactive Delete Average value active power 297
16 - Energy, positive Reset Energy, positive 301 parameter
17 - Energy, negative Reset Energy, negative 302 parameter
100 - All peak values Reset all saved peak values
101 - All average values Delete average and saved values
102 - All values Delete entire actual value memory
Tab. 249
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162
19 Error protocol
19.1 General
The different control and regulating processes and the hardware of the frequency inverter include functions which
continuously monitor the application. The operation and error diagnosis is simplified by the information saved in the
error protocol.
19.2 Error list
19.2.1 General
The last 16 error messages which have occurred with the modulation switched on are saved in the error list in
chronological order and the No. of Errors 362 shows the total number of errors which have occurred.
Error messages 0700 , 1102 , 2100 and 2150 are additionally entered in the error list, even if the modulation is
switched off.
The error code Fxxxx is shown in the VAL sub-menu of the operating unit and the operation hours (h), the operation
minutes (m) and the error message can additionally be read out via the PC user interface. The current operating
hours can be read out via the Operation hours counter 245. The error message must be acknowledged via
the keyboard of the operating unit according to the link Error acknowledgment 103.
Error list
310 Last error hhhhh:mm ; Fxxxx error message
311 Last error but one hhhhh:mm ; Fxxxx error message
312 to 325 Error 3 to error 16
362 No. of Errors Number of errors that have occurred after the frequency inverter was put into operation
Tab. 250
The behaviour of the frequency inverter in the case of errors and warnings can be programmed variously. Automatic
error acknowledgement makes it possible to acknowledge the Overcurrent F0500, Overcurrent F0507 and Over‐
voltage F0700 errors without any intervention by a higher-level control system or by a user. The
No. of self acknowledged errors 363 shows the total number of automatic error acknowledgements.
Error list
363 No. of self acknowledged errors Total number of automatic error acknowledgements with synchronisation
Tab. 251
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163
19.2.2 Error messages
The error code saved following an error is made up of fault group FXX and the following code number XX.
For error messages SFxxx, ⇒ "Plausibility check", Page 64 and ⇒ "Parameter identification", Page 65.
Error messages
Code Meaning
F0000 No fault has occurred
Overload
F0102 Frequency inverter overloaded (60 s), check load beahviour
F0103 Short-term overload (10 s), check the motor and application parameters
Heat sink
F0200 Heat sink temperature too high, check the cooling and fan
F0201 Temperature sensor defective or ambient temperature too low
Interior
F0300 Interior temperature too high, check the cooling and fan
F0301 Interior temperature too low, check the electrical cabinet heating
Motor connection
F0400 Motor temperature too high or sensor defective, check motor thermal contact or EM-PTC connection.
F0401 The motor circuit-breaker has been actuated. Check drive
F0403 Motor phase failure, check the motor and wiring.
F0405 Brake release monitoring, see ⇒ „Brake release monitoring“, Page 90
Output current
F0500 Overloaded, check the load conditions and ramps
F0503 Short circuit or earth fault, check the motor and wiring
F0504 Overloaded, check the load conditions and current limit controller
F0505 Asymmetrical motor current, check the motor and wiring
F0506 Motor phase current too high, check the motor and wiring.
F0507 Message of the phase supervision, check the motor and wiring
DC-Link Voltage
F0700 Link voltage too high, check deceleration ramps and connected braking resistor
F0701 Link voltage too low, check line voltage
F0702 Mains failure, check line voltage and circuit
F0703 Phase failure, check line voltage and circuit
F0704 Reference DC link limitation 680 too low, check line voltage
F0705 Brake chopper Trigger threshold 506 too low, check line voltage
F0706 Motor chopper Trigger threshold 507 too low, check line voltage
Electronics voltage
F0801 Electronics voltage 24 V too low, check the control terminals
F0804 Electronic voltage too high, check wiring of control terminals
Optional components
F0B13 The communications module at slot B was installed without disconnection from the mains supply, disconnect the mains supply.
Output frequency
F1100 Output frequency too high, check control signals and settings
F1101 Mx. frequency reached by control, check deceleration ramps and connected braking resistor
F1102 Max. frequency deviation exceeded.
This error occurs particularly when the controller enable on input S1IND is switched off while a rotary encoder is active in regular operation.
F1120 Limit switch monitoring frequency exceeded
Tab. 252
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164
Error messages
Code Meaning
Motor connection
F1300 Earth fault at output, check the motor and wiring.
F1301 Set limit IDC compensation limit 415 reached, check the motor and wiring, increase limit as required
F1310 Minimum current control, check the motor and wiring.
Control connection
F1401 Reference value signal at multi-function input 1 not available, check the signal
F1402 Setpoint value signal missing at analogue input EM-S1INA, check the signal
F1407 Overcurrent at multi-function input 1, check the signal
F1430 Encoder signal is defective:
- Check connections S4IND and S5IND
- Check connections on EM-xxx extension module
- Encoder 2 is active, but the extension module is not fitted
F1431 One encoder signal track not available, check the connections
F1432 Incorrect direction of rotation from the rotary encoder, check connections
F1440 No rotary encoder activated, although configuration 2xx is selected
F1454 External error, see ⇒ „External error / quick stop“, Page 95
Field bus communication
F2010 Communication watchdog RS232/RS485
F2023 CAN error state
F2061 Failure Profibus module
F2062 Profibus OFF (failure DP master)
F2065 Profibus configuration error
F2100 Field bus toggle OFF: Field bus monitoring reports the failure of the bus system.
F21nn Error message on system bus master with error system bus slave nn = node ID of the slave (hex)
F2200 Communication error system bus, timeout SYNC telegram
F2201 Communication error system bus, timeout RxPDO1
F2210 Communication error system bus, bus OFF
F2301 Unknown extension module.
The extension module is not supported by the device software. Please switch off the DIC, remove the extension module and switch the
DIC on again.
Tab. 253
Apart from the error messages mentioned above there are further error messages which, however, can only be used
for internal purposes and are not listed here. If you receive error messages which are not listed here, please contact
the after-sales-service of Demag Cranes & Components.
19.3 Error environment

The parameters of the error environment facilitate trouble shooting. The error environment records the operating
behaviour of the frequency inverter at the point of time of the last four errors.
Error environment
330 Link voltage DC voltage in the link
331 Output voltage Calculated output voltage (motor voltage) of the frequency inverter.
332 Stator frequency The output frequency (motor frequency) of the frequency inverter
334 Encoder 2 frequency Only with EM extension module
Calculated from the data of rotary encoder 1, the No. of pole pairs 373 and the
335 Phase current Ia Current measured in motor phase U
336 Phase current Ib Current measured in motor phase V
337 Phase current Ic Current measured in motor phase W
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338 R.m.s Current Calculated root-mean-square output current (motor current) of the frequency inverter
339 Flow current share Isd The magnetic flux-forming current component or the calculated reactive current
340 Torque current share Isq The torque-forming current component or the calculated active current
341 Rotor magnetizing current Magnetising current related to the rated motor parameters and the working point
165
Error environment
342 Torque Torque calculated from voltage, current and controlled variables
343 Analogue input MFI1A Input signal on multi-function input 1 in Operation mode 452
„1 – voltage input“ or „2 – current input“
344 Analogue input EM-S1INA Signal on analogue input EM-S1INA
346 Analogue output MFO1A Output signal on multi-function output 1 in Operation mode 550 „2 – Analogue“
347 Analogue output EM-S1OUTA Signal on analogue output EM-S1OUTA only with EM – UNI-01 extension module
348 Analogue output EM-S1OUTA Signal on analogue output EM-S1OUTA only with EM – UNI-01 extension module
349 Repetition frequency output Signal on the repetition frequency output acc. to the
Operation mode repetition freq. MFO1F 555
350 Status of digital inputs Decimal-coded status of the six digital inputs and of multi-function input 1 in
Operation mode 452 „3 – digital input“
351 Status of digital outputs Decimal-coded status of the two digital outputs and of multi-function output 1 in
Operation mode 550 „1 – Digital“
352 Time since Release The point of time of the error in hours (h), minutes (m) and seconds (s) after the release
signal: hhhhh:mm:ss . sec/10 sec/100 sec/1000
353 Heat sink temperature Measured heat sink temperature
354 Housing temperature Temperature measured inside housing
355 Controller status The reference value signal is limited by the controllers coded in the controller status.
356 Warning status Warning messages coded in the warning status
357 Int. value 1 Software service parameter
358 Int. value 2 Software service parameter
359 Long value 1 Software service parameter
360 Long value 2 Software service parameter
Tab. 254
The Checksum 361 parameter shows whether the error environment has been saved correctly (OK) or incompletely
(NOK).
Error environment
361 Checksum Check-log of the error environment
Tab. 255
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20 Operation and error diagnosis
20.1 General
The operation of the frequency inverter and the connected load is continuously monitored. Different functions record
the operating behaviour and simplify operation and error diagnosis.
20.2 Status display
43203344_xml.eps
Fig. 97
The red green LED’s provide information on the operational point of the frequency inverter. If the operating unit is
plugged in, status messages are also displayed by display elements RUN, WARN and FAULT.
Status display
Green LED Red LED Display Description
Off Off - - No power supply
- If the supply voltage is applied to L1, L2, L3, a serious device error has
occured. Please contact the Demag Cranes & Components GmbH customer
service.
On On - Brief initialisation and self-test after the power supply is switched on.
Flashes Off RUN flashes With S1IND=LOW: Ready, no modulation possible since there is no control
enable.
Flashes Off RUN flashes With S1IND=HIGH: Ready for operation, control enable on; no modulation,
since there is no travel command at SW-Step 1+ or 1-.
On Off RUN Operational message, inverter output active.
On Flashes quickly RUN + WARN Operational message, there is a warning, see Warnings 269
Flashes Flashes quickly RUN flashes slowly + Ready, there is a warning, see Warnings 269
WARN
Off Flashes FAULT flashes slow‐ An error has occurred. See KP500 display or Current error 259.
ly + WARN The error cannot be acknowledged, since:
- The cause of the error is still present,
- The waiting time of 15 sec. has not yet elapsed.
Off On FAULT An error has occurred. See KP500 display or Current error 259, error can
be acknowledged.
Tab. 256
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20.3 Status of the digital signals
General
The status of the digital signals can be read out as decimal-coded output via the actual value parameters. The
displayed information makes it possible to review the various control signals. The information is displayed with
characters in addition to the digital value with Parcom Compact version 5.09 and higher.
Example: Active Bit 0 and Bit 2 result in decimal value 5
Bit Bit
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
! ∙ ! ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙ ∙
1 4
Tab. 257
! = active
∙ = inactive
Status of the digital inputs
The status of the digital inputs is displayed by means of the Digital inputs 250 parameter.
Bit Decimal value Description Terminal

0 1 S 1 IND X210 A.3
1 2 S 2 IND X210 A.4
2 4 S 3 IND X210 A.5
3 8 S 4 IND X210 A.6
4 16 S 5 IND X210 A.7
5 32 S 6 IND X210 B.1
6 64 MFI 1 D X210 B0,6
7 128 EM – S 1 IND X410 A.7
8 256 EM – S 2 IND X410 A.1
9 512 EM – S 3 IND X410 A.3
Tab. 258
Status of the digital outputs
The status of the digital outputs is displayed by means of the Digital outputs 254 parameter.
Bit Decimal value Description Terminal

0 1 S 1 OUT X210 B.3
1 2 MFO 1 D X210 B.4
2 4 S 3 OUT X10
3 8 EM – S 1 OUT D X412
4 16 EM – S 1 IOD A X410 A.7
Tab. 259
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20.4 Controller status
The controller status can be used to determine which control functions are active. If more than one controller is active
at that point of time, a controller code is displayed which is a combination of the individual codes. Display of the
controller status via the operating unit and the LED’s can be programmed by the
Controller status message 409 parameter.
Coding of the controller status

CXXXX ABCDE
I I
Controller code Controller acronym
Code Controller status
C 00 00 - No controller active
C 00 01 UDdyn Voltage controller is in the rise phase according to Operation mode 670
C 00 02 UDstop The output frequency at power failure is below the Shutdown threshold 675.
C 00 04 UDctr Failure of the mains voltage and mains support active according to Operation mode 670 of the voltage
controller
C 00 08 UDlim The link voltage has exceeded the Reference DC link limitation 680.
C 00 10 Boost Dyn. voltage pre-control 605 accelerates the control behaviour.
C 00 20 Ilim The output current is limited by the current limit controller or speed controller.
C 00 40 Tlim The output power or the torque is limited on the speed controller.
C 00 80 Tctr Change-over of the FOR between speed and torque control
C 01 00 Rstp The Operation Mode 620 selected in the starting behaviour limits the output current.
C 02 00 IxtLtLim The overload limit of the long term Ixt (60s) has been reached, intelligent current limits active according to
Operation mode 573
C 04 00 IxtStLim The overload limit of the short term Ixt (10s) has been reached, intelligent current limits active according to
Operation mode 573
C 08 00 Tclim Max. heat sink temperature TK reached, intelligent current limits active according to Operation mode 573
C 10 00 PTClim Max. motor temperature TPTC reached, intelligent current limits active 573 according to
Operation mode 573
C 20 00 Flim The reference frequency has reached the Maximum frequency 419. The frequency limitation is active.
Tab. 260
Example:
The controller status displayed is
C0024 UDctr Ilim
The controller status results from the hexadecimal sum of the controller codes (0004+0020 = 0024). Simultaneously
the mains support as well as the current limitation of the speed controller is active.
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20.5 Warning status
The current warning is displayed by a message in the warning status and can be used for displaying a critical
operating status at an early point of time. The combination of different warnings can be created by the
Create warning mask 536 parameter. In the case of a warning, it is displayed by the flashing red LED and the
WARN display field of the operating unit. In the case of several warnings the warning status is displayed as the sum
of the individual warning codes.
Coding of the warning status

AXXXX ABCDE
I I
Warning code Warning acronym
Code Warning status
A 00 00 - No warning messages.
A 00 01 Ixt Frequency inverter overloaded, (A0002 or A0004)
A 00 02 IxtSt Short-term overload for 10 s related to the rated output of the frequency inverter
A 00 04 IxtLt Overload for 60 s related to the rated output of the frequency inverter
A 00 08 Tc The max. heat sink temperature TK of 80 °C minus the Warning limit heat sink temp. 407 has been
reached
A 00 10 Ti The max. inside temperature TK of 65 °C minus the Warning limit inside temp. 408 has been reached
A 00 20 Lim The controller listed in the Controller Status 275 limits the reference value.
A 00 40 LK The load spectrum function signals that 90% of the safe working period of the hoist unit has elapsed, ⇒ „Load
spectrum calculation“, Page 90.
A 00 80 PTC Warning after programmed Motor-PTC operation mode 570 at max. motor temperature TPTC
A 01 00 Mains The Phase supervision 576 signals a phase failure in the power supply.
A 02 00 PMS The internal software motor circuit-breaker has been tripped according to the programmed
Operation mode 571
A 04 00 Flim The Maximum frequency 419 has been exceeded. The frequency limitation is active.
A 08 00 A1 The MFI1A input signal is lower than 1V / 2 mA depending on the operation mode
A 10 00 A2 Only with EM – UNI-01 extension module
The MFI1A input signal is lower than 1V / 2 mA depending on the operation mode
A 20 00 Sysbus A slave on the system bus signals an error, warning only relevant with EM – UNI-01 option.
A 40 00 UDC The link voltage has reached the minimum value which depends on the type.
A 80 00 Toggle bit Field bus monitoring reports the failure of the bus system.
Tab. 261
⇒ "Warning mask", Page 126
Example:
The warning status displayed is
A008D Ixt IxtLt Tc PTC
The warning status results from the hexadecimal sum of the warning codes (0001+0004+0008+0080 = 008D).
The warning overload (60 s), the warning limit heat sink temperature and the warning limit motor temperature are
applied.
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21 Parameter list
21.1 General
The parameter list is divided into the sub-menus of the Parcom Compact programming software.
To provide a more detailed overview, the parameters are marked with pictograms.
⌸ The parameter is available with data set change-over in the four data sets
☑ The parameter value is interrogated by the SETUP routine
ID The parameter value is set by the parameter identification. It should only be changed manually by trained personnel.
Ⓧ This parameter cannot be written during operation of the frequency inverter (modulation on).
Tab. 262
The EM reference in the Chapter column indicates that the corresponding parameter is described in the operating
instructions of the extension module.
21.2 Actual value menu (VAL)

No. Description Unit Display range Chapter
Actual values ➜ Actual machine values
210 Stator frequency Hz 0,00 … 999,99
211 Motor current A 0,0 … Imax
212 Motor voltage V 0,0 … UFUN
213 Active power kW 0,0 … Pmax
214 Active current A 0,0 … Imax ⇒ „Actual frequency inverter values“, Page 160
215 Flow current share Isd A 0,0 … Imax
216 Torque current share Isq A 0,0 … Imax
217 Encoder 1 frequency Hz 0,00 … 999,99
218 Encoder 1 speed rpm 0 … 60000
219 Encoder 2 frequency Hz 0,00 … 999,99 EM
220 Encoder 2 speed rpm 0 … 60000 EM
221 Slip frequency Hz 0,0 … 999,99 ⇒ „Actual machine values“, Page 160
Actual values➜ Actual frequency inverter values
222 Link voltage V 0,0 … Udmax-25
⇒ „Actual frequency inverter values“, Page 160
223 Output voltage ratio % 0 … 100
224 Torque Nm ± 9999,9
225 Rotor flux % 0 … 100
⇒ „Actual machine values“, Page 160
226 Winding temperature deg.C 0 … 999
227 Current rotor time constant ms 0 … Ƭmax
228 Internal reference frequency Hz 0,00 … fmax
229 Reference percentage value % ± 300,00 ⇒ „Actual frequency inverter values“, Page 160
230 Actual percentage value % ± 300,00
Actual values ➜ actual value memory
231 Peak value long term Ixt % 0,00 … 100,00
⇒ „Actual value memory“, Page 161
232 Peak value short term Ixt % 0,00 … 100,00
235 Flux-forming voltage V 0,0 … UFUN
236 Torque-Forming Voltage V 0,0 … UFUN
238 Flux value % 0,0 … 100,0
⇒ „Actual machine values“, Page 160
239 Reactive current A 0,0 … Imax
240 Actual speed rpm 0 … 60000
241 Actual frequency Hz 0,0 … 999,99
Tab. 263
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Actual values ➜ Actual system values
242 Actual value system - ⇒ „Actual system values“, Page 161
244 Working hours counter h 99999
245 Operating hours counter h 99999
249 Active Data Set - 1…4 ⇒ „Data set change-over“, Page 129
250 Digital inputs - 0 … 65535 ⇒ „Status of the digital signals“, Page 168
251 Analogue input MFI1A % ± 100,00 ⇒ „Analogue input MFI1A“, Page 118
252 Repetition frequency input Hz 0,00 … 999,99 ⇒ „Repetition frequency input“, Page 111
253 Analogue input EM-S1INA % -100 … +100 EM
254 Digital outputs - 0 … 65535 ⇒ „Status of the digital signals“, Page 168
255 Heat sink temperature deg.C 0 … Tkmax
256 Interior temperature deg.C 0 … Timax
257 Analogue output MFO1A V 0,0 … 24,0 ⇒ „Operation mode analogue MFO1A“, Page
122
259 Current Error - FXXXX ⇒ „Actual frequency inverter values“, Page 160
266 Analogue output EM-S1OUTA V 0,0 … 10,0 EM – I/O
267 Analogue output EM-S1OUTA mA 0,0 … 20,0 EM – ENC-02-24
269 Warnings - AXXXX ⇒ „Actual frequency inverter values“, Page 160
271 Interior temperature 24 h deg.C 0 … Tkmax ---
272 Cyclic duration factor % 0,0 … 100,0 ---
275 Controller status - CXXXX ⇒ „Actual frequency inverter values“, Page 160
278 Frequency MFO1F Hz 0,00 … fmax ⇒ „Operation mode repetition frequency
MFO1F“, Page 123
281 DP-Master OUT - String CM – PDP-24
282 Reference bus frequency Hz 0,00 … 999,99
283 Reference Ramp Frequency Hz 0,00 … 999,99
284 DP-Master IN - String CM – PDP-24
287 Peak Value Vdc V 0,0 … Udmax
288 Average Value Vdc V 0,0 … Udmax
289 Peak value heat sink temp. deg.C 0 … Tkmax
290 Average value heat sink temp. deg.C 0 … Tkmax
291 Peak value inside temperature deg.C 0 … Timax
292 Average value inside temperature deg.C 0 … Timax
293 Peak value Irms A 0,0 … ü·IFUN ⇒ „Actual value memory“, Page 161
294 Average value Irms A 0,0 … ü·IFUN
295 Peak value active power pos. kW 0,0 … ü·PFUN
296 Peak value active power neg. kW 0,0 … ü·PFUN
297 Average value active power kW 0,0 … ü·PFUN
301 Energy, positive kWh 0 … 99999
302 Energy, negative kWh 0 … 99999
Tab. 264
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Error protocol ➜ Error list
310 Last error h:m; F 00000:00; FXXXX
311 Last error but one h:m; F 00000:00; FXXXX
312 Error 3 h:m; F 00000:00; FXXXX
313 Error 4 h:m; F 00000:00; FXXXX
314 Error 5 h:m; F 00000:00; FXXXX
315 Error 6 h:m; F 00000:00; FXXXX
316 Error 7 h:m; F 00000:00; FXXXX
317 Error 8 h:m; F 00000:00; FXXXX
⇒ „Error list“, Page 163
318 Error 9 h:m; F 00000:00; FXXXX
319 Error 10 h:m; F 00000:00; FXXXX
320 Error 11 h:m; F 00000:00; FXXXX
321 Error 12 h:m; F 00000:00; FXXXX
322 Error 13 h:m; F 00000:00; FXXXX
323 Error 14 h:m; F 00000:00; FXXXX
324 Error 15 h:m; F 00000:00; FXXXX
325 Error 16 h:m; F 00000:00; FXXXX
Error protocol ➜ Error environment
⌸ 330 Link voltage V 0,0 … Udmax
⌸ 331 Output voltage V 0,0 … UFUN
⌸ 332 Stator frequency Hz 0,00 … 999,99
⌸ 333 Encoder 1 frequency Hz 0,00 … 999,99
⌸ 334 Encoder 2 frequency Hz 0,00 … 999,99
⌸ 335 Phase current Ia A 0,0 … Imax
⌸ 336 Phase current Ib A 0,0 … Imax
⌸ 337 Phase current Ic A 0,0 … Imax
⌸ 338 R.m.s Current A 0,0 … Imax
⌸ 339 Flow current share Isd A 0,0 … Imax ⇒ „Error environment“, Page 165
⌸ 340 Torque current share Isq A 0,0 … Imax

⌸ 341 Rotor magnetizing current A 0,0 … Imax
⌸ 342 Torque Nm ± 9999,9
⌸ 343 Analogue input MFI1A % ± 100,00
⌸ 344 Analogue input EM-S1INA % ± 100,00
⌸ 346 Analogue output MFO1A V 0,0 … 24,0
⌸ 347 Analogue output EM-S1OUTA V 0,0 … 10,0
⌸ 348 Analogue output EM-S1OUTA mA 0,0 … 20,0
⌸ 349 Repetition frequency output Hz 0,00 … 999,99
⌸ 350 Status of digital inputs - 00 … 255
⇒ „Status of the digital signals“, Page 168
⌸ 351 Status of digital outputs - 00 … 255
⌸ 352 Time since Release h:m:s.ms 00000:00:00.000
⌸ 353 Heat sink temperature deg.C 0 … Tkmax ⇒ „Error environment“, Page 165
⌸ 354 Housing temperature deg.C 0 … Timax
⌸ 355 Controller status - C0000 … CFFFF ⇒ „Controller status“, Page 169
⌸ 356 Warning status - A0000 … AFFFF ⇒ „Warning status“, Page 170
⌸ 357 Int. value 1 - ± 32768
⌸ 358 Int. value 2 - ± 32768
⌸ 359 Long value 1 - ± 2147483647 ⇒ „Error environment“, Page 165
⌸ 360 Long value 2 - ± 2147483647
⌸ 361 Checksum - OK / NOK
Tab. 265
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Error protocol ➜ Error list
362 No. of Errors - 0 … 32767
⇒ „Error list“, Page 163
363 No. of self acknowledged errors - 0 … 32767
Operational behaviour ➜ Positioning
470 Rotations U 0,000 … 1 ‧ 106 ⇒ „Positioning“, Page 82
Control inputs/outputs ➜ Digital outputs
537 Actual warning mask - AXXXXXXXX ⇒ „Warning mask“, Page 126
Motor data ➜ Setup
797 Status of motor parameter identification - OK / NOK ⇒ „Set-up by means of the communication inter‐
face“, Page 68
Operational behaviour ➜ Load spectrum calculation
835 Actual duration of service h 0,0 … 100000,0 ⇒ „Actual duration of service“, Page 92
836 Remaining service life % 0,00 … 100,00 ⇒ „Remaining service life“, Page 93
837 Relative torque % 0,00 … 300,00 ⇒ „Relative torque“, Page 93
Reference values ➜ ProHub function
860 Current measuring value % 0,00 … 650,00 ⇒ „Current measuring value“, Page 115
861 Valid max. frequency Hz 0,00 … 999,99 ⇒ „Valid maximum frequency“, Page 115
862 Maximum interior temperature deg.C 0 … Timax ---
863 Maximum Interior temperature 24h deg.C 0 … Timax ---
864 Time of maximum interior temperature h 99999 ---
Actual values ➜ System bus
978 Node state - 1…3
System bus
979 CAN state - 1…3
Tab. 266
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21.3 Parameter menu (PARA)
No. Description Unit Setting range Chapter
Inverter Data
0 Serial number - Reference ⇒ „Serial number“, Page 71
1 Optional modules - Reference ⇒ „Optional modules“, Page 71
⌸ 10 Baud rate - Selection -
12 Inverter software version - Reference ⇒ „Inverter software version“, Page 71
27 Set password - 0 … 999 ⇒ „Set password“, Page 71
28 Control level - 1…3 ⇒ „Control level“, Page 71
29 User name - 32 characters ⇒ „User name“, Page 72
☑ Ⓧ 30 Configuration - Selection ⇒ „Configuration“, Page 72
33 Language - Selection ⇒ „Language“, Page 73
Ⓧ 34 Program - 0 … 999 ⇒ „Programming“, Page 73
Positioning ➜ Axle positioning
37 Start positioning of axle - Selection ⇒ „Axle positioning“, Page 84
Special functions ➜ Fan
39 Switch-on temperature deg.C 0 … 60 ⇒ „Fan“, Page 153
Special functions ➜ Tandem
40 Source reference frequency - Selection -
Control inputs/outputs ➜ Digital inputs
62 (SOSP) Acceleration - Selection ⇒ „SOSP reference value memory function“,
Page 130
66 (SOST) Step 2 - Selection ⇒ „SOST reference value step change-over“,
67 (SOST) Step 3/4 - Selection Page 129
68 SW-Step 1+ - Selection
⇒ „Starting command“, Page 129
69 SW-Step 1 - - Selection
70 Data set change-over 1 - Selection
⇒ „Data set change-over“, Page 129
71 Data set change-over 2 - Selection
72 Percent Motorpoti Up - Selection
⇒ „Percent motor potentiometer“, Page 132
73 Percent Motorpoti Down - Selection
75 Fixed percent change-over 1 - Selection ⇒ „Fixed percentage value change-over“,
76 Fixed percent change-over 2 - Selection Page 130
83 Timer 1 - Selection
⇒ „Timers“, Page 130
84 Timer 2 - Selection
95 Brake Chopper Release - Selection ⇒ „Brake chopper“, Page 154
99 Remote Control Word - Selection -
103 Error Acknowledgment - Selection ⇒ „Error Acknowledgment“, Page 132
Special functions ➜ Electronic gearbox
125 Source el. gear - -
131 (SOST) Step 5-8 - Selection EM
Special functions ➜ Tandem
137 Source Reference Line Value - Selection -
Special functions ➜ Electronic gearbox
147 Source Position Reference Value - Selection -
148 Source Position Actual Value - Selection -
164 n-/M-control change-over - Selection ⇒ „n-/M-control change-over“, Page 132
183 External error / quick stop - Selection ⇒ „External error / quick stop“, Page 95
Tab. 267
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Timer and logic functions ➜ Logic function 1
198 Operation mode - Selection
199 Input 1 - Selection ⇒ „Logic function“, Page 134
200 Input 2 - Selection
204 Motor thermal contact - Selection ⇒ „Motor thermal contact“, Page 130
237 Reset memory - Selection ⇒ „Actual value memory“, Page 161
Motor data ➜ Additional motor data
ID ⌸ 368 Rated voltage correction factor % ---
Motor data ➜ Rated motor parameters
☑ ⌸ 370 Rated voltage V 0,17·UFUN … 2·UFUN
☑ ⌸ 371 Rated current A 0,01·IFUN … 10·ü·IFUN
☑ ⌸ 372 Rated speed rpm 96 … 60000
⌸ 373 No. of pole pairs - 1 … 24 ⇒ „Rated motor parameters“, Page 74
☑ ⌸ 374 Rated cosinus Phi - 0,01 … 1,00
☑ ⌸ 375 Rated frequency Hz 10,00 … 1000,00
☑ ⌸ 376 Rated mech. power kW 0,1·PFUN … 10·PFUN
ID ⌸ 377 Stator resistance mOhm 0 … 65535 ⇒ „Additional motor data“, Page 74
ID ⌸ 378 Leakage factor % 1,0 … 20,0
System data
⌸ 389 Factor actual value system ⇒ „System data“, Page 77
Special functions ➜ Profibus
⌸ 390 Profibus reference Hz 0,00 … 999,99 CM – PDP-24
391 Profibus Node-ID - 1 … 126 CM – PDP-24
Special functions ➜ Bus controller
392 State-transition 5 - Selection ---
Special functions ➜ Profibus
⌸ 393 Profibus PPO-Type - 1…4 CM – PDP-24
Special functions ➜ RS485 / RS 232
⌸ 394 RS232/RS485 NodeID - Selection
Special functions ➜ Pulse width modulation
ID ⌸ 399 Voltage Drop Compensation - - -
400 Modulation frequency - Selection
⇒ „Pulse width modulation“, Page 153
401 Min. modulation frequency - Selection
402 Switching Compensation % 0 … 200 % -
Tab. 268
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Error/warning Behaviour
405 Warning Limit Short Term Ixt % 6 … 100
⇒ „Overload Ixt“, Page 97
406 Warning Limit Long Term Ixt % 6 … 100
407 Warning Limit Heat Sink Temp. deg.C -25 … 0
⇒ „Temperature“, Page 97
408 Warning Limit Inside Temp. deg.C -25 … 0
409 Controller-Status Message - Selection ⇒ „Controller status“, Page 97
Special functions ➜ Bus controller
410 Control word ---
411 Status word ---
⌸ 412 Local/Remote - Selection ⇒ „Bus controller“, Page 157
413 RS232/RS485 Watchdog Timer S 0 … 10000 ---
415 IDC compensation limit V 0,0 … 1,5 ⇒ „IDC compensation limit“, Page 97
417 Frequency switch-off limit Hz 0,00 … 999,99 ⇒ „Frequency switch-off limit“, Page 98
Reference values ➜ Frequency limits
☑ ⌸ 418 Minimum frequency Hz 0,00 … 300,00
⇒ „Frequency limits“, Page 100
☑ ⌸ 419 Maximum frequency Hz 0,00 … 300,00
Reference values ➜ Frequency ramps
☑ ⌸ 420 Acceleration Hz/s 0,01 … 999,99
☑ ⌸ 421 Deceleration Hz/s 0,01 … 999,99
⌸ 422 Acceleration anticlockwise Hz/s -0,01 … 999,99
⌸ 423 Deceleration anticlockwise Hz/s -0,01 … 999,99 ⇒ „Frequency ramps“, Page 107
⌸ 424 Emergency stop clockwise Hz/s 0,01 … 999,99
⌸ 425 Emergency stop anticlockwise Hz/s 0,01 … 999,99
⌸ 426 Maximum leading Hz 0,01 … 999,99
⌸ 429 Max. frequency deviation Hz 0,01 … 15,00 ⇒ „Max. frequency deviation“, Page 99
Reference values ➜ Frequency ramps
⌸ 430 Ramp rise time clockwise ms 0 … 65000
⌸ 431 Ramp fall time clockwise ms 0 … 65000
⌸ 432 Ramp rise time anticlockwise ms 0 … 65000 ⇒ „Frequency ramps“, Page 107
⌸ 433 Ramp fall time anticlockwise ms 0 … 65000
⌸ 434 Ramp Setpoint - Selection
Control functions ➜ Technology controller
⌸ 440 Operation mode - Selection
⌸ 441 Fixed Frequency Hz -999,99 … 999,99
⌸ 442 Max. P-Component Hz 0,01 … 999,99
⌸ 443 Hysteresis % 0,01 … 100,00 ⇒ „Technology controller“, Page 143
⌸ 444 Amplification - -15,00 … 15,00
⌸ 445 Integral time ms 0 … 32767
⌸ 446 Ind. Volume Flow Control Factor - 0,10 … 2,00
Reference values ➜ Blocking frequencies
⌸ 447 1. blocking frequency Hz 0,00 … 999,99
⌸ 448 2. blocking frequency Hz 0,00 … 999,99 ⇒ „Blocking frequencies“, Page 109
⌸ 449 Frequency hysteresis Hz 0,00 … 100,00
Tab. 269
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Control inputs/outputs ➜ Multi-function input MFI1
⌸ 450 Tolerance band % 0,00 … 25,00 ⇒ „Tolerance range and hysteresis“, Page
120
452 Operation mode - Selection ⇒ „Multi-function input MFI1“, Page 118
453 Error/warning behaviour - Selection ⇒ „Error and warning behaviour“, Page 121
⌸ 454 Point X1 % 0,00 … 100,00
⌸ 455 Point Y1 % -100,00 … 100,00
⇒ „Characteristic curve“, Page 118
⌸ 456 Point X2 % 0,00 … 100,00
⌸ 457 Point Y2 % -100,00 … 100,00
Operational behaviour ➜ Positioning
459 Signal source - Selection
⌸ 460 Positioning distance U 0,000 … 1 106
⌸ 461 Signal correction ms -327,68 … 327,67 ⇒ „Positioning“, Page 82
⌸ 462 Load correction - -327,68 … 327,67
⌸ 463 Activity after positioning - Selection
⌸ 464 Time to wait ms 0 … 3,6 106
Special functions ➜ Temperature adjustment
⌸ 466 Temperature coefficient %/100 0,00 … 300,00 ⇒ „Temperature adjustment“, Page 157
⌸ 467 Adjusting temperature deg.C -50,0 … 300,0
⌸ 468 Frequency monitoring - Selection ⇒ „Frequency monitoring“, Page 99
⌸ 469 Reference orientation degree 0,0 … 359,9
⌸ 471 Positioning Frequency Hz 1,00 … 50,00 ⇒ „Axle positioning“, Page 84
⌸ 472 Max positional error degree 0,1 … 90,0
Reference values ➜ Keypad motor potentiometer
473 Ramp Keypad-Motorpoti Hz/s 0,01 … 999,99 ⇒ „Keypad motor potentiometer“, Page 111
Reference values ➜ SOSP function
474 SOSP-Function - Selection ⇒ „SOSP reference value memory“, Page
110
Reference values ➜ Reference frequency channel
☑ ⌸ 475 Drive control - Selection ⇒ „Reference frequency channel“, Page 101
Reference values ➜ Reference percentage value channel
⌸ 476 Reference percentage source - Selection ⇒ „Reference percentage channel“, Page
103
Reference values ➜ Percentage value ramps
⌸ 477 Gradient percentage ramp %/s 0 … 60000 ⇒ „Percentage ramps“, Page 109
Control functions ➜ Technology controller
⌸ 478 Actual percentage source - Selection ⇒ „Technology controller“, Page 143
⌸ 479 Time constant positioning contr. ms 1,00 … 9999,00 ⇒ „Axle positioning“, Page 84
Reference values ➜ SOST parameters
☑ ⌸ 480 SOST step 1 Hz -300,00 … 300,00
☑ ⌸ 481 SOST step 2 Hz -300,00 … 300,00
⇒ „SOST reference value steps“, Page 105
⌸ 482 SOST step 3 Hz -300,00 … 300,00
⌸ 483 SOST step 4 Hz -300,00 … 300,00
⌸ 485 SOST step 5 Hz -300,00 … 300,00 EM
⌸ 486 SOST step 6 Hz -300,00 … 300,00 EM
⌸ 487 SOST step 7 Hz -300,00 … 300,00 EM
⌸ 488 SOST step 8 Hz -300,00 … 300,00 EM
489 JOG frequency Hz -300,00 … 300,00 ⇒ „JOG frequency“, Page 106
Tab. 270
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Motor data ➜ Encoder 1
☑ Ⓧ 490 Operation mode encoder 1 - Selection ⇒ „Operation mode encoder 1“, Page 76
☑ Ⓧ 491 Division marks encoder 1 - 1 … 8192 ⇒ „Division marks encoder 1“, Page 76
Ⓧ 493 Operation mode encoder 2 - Selection EM
Ⓧ 494 Division marks encoder 2 - 1 … 8192 EM
Ⓧ 495 Level Encoder 2 - Selection EM
Reference values ➜ Repetition frequency input
Ⓧ 496 Operation mode - Selection
⇒ „Repetition frequency input“, Page 111
Ⓧ 497 Divider - 1 … 8192
Special functions ➜ Brake chopper
506 Trigger threshold V Udmin + 25 … 1000,0 ⇒ „Brake chopper“, Page 154
Special functions ➜ Motor chopper
⌸ 507 Trigger threshold V Udmin + 25 … 1000,0 ⇒ „Motor chopper“, Page 154
ID ⌸ 508 Current Limit A
⌸ 510 Setting frequency Hz 0,00 … 999,99 ⇒ „Setting frequency“, Page 124
Reference values ➜ Percentage limits
⌸ 518 Minimum reference percentage % 0,00 … 300,00
⇒ „Percentage limits“, Page 100
⌸ 519 Maximum reference percentage % 0,00 … 300,00
Reference values ➜ Fixed percentage values
⌸ 520 Fixed percentage 1 % -300,00 … 300,00
⇒ „Fixed percentage values“, Page 106
⌸ 523 Fixed percentage 4 -300,00 … 300,00
530 Op. mode digital output 1 S1OUT - Selection
⇒ „Digital outputs“, Page 123
532 Op. mode digital output 3 S3OUT - Selection
533 Op. mode digital output 4 - Selection
EM
EM-S1OUTD
External error / quick stop
535 Operation mode - Selection ⇒ „External error / quick stop“, Page 95
536 Create Warning Mask - Selection ⇒ „Warning mask“, Page 126
540 Op. mode comparator 1 - Selection
541 Comparator 1 on above % -300,00 … 300,00
542 Comparator 1 off below % -300,00 … 300,00
543 Op. mode comparator 2 - Selection ⇒ „Comparator“, Page 125
544 Comparator 2 on above % -300,00 … 300,00
545 Comparator 2 off below % -300,00 … 300,00
549 Max. control deviation % 0,01 … 20,00
Tab. 271
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Control inputs/outputs ➜ Multi-function output MFO1
550 Operation mode MFO1 - Selection ⇒ „Multi-function output MFO1“, Page 121
551 Voltage 100% V 0,0 … 24,0
⇒ „Output characteristic“, Page 122
552 Voltage 0% V 0,0 … 24,0
553 Operation mode analogue MFO1A - Selection ⇒ „Operation mode analogue MFO1A“, Page
122
554 Operation mode digital MFO1D - Selection ⇒ „Digital outputs“, Page 123
555 Operation Mode Repetition Freq. MFO1F - Selection ⇒ „Operation mode repetition frequency
MFO1F“, Page 123
Ⓧ 556 Division marks - 30 … 8192 ⇒ „Output characteristic“, Page 122
Control inputs/outputs ➜ Digital port EM-S1IOD
558 Operation mode EM-S1IOD - Selection EM
559 Output Operation EM-S1IOD A - Selection EM
Control inputs/outputs ➜ Analogue input EM-S1INA
⌸ 560 Tolerance band % 0,00 … 25,00 EM
561 Filter time constant - Selection EM
562 Operation mode - Selection EM
563 Error/warning behaviour - Selection EM
⌸ 564 Point X1 % -100,00 … 100,00 EM
⌸ 565 Point Y1 % -100,00 … 100,00 EM
⌸ 566 Point X2 % -100,00 … 100,00 EM
⌸ 567 Point Y2 % -100,00 … 100,00 EM
568 Adjustment - Selection EM
570 Motor-PTC Operation Mode - Selection ⇒ „Motor temperature“, Page 98
Special functions ➜ Motor protective switch
⇒ „Motor protective switch“, Page 155
⌸ 572 Frequency limit % 0 … 300
Control functions ➜ Intelligent current limits
⌸ 574 Power limit % 40,00 … 95,00 ⇒ „Intelligent current limits“, Page 138
⌸ 575 Limitation Time min 5 … 300
⌸ 576 Phase supervision - Selection ⇒ „Phase failure“, Page 98
578 Allowed No. of Auto-Acknowl. - 0 … 20 ⇒ „Automatic error acknowledgement“, Page
579 Restart delay ms 0 … 1000 99
Special functions ➜ Pulse width modulation
580 Reduction limit Ti/Tc deg.C -25 … 0 ⇒ „Pulse width modulation“, Page 153
Control inputs/outputs ➜ Analogue output EM-S1OUTA
584 Operation mode - Selection EM – I/O
585 Offset % -100,00 … 100,00 EM
586 Amplification % 5,0 … 1000,0 EM
587 Adjustment V -15,00 … 15,00 EM – I/O
590 Operation mode - Selection EM – UNI-01
599 Adjustment mA -10 … 30,00 EM – UNI-01
V/f characteristic
ID ⌸ 600 Boost for f=0 V 0,0 … 100,0
ID ⌸ 601 Voltage rise % -100 … 200
ID ⌸ 602 Rise frequency % 0 … 100 ⇒ „V/f characteristic“, Page 136
⌸ 603 Cut-Off Voltage V 60,0 … 560,0
⌸ 604 Cut-Off Frequency Hz 0,00 … 999,99
⌸ 605 Dynamic voltage pre-control % 0 … 200 ⇒ „Dynamic voltage pre-control“, Page 137
Tab. 272
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Control functions ➜ Current limit controller
⌸ 611 Amplification - 0,01 … 30,00
⌸ 612 Integral time ms 1 10000 ⇒ „Current limit controller“, Page 142
⌸ 613 Current Limit A 0,0 … ü·IFUN
⌸ 614 Frequency limit Hz 0,00 … 999,99
Operational behaviour ➜ Starting behaviour
⌸ 621 Amplification - 0,01 … 10,00
⌸ 622 Integral time ms 1 … 30000 ⇒ „Start-up behaviour“, Page 78
ID ⌸ 623 Starting current A 0,0 … ü·IFUN
ID ⌸ 624 Frequency limit Hz 0,00 … 100,00
Operational behaviour ➜ Stopping behaviour
⌸ 630 Operation mode - Selection ⇒ „Stopping behaviour“, Page 80
Operational behaviour➜ Search run
⌸ 646 Brak. time after search run s 0,0 … 200,0
⌸ 647 Current / rated motor current % 1,00 … 100,00 ⇒ „Search run“, Page 81
⌸ 648 Amplification - 0,00 … 10,00
Operational behaviour ➜ Auto-start
651 Operation mode - Selection ⇒ „Auto-start“, Page 80
Control functions ➜ Slip compensation
⌸ 661 Amplification % 0,0 … 300,0
⇒ „Slip compensation“, Page 142
⌸ 662 Max. slip ramp Hz/s 0,01 … 650,00
⌸ 663 Minimum Frequency Hz 0,01 … 999,99
Control functions ➜ Voltage controller
671 Mains failure threshold V -200,0 … –50,0
672 Reference mains support value V -200,0 … –10,0
⌸ 673 Mains support deceleration Hz/s 0,01 … 9999,99
⌸ 674 Acceleration on Mains Resumption Hz/s 0,01 … 9999,99
⌸ 675 Shutdown Threshold Hz 0,00 … 999,99
⇒ „Voltage controller“, Page 138
676 Reference Shutdown Value V Udmin+25 … Udmax-25
⌸ 677 Amplification - 0,00 … 30,00
680 Reference DC-Link Limitation A Udmin+25 … Udmax-25
681 Max. frequency rise Hz 0,00 … 999,99
⌸ 683 Gen. Ref. Current Limit A 0,0 … ü·IFUN
Control functions ➜ Current controller
ID ⌸ 700 Amplification - 0,00 … 2,00
⇒ „Current controller“, Page 146
ID ⌸ 701 Integral time ms 0,00 … 10,00
ID ⌸ 702 Factor P, Ta=125us - - ---
ID ⌸ 703 Factor P, Ta=250us - - ---
ID ⌸ 704 Factor P, Ta=500us - - ---
ID ⌸ 705 Factor P, Ta=1000us - - ---
ID ⌸ 706 Factor Tn, Ta=125us - - ---
ID ⌸ 707 Factor Tn, Ta=250us - - ---
ID ⌸ 708 Factor Tn, Ta=500us - - ---
ID ⌸ 709 Factor Tn, Ta=1000us - - ---
Tab. 273
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ID ⌸ 713 Magnetising Current 50% Flux % 1 … 50
⇒ „Magnetising current“, Page 75
ID ⌸ 716 Idle current A 0,01·IFUN … ü·IFUN
Control functions ➜ Field controller
⌸ 717 Flow correction factor % 0,01 … 300,00 ⇒ „Field controller“, Page 150
ID ⌸ 718 Rotor time constant correction factor % 0,01 … 300,00 ⇒ „Rotor time constant correction factor“,
Page 75
Reference values ➜ Frequency limits
⌸ 719 Slip limit % 0 … 10000 ⇒ „Frequency limits“, Page 100
Control functions ➜ Speed controller
ID ⌸ 721 Amplification - 0,00 … 200,00
⌸ 722 Integral time ms 0 … 60000 ⇒ „Speed controller“, Page 147
⌸ 723 Amplification f > f um - 0,00 … 200,00
⌸ 724 Integral time f > f um ms 0 … 60000
Control functions ➜ Acceleration pre-control
⌸ 726 Minimum Acceleration Hz/s 0,1 … 6500,0 ⇒ „Acceleration pre-control“, Page 150
⌸ 727 Mech. time constant ms 1 … 60000
⌸ 728 Motor current limit A 0,0 … ü·IFUN
⌸ 729 Generative current limit A -0,1 … ü·IFUN
⌸ 730 Motor torque limitation % 0,00 … 650,00 ⇒ „Limitation of the speed controller“, Page
⌸ 731 Generative torque limitation % 0,00 … 650,00 149
⌸ 732 P share motor torque limitation % 0,00 … 650,00

⌸ 733 P share generative torque limitation % 0,00 … 650,00
⌸ 734 Isq Limit Source Motor Operation - Selection
⌸ 735 Isq Limit Source Generator Op. - Selection
⇒ „Limit value sources“, Page 149
⌸ 736 Torque Limit Source Motor Op. - Selection
⌸ 737 Torque Limit Source Gen. Op. - Selection
ID ⌸ 738 Switch-over frequency f um Hz 0,00 … 999,99 ⇒ „Speed controller“, Page 147
⌸ 739 Power Limit Motor Operation kW 0,00 … 2·ü·PFUN ⇒ „Limitation of the speed controller“, Page
⌸ 740 Power limit generator operation kW 0,00 … 2·ü·PFUN 149

⌸ 741 Amplification - 0,0 … 100,0
⇒ „Field controller“, Page 150
ID ⌸ 742 Integral time ms 0,0 … 1000,0
ID ⌸ 743 Ref. Isd Upper Limit A 0,1·IFUN … ü·IFUN ⇒ „Limitation of the field controller“, Page
ID ⌸ 744 Ref. Isd Lower Limit A -IFUN … IFUN 151

ID ⌸ 745 Stator+Rotor Resistance mOhm 0 … 65535 ---
Control functions ➜ Current controller
ID ⌸ 746 Crosscouple Factor % 0,00 … 300,00 % ---
Tab. 274
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748 Backlash damping % 0 … 300 ⇒ „Limit value sources“, Page 147
Control functions ➜ Modulation controller
⌸ 750 Reference modulation % 3,00 … 105,00 ⇒ „Modulation controller“, Page 152
⌸ 752 Integral time ms 0,0 … 1000,00
⇒ „Modulation controller“, Page 152
⌸ 755 Reference Imr lower limit A 0,01·IFUN … ü·IFUN ⇒ „Limitation of the modulation controller“,
⌸ 756 Control deviation limitation % 0,00 … 100,00 Page 152
Special functions ➜ Encoder monitoring

⌸ 761 Timeout: Signal fault ms 0 … 65000
⇒ „Rotary encoder monitoring“, Page 158
⌸ 762 Timeout: Channel fault ms 0 … 65000
⌸ 763 Time-out: Direction fault ms 0 … 65000
⌸ 766 Source Actual Speed - Selection EM
Control functions ➜ Torque controller
⌸ 767 Frequency upper limit Hz -999,99 … 999,99
⇒ „Torque controller“, Page 147
⌸ 768 Frequency lower limit Hz -999,99 … 999,99
⌸ 769 Frequency Upper Limit Source - Selection
⇒ „Limit value sources“, Page 147
⌸ 770 Frequency Lower Limit Source - Selection
Operational behaviour ➜ Starting behaviour
⌸ 780 Max. flux build-up time ms 1 … 10000
⇒ „Starting behaviour of the FOR“, Page 79
⌸ 781 Current during flux formation A 0,1·IFUN … ü·IFUN
Timer and Logic Functions ➜ Timers
790 Operation mode timer 1 - Selection ⇒ „General“, Page 132
791 Time 1 Timer 1 s/m/h 0 … 650,00
⇒ „Timer time constant“, Page 133
792 Time 2 Timer 1 s/m/h 0 … 650,00
793 Operation mode timer 2 - Selection ⇒ „General“, Page 132
794 Time 1 Timer 2 s/m/h 0 … 650,00
⇒ „Timer time constant“, Page 133
795 Time 2 Timer 2 s/m/h 0 … 650,00
SETUP
796 Motor parameter identification - Selection ⇒ „Set-up by means of the communication in‐
terface“, Page 68
800 Additional fixed frequency selection 1 - Selection ⇒ „Additional fixed frequency selection“,
801 Additional fixed frequency selection 2 - Selection Page 130
802 Additional setpoint value release - Selection ⇒ „Additional setpoint value release“, Page
131
803 Fast to slow limit switch limitation 1+ - Selection ⇒ „Fast-to-slow limit switch limitation 1+ and
804 Fast-to-slow limit switch limitation 1- - Selection fast-to-slow limit switch limitation 1-“, Page
131
805 Fast-to-slow limit switch limitation 2 - Selection ⇒ „Fast-to-slow limit switch limitation 2“,
Page 131
806 Operating limit switch + - Selection
⇒ „Operating limit switches“, Page 132
807 Operating limit switch - - Selection
Motor data ➜ Rated motor parameters
⌸ 812 Cyclic duration factor % Selection ⇒ „Motor data“, Page 63
⌸ 813 KB de-magnetization time ms- 0 … 200 ⇒ „KB de-magnetization time“, Page 151
Tab. 275
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815 Filter time constant encoder 1 - Selection ⇒ „Filter time constant encoder 1“, Page 77
816 Filter time constant encoder 2 - Selection EM
Operational behaviour ➜ Brake control
⌸ 820 Start delay ms 0 … 1000 ⇒ „Start delay“, Page 87
⌸ 821 DC pre-magnetisation time ms 0 … 1000 ⇒ „DC pre-magnetisation time“, Page 87
⌸ 822 DC post-magnetization time s 0,0 … 30,0 ⇒ „DC post-magnetization time“, Page 87
⌸ 823 DC magnetisation % 0 … 250 ⇒ „DC magnetisation“, Page 79
⌸ 824 Brake release delay ms 0 … 5000 ⇒ „Brake release delay“, Page 88
⌸ 825 Brake application time ms 0 … 2000 ⇒ „Brake application time“, Page 88
Operating behaviour ➜ Brake release monitoring
826 Operation mode - Selection ⇒ „Brake release monitoring“, Page 90
828 Brake release time ms 0 … 5000 ⇒ „Brake release monitoring“, Page 90
Operational behaviour ➜ Load spectrum calculation
829 Factor - 0,50 … 2,00 ⇒ „Factor“, Page 93
830 Operation mode - Selection ⇒ „Load spectrum calculation mode“, Page
91
831 Theoretical duration of service h 0,0 … 100000,0 ⇒ „Theoretical duration of service“, Page 91
832 Lifting correction factor % 30 … 200 ⇒ „Lifting correction factor“, Page 92
833 Lowering correction factor % 30 … 200 ⇒ „Lowering correction factor“, Page 92
834 Duration of service specification h 0,0 … 100000,0 ⇒ „Duration of service specification“, Page
92
838 Ramp factor - 0,0 … 1,0 ⇒ „Ramp factor“, Page 93
839 Frequency at rated hoist speed Hz 0,00 … 300,00 ⇒ „Frequency at rated hoist speed“, Page
93
Reference values ➜ Additional setpoint value
⌸ 840 Operation mode - Selection ⇒ „Additional setpoint value“, Page 115
⌸ 841 Additional setpoint value source - Selection ⇒ „Additional control“, Page 116
⌸ 842 Max. additional frequency negative Hz -300,00 … 0 ⇒ „Additional setpoint value frequency limits“,
⌸ 843 Max. additional frequency positive Hz 0,00 … 300,00 Page 116
⌸ 844 Acceleration additional setpoint value Hz/s 0,01 … 999,99 ⇒ „Additional setpoint value frequency
⌸ 845 Deceleration additional setpoint value Hz/s 0,01 … 999,99 ramps“, Page 116
⌸ 846 Additional setpoint value bus operation Hz -300,00 … 300,00 ⇒ „Additional setpoint value bus operation“,
Page 116
⌸ 847 Additional fixed frequency 1 Hz -300,00 … 300,00
⇒ „Additional fixed frequencies“, Page 117
⌸ 848 Additional fixed frequency 2 Hz -300,00 … 300,00
Reference values ➜ ProHub function
⌸ 849 Hoist rating factor - 1,00 … 3,00 ⇒ „Hoist rating factor“, Page 115
Ⓧ ⌸ 850 Operation mode - Selection ⇒ „ProHub function operation mode“, Page
113
851 Field weakening enable - Selection ⇒ „Field weakening enable“, Page 113
Ⓧ ⌸ 852 Field weakening start % 50 … 200 ⇒ „Field weakening start“, Page 113
Ⓧ ⌸ 853 Lifting correction value % 0 … 50 ⇒ „Lifting correction value“, Page 114
Ⓧ ⌸ 854 Lowering correction value % 0 … 50 ⇒ „Lowering correction value“, Page 114
Ⓧ ⌸ 855 Start of measurement Hz 5,00 … 999,99 ⇒ „Start of measurement“, Page 114
Ⓧ ⌸ 856 Field weakening factor - 0,50 … 1,00 ⇒ „Field weakening factor“, Page 114
Tab. 276
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Operational behaviour ➜ Limit switch functions
866 State 1 - Selection
⇒ „Limit switch status“, Page 95
Control inputs/outputs ➜ Multi-function input MFI1
⌸ 870 Characteristic type - Selection ⇒ „Characteristic curve“, Page 118
Operational behaviour ➜ Limit switch functions
871 Setpoint val. limit 1+ Hz 0,00 … 300,00 ⇒ „Setpoint val. limit 1+ and setpoint val. limit
872 Setpoint val. limit 1- Hz 0,00 … 300,00 1-“, Page 94
873 Setpoint val. limit 2+ Hz 0,00 … 300,00 ⇒ „Setpoint val. limit 2+ and Setpoint val. limit
874 Setpoint val. limit 2- Hz 0,00 … 300,00 2-“, Page 95
875 Limit switch monitoring freq. + Hz 0,00 … 300,00 ⇒ „Limit switch monitoring frequency“, Page
876 Limit switch monitoring freq. - Hz 0,00 … 300,00 95
Special functions ➜ Field bus monitoring
⌸ 880 Toggle bit error behaviour - Selection CM – CAN
881 Toggle bit time ms 0 … 5000 CM – CAN
Operating behaviour ➜ Brake release monitoring
894 Brake application time ms 0 … 5000 ⇒ „Brake release monitoring“, Page 90
899 Error response time ms 0 … 5000 ⇒ „Brake release monitoring“, Page 90
System bus
900 System bus parameter only with correspond‐ - Selection
… ing optional module EM
989
Tab. 277
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22 Accessories for Dedrive Compact frequency inverters
22.1 Size 1 DIC - 4 - 002 to 004

Assignment of line fuses, line reactors, line filters, braking resistors, thermal overload relay
Dedrive Compact DIC - 4 - 002 003 004 Remarks
frequency inverter Order no. 537 711 84 537 712 84 537 713 84
Part
3 fuse links Type D – in A (slow) 6
Fuse element 451 663 99
Fuse base 575 049 44
Screw cap Order no. 451 700 99
Close-tolerance bolt 504 905 99
Line reactor 380 V to 480 V ----- 537 739 84
up to 10 m Internal
Line filter 380 V to 480 V motor cable.
radio interference sup‐ Order no.
pression level B 10 m up to 50 m 537 748 84
motor cable
Type PWR R 200 PWR R 200 PWR R 200
R Ohm 470 330 220
Standard braking resistors
P kW 0,2 0,2 0,2
for travel applications
Operating figure % 30 20 15 PBr rated / Pgen
Order no. 537 728 84 537 729 84 537 730 84
Type 3RU1116 – 0HB1 3RU1116 – 0HB1
A 0,55 – 0,8 0,7 – 1,0 For braking resis‐
Thermal overload relay tor
Setting A 0,65 0,78 0,95 item 4
Order no. 537 751 84 537 239 84
up to 60 Hz 537 757 84 537 759 84
Output filters
Order no. up to 87 Hz ----- ----- -----
(du/dt)
up to 200 Hz 537 758 84 537 760 84
EMC accessories
Assembly kit highly conductive clips Order no. 537 770 84
Parameter programming accessories
KP500 operating unit 537 722 84
Parcom Compact parameter programming 537 752 84
software
KP232 Interface adapter Order no. 537 769 84
PC data line 1.8 m 537 237 84
KP CMK switchgear cabinet fitting acces‐ 537 869 84
sories
Optional modules
RS 232 module CM - 232 537 723 84
RS 485 module CM - 485 537 724 84
Profibus module CM - PDP-24 kit Order no. 537 898 84
CAN bus module CM - CAN 537 726 84
Extension module EM – UNI-01 537 900 84
Further accessories
Analogue-PWM converter Order no. 537 782 84
Tab. 278
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22.2 Size 2 DIC - 4 - 006 to 009
Part
Line reactor 380 V to 480 V 537 740 84 537 741 84
up to 10 m Internal
motor cable
Type PWR R 400 PWR R 400 PWR R 600
R Ohm 150 120 100
P kW 0,4 0,4 0,6
Order no. 537 731 84 537 732 84 537 733 84
Type 3RU1116 – 1BB1 3RU1116-
1DB1
For braking resis‐
Thermal overload relay A 1,4 – 2,0 2,2 – 3,2 tor
Setting A 1,63 1,83 2,45 item 4
Order no. 537 240 84 537 241 84
up to 60 Hz 537 763 84 537 765 84 537 767 84
Output filters
Order no. up to 87 Hz ----- ----- -----
(du/dt)
up to 200 Hz 537 764 84 537 766 84 537 768 84
EMC accessories
software
PC data line 1.8 m 537 237 84
sories
Optional modules
RS 232 module CM - 232 537 723 84
RS 485 module CM - 485 537 724 84
Further accessories
Tab. 279
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22.3 Size 3 DIC - 4 - 014 to 017
Dedrive Compact DIC - 4 - 014 017 Remarks
frequency inverter Order no. 537 717 84 537 718 84
Part
3 fuse links Type D – in A (slow) 16 20
Fuse element 451 644 99 451 645 99
Close-tolerance bolt 504 907 99 504 908 99
up to 10 m Internal
motor cable
Type PWR R 600 FZG 500x65-56
R Ohm 68 56
P kW 0,6 0,8
Operating figure % 12 13 PBr rated / Pgen
Order no. 537 734 84 537 735 84
Type 3RU1116-1DB1 3RU1116-1FB1
A 2,2 – 3,2 3,5 – 5,0 For braking resistor
Thermal overload relay
Setting A 2,97 3,78 item 4
Order no. 537 241 84 537 243 84
up to 60 Hz ----- -----
Output filters
Order no. up to 87 Hz 537 154 84 537 155 84
(du/dt)
up to 200 Hz 537 171 84 537 172 84
EMC accessories
software
PC data line 1.8 m 537 237 84
KP CMK switchgear cabinet fitting accesso‐ 537 869 84
ries
Optional modules
RS 232 module CM - 232 537 723 84
RS 485 module CM - 485 537 724 84
Further accessories
Tab. 280
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22.4 Size 4 DIC - 4 - 025 to 040
Part
3 fuse links Type D – in A (slow) 35 50
Fuse element 451 647 99 451 648 99
Close-tolerance bolt 504 910 99 504 911 99
Line reactor 380 V to 480 V 537 744 84 537 745 84 537 753 84
up to 10 m 537 747 84
motor cable
Type FZZG 400x65-33 FZZG 500x65-27 FZZG 600x65-27
R Ohm 33 27 27
P kW 1,2 1,6 2,0
Order no. 537 736 84 537 737 84 537 738 84
Type 3RU1116-1HB1 3RU1116-1JB1
A 5,5 – 8,0 7,0 – 10,0 For braking resis‐
Setting A 6,03 7,70 8,61 item 4
Order no. 537 245 84 537 246 84
up to 60 Hz ----- ----- -----
Output filters
Order no. up to 87 Hz 537 156 84 537 157 84 537 158 84
(du/dt)
up to 200 Hz 537 173 84 537 174 84 537 175 84
EMC accessories
software
PC data line 1.8 m 537 237 84
sories
Optional modules
RS 232 module CM - 232 537 723 84
RS 485 module CM - 485 537 724 84
Further accessories
Tab. 281
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22.5 Size 5 DIC - 4 - 045 to 060
Dedrive Compact DIC - 4 - 045 060 Remarks
frequency inverter Order no. 537 881 84 537 882 84
Part
Line filter 380 V to 480 V up to 100 m Order no. 537 891 84 537 892 84
radio interference sup‐ motor cable.
pression level B
Type FGF 310 0702
R Ohm 15,4
P kW 3,5
Operating figure % 14,3 12,9 PBr rated / Pgen
Order no. 537 632 84
Type 3RU1126-4BB1
A 14 – 20 For braking resistor
Thermal overload relay
Setting A 15,0 item 4
Order no. 537 249 84
up to 60 Hz ----- -----
Output filters
Order no. up to 87 Hz 537 158 84 537 159 84
(du/dt)
up to 200 Hz 537 175 84 537 176 84
EMC accessories
software
PC data line 1.8 m 537 237 84
KP CMK switchgear cabinet fitting accesso‐ 537 869 84
ries
Optional modules
RS 232 module CM - 232 537 723 84
RS 485 module CM - 485 537 724 84
Further accessories
Tab. 282
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22.6 Size 6 DIC - 4 - 075 to 110
Part
3 fuse links Type D – in A (slow) 80 100 125
Fuse element 894 317 44 894 318 44 894 319 44
Order no.
Switch-isolator 891 791 44
Line reactor 380 V to 480 V 537 194 84 537 195 84 537 196 84
Line filter 380 V to 480 V up to 100 m Order no. 537 893 84 537 894 84 537 894 84
radio interference sup‐ motor cable.
pression level B
Type FGFG 311 1002 FGFKQU 312
2004
R Ohm 8,2 8,0
for travel applications P kW 5,0 10,0
Operating figure % 15,0 12,3 20,2 PBr rated / Pgen
Order no. 537 816 84 538 776 84
Type 3RU1136-4EB1 3RU1136-4FB1
A 22 – 32 28 – 40 For braking resis‐
Setting A 24,7 35,4 item 4
Order no. 537 252 84 537 253 84
up to 60 Hz ----- ----- -----
Output filters
Order no. up to 87 Hz 537 160 84 537 161 84 537 162 84
(du/dt)
up to 200 Hz 537 177 84 537 178 84 537 179 84
EMC accessories
Assembly kit highly conductive clips Order no. -----
software
PC data line 1.8 m 537 237 84
sories
Optional modules
RS 232 module CM - 232 537 723 84
RS 485 module CM - 485 537 724 84
Further accessories
Tab. 283
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191
22.7 Braking resistors
22.7.1 General
Note
Technical data for max. 40°C ambient temperature.
Braking resistors can be overloaded by much more than their rated load in temporary duty, however, 120 sec. ON
time already represents continuous operation.
The "Operating figure" given in the table is the maximum permissible ratio of load time to the total period duration
(load time + cooling time) of a braking resistor.
If the total period duration is to exceed 120 sec., this value must be limited to 120 sec.
For hoist units, the load time is the entire duration of a lowering operation; for travel applications - with no incline or
wind - it is the deceleration period.
Load time
„Operating figure“ =
(Load time + cooling time) ≤ 120 s
Tab. 284
Example
Hoist with a lifting time of 30 sec., a lowering The total period duration amounts to 60 sec. Required operating figure of ≥ 50 %
time of 30 sec. and no time at standstill. The operating figure is calculated from the ratio
of lowering time to the total cycle time of 30
sec. / 60 sec. = 0,5.
Hoist unit with a lowering time > 120 seconds. The period duration is > 120 sec., therefore, a Required operating figure of 100 %
braking resistor that is suitable for continuous
operation must be used.
Hoist with a lifting time of 90 sec., a lowering The total period duration amounts to 300 sec. Required operating figure of ≥ 75 %
time of 90 sec. and a time at standstill of 120 The operating figure is calculated from the ratio
sec. of lowering time to 120 sec.
90 s / 120 s = 0,75.
Tab. 285
22.7.2 Frequency inverter → braking resistor assignment
Frequency inverters12) Order no. Resistive value Scope Braking resistor Operating fig‐ Application 13)
ure
Type [Ohm] [kW] Type Type
537 728 84 470 0,2 PWR R 200 30% S
DIC-4-002-01 537 852 84 470 0,5 FZG 400*65-470 74% B
537 773 84 470 1,0 FZG 600*65-470 > 100% H
537 729 84 330 0,2 PWR R 200 20% S
DIC-4-003-01 537 852 84 470 0,5 FZG 400*65-470 51% B
537 773 84 470 1,0 FZG 600*65-470 > 100% H
537 730 84 220 0,2 PWR R 200 15% S
DIC-4-004-01 537 853 84 220 1,0 FZG 600*65-220 74% B
537 774 84 220 1,6 FZZG 500*65-220 > 100% H
537 731 84 150 0,4 PWR R 400 20% S
537 853 84 220 1,0 FZG 600*65-220 51% B
DIC-4-006-01
537 774 84 220 1,6 FZZG 500*65-220 81%
537 775 84 220 2,0 FZZG 600*65-220 > 100% H
Tab. 286
214 716 44/200710
12) See also ⇒ "DIC-4-002 to 009 frequency inverters", Page 21 to ⇒ "DIC-4-045 to 110 frequency inverters", Page 23
192 13) S = Standard travel, B = Special travel application, H = Lifting application. Further braking resistors on request.
ure
537 732 84 120 0,4 PWR R 400 15% S
DIC-4-007-01 537 854 84 120 1,6 FZZG 500*65-120 59% B
537 776 84 120 3,0 FZDG 600*65-120 > 100% H
537 733 84 100 0,6 PWR R 600 17% S
535 973 84 100 1,0 FZG 600*65-100 28%
537 854 84 120 1,6 FZZG 500*65-120 44%
DIC-4-009-01 537 855 84 100 2,0 FZZG 600*65-100 56% B
537 856 84 100 2,4 FZDG 500*65-100 67%
537 776 84 120 3,0 FZDG 600*65-120 83%
535 975 84 100 3,7 FZZG 800*85-100 > 100% H
537 734 84 68 0,6 PWR R 600 12% S
535 973 84 100 1,0 FZG 600*65-100 20%
537 855 84 100 2,0 FZZG 600*65-100 40%
DIC-4-014-01 537 856 84 100 2,4 FZDG 500*65-100 48% B
537 857 84 68 3,0 FZDG 600*65-68 61%
535 975 84 100 3,7 FZZG 800*85-100 75%
537 778 84 68 6,0 FGFG 311 1202-68 > 100% H
537 735 84 56 0,8 FZG 500*65-56 12% S
538 765 84 50 1,6 FZZCQU 500x65-50 24%
534 626 84 51 2,4 FZDG 500*65-51 36%
537 857 84 68 3,0 FZDG 600*65-68 44% B
DIC-4-017-01
535 967 84 51 4,0 FZDG 600*85-51 59%
538 770 84 50 4,5 FGFKQU 310 0904-50 67%
538 771 84 50 6,0 FGFKQU 311 1204-50 89%
537 848 84 56 7,0 FGFG 311 1402-56 > 100% H
537 736 84 33 1,2 FZZG 400*65-33 12% S
538 766 84 50 2,0 FZZCQU 600x65-50 20%
535 966 84 51 3,0 FZDG 600*65-51 30%
535 967 84 51 4,0 FZDG 600*85-51 40%
DIC-4-025-01 537 858 84 33 5,0 FGFG 311 1002-33 51% B
537 833 84 47 6,0 FGFG 311 1202-47 61%
537 859 84 33 7,0 FGFG 312 1402-33 71%
534 631 84 33 7,5 FGF 312 1502-33 76%
537 849 84 33 10,0 FGFG 312 2002-33 > 100% H
537 737 84 27 1,6 FZZG 500*65-27 12% S
538 767 84 25 2,4 FZDCQU 500x65-25 18%
534 629 84 33 3,5 FGF 310 0702-33 26%
537 858 84 33 5,0 FGFG 311 1002-33 37%
DIC-4-032-01 538 772 84 25 6,0 FGFKQU 311 1204-25 44%
537 859 84 33 7,0 FGFG 312 1402-33 52% B
537 860 84 27 8,0 FGFG 312 1602-27 59%
537 849 84 33 10,0 FGFG 312 2002-33 74%
537 850 84 28 14,0 FGFG 313 2802-28 > 100% H
Tab. 287
214 716 44/200710
15) S = Standard travel, B = Special travel application, H = Lifting application. Further braking resistors on request. 193
ure
537 738 84 27 2,0 FZZG 600*65-27 12% S
534 629 84 33 3,5 FGF 310 0702-33 21%
537 858 84 33 5,0 FGFG 311 1002-33 30%
538 772 84 25 6,0 FGFKQU 311 1204-25 36%
537 859 84 33 7,0 FGFG 312 1402-33 42%
DIC-4-040-01
537 860 84 27 8,0 FGFG 312 1602-27 48% B
537 849 84 33 10,0 FGFG 312 2002-33 60%
537 850 84 28 14,0 FGFG 313 2802-28 84%
727 005 46 24,6 15,0 FGFG 313 3002-24.6 90%
537 851 84 27 17,0 FGFG 313 3402-27 > 100% H
534 632 84 15,4 3,5 FGF 310 0702-15 18% S
534 633 84 15 5,0 FGF 311 1002-15 25%
538 772 84 25 6,0 FGFKQU 311 1204-25 30%
537 860 84 27 8,0 FGFG 312 1602-27 40%
534 636 84 15 10,5 FGF 312 2202-15 53% B
DIC-4-045-01
727 003 46 22 11,0 FGFG 312 2202-22 56%
534 637 84 15 15,0 FGF 314 3202-15 76%
537 851 84 27 17,0 FGFG 313 3402-27 86%
535 568 84 15 19,0 FGF 314 3802-15 96%
535 968 84 15 25,0 FA 323 5002-15 > 100% H
534 632 84 15,4 3,5 FGF 310 0702-15 13% S
534 633 84 15 5,0 FGF 311 1002-15 19%
534 635 84 15 7,5 FGF 312 1502-15 28%
DIC-4-060-01 534 636 84 15 10,5 FGF 312 2202-15 39%
534 637 84 15 15,0 FGF 314 3202-15 56% B
535 568 84 15 19,0 FGF 314 3802-15 70%
535 968 84 15 25,0 FA 323 5002-15 93% H
537 816 84 8,2 5,0 FGFG 311 1002-8,2 15% S
534 639 84 10 7,5 FGF 312 1502-10 23%
538 776 84 8 10,0 FGFKQU 312 2004-8 30%
534 641 84 10 12,5 FGF 313 2502-10 38%
537 836 84 8 15,0 FGFL 313 3002-8 45%
DIC-4-075-01 538 782 84 8 16,0 FGFKQU 313 3204-8 48% B
534 648 84 7,5 20,0 FGF 314 4202-7.5 60%
537 839 84 8 24,0 FA 322 4802-8 72%
534 645 84 10 27,0 FA 323 5402-10 81%
538 789 84 8 32,0 FAQU 323 6404-8 96% H
537 842 84 8 37,5 FAQ 324 7504-8 > 100%
Tab. 288
214 716 44/200710
194 17) S = Standard travel, B = Special travel application, H = Lifting application. Further braking resistors on request.
ure
537 816 84 8,2 5,0 FGFG 311 1002-8,2 12% S
534 639 84 10 7,5 FGF 312 1502-10 19%
538 776 84 8 10,0 FGFKQU 312 2004-8 25%
534 641 84 10 12,5 FGF 313 2502-10 31%
537 836 84 8 15,0 FGFL 313 3002-8 37%
538 782 84 8 16,0 FGFKQU 313 3204-8 40%
DIC-4-090-01
534 648 84 7,5 20,0 FGF 314 4202-7.5 49% B
537 839 84 8 24,0 FA 322 4802-8 59%
534 645 84 10 27,0 FA 323 5402-10 67%
538 789 84 8 32,0 FAQU 323 6404-8 79%
537 842 84 8 37,5 FAQ 324 7504-8 93%
538 791 84 8 40,0 FAQU 324 8004-8 99% H
538 776 84 8 10,0 FGFKQU 312 2004-8 20% S
537 836 84 8 15,0 FGFL 313 3002-8 30%
538 782 84 8 16,0 FGFKQU 313 3204-8 32%
534 648 84 7,5 20,0 FGF 314 4202-7.5 40%
537 839 84 8 24,0 FA 322 4802-8 48% B
534 645 84 10 27,0 FA 323 5402-10 55%
DIC-4-110-01
538 789 84 8 32,0 FAQU 323 6404-8 65%
537 842 84 8 37,5 FAQ 324 7504-8 76%
538 791 84 8 40,0 FAQU 324 8004-8 81%
538 793 84 10 42,0 FAQU 324 8404-10 85%
537 844 84 8 44,0 FAQ 324 8804-8 89%
537 846 84 8 54,0 FAQ 334 0804-8 > 100% H
Tab. 289
22.7.3 Thermal overload protection for braking resistors
The thermal protection of braking resistors can either be implemented by a thermal overload relay in the power
supply of the braking resistor or, as an alternative, by means of a thermal contact on the braking resistor.
Due to the design, partly one of the two or partly also both variants are available:
● Braking resistors with the additional designation "Fx..Qx" (e.g. FAQ...) feature a thermal contact for monitoring
and protection against overload.
● Refer to the tables in ⇒ "Braking resistor → thermal overload relay assignment", Page 196 for possible thermal
overload relays.
Please also note that the thermal overload relays are only suitable for operation of the braking resistor on inverters
with a max. line voltage of 500 V.
22.7.4 Thermal overload relay
22.7.4.1 General
Section ⇒ "Braking resistor → thermal overload relay assignment", Page 196 lists all braking resistors available for
Demag frequency inverters. Only resistors up to 55 KW and a minimum resistance of 7,5 ohms should be used for
Dedrive Compact frequency inverters.
214 716 44/200710
19) S = Standard travel, B = Special travel application, H = Lifting application. Further braking resistors on request. 195
22.7.4.2 Braking resistor → thermal overload relay assignment
Braking resistor Thermal overload relay 20)

Qty. Type 21) Order no. Scope Resistive Qty. Type Order no. Setting range Setting
value value
[kW] [Ohm] [A] [A]
PWR R 200 537 730 84 0,200 220,0 3RU1116-0JB1 537 239 84 0.7 - 1.0 1,00
PWR R 200 537 729 84 0,200 330,0 3RU1116-0JB1 537 239 84 0.7 - 1.0 0,80
PWR R 200 537 728 84 0,200 470,0 3RU1116-0HB1 537 751 84 0.55 - 0.8 0,65
FZG 300*45-100 535 970 84 0,285 100,0 3RU1116-1BB1 537 240 84 1.4 - 2.0 1,70
PWR R 400 537 732 84 0,400 120,0 3RU1116-1BB1 537 240 84 1.4 - 2.0 1,80
PWR R 400 537 731 84 0,400 150,0 3RU1116-1BB1 537 240 84 1.4 - 2.0 1,60
FZG 300*65-51 515 696 84 0,430 51,0 3RU1116-1DB1 537 241 84 2.2 - 3.2 2,90
FZG 400*65-470 537 852 84 0,500 470,0 3RU1116-0JB1 537 239 84 0.7 - 1.0 1,00
PWR R 600 537 734 84 0,600 68,0 3RU1116-1DB1 537 241 84 2.2 - 3.2 3,00
PWR R 600 537 733 84 0,600 100,0 3RU1116-1DB1 537 241 84 2.2 - 3.2 2,40
FZG 500*65-56 537 735 84 0,800 56,0 3RU1116-1FB1 537 243 84 3.5 - 5 3,80
FZECQU 600x65-50 538 764 84 1,000 50,0 3RU1116-1FB1 537 243 84 3.5 - 5 4,50
FZG 600*65-51 534 625 84 1,000 51,0 3RU1116-1FB1 537 243 84 3.5 - 5 4,40
FZG 600*65-100 535 973 84 1,000 100,0 3RU1116-1EB1 537 242 84 2.8 - 4.0 3,20
FZG 600*65-220 537 853 84 1,000 220,0 3RU1116-1DB1 537 241 84 2.2 - 3.2 2,10
FZG 600*65-470 537 773 84 1,000 470,0 3RU1116-1BB1 537 240 84 1.4 - 2.0 1,50
FZZG 400*65-33 537 736 84 1,200 33,0 3RU1116-1HB1 537 245 84 5.5 - 8.0 6,00
FZZG 500*65-15 537 811 84 1,600 15,0 3RU1116-1KB1 537 247 84 9.0 - 12.0 10,30
FZZG 500*65-27 537 737 84 1,600 27,0 3RU1116-1JB1 537 246 84 7.0 - 10.0 7,70
FZZCQU 500x65-50 538 765 84 1,600 50,0 3RU1116-1GB1 537 244 84 4.5 - 6.3 5,70
FZZG 500*65-120 537 854 84 1,600 120,0 3RU1116-1FB1 537 243 84 3.5 - 5 3,70
FZZG 500*65-220 537 774 84 1,600 220,0 3RU1116-1DB1 537 241 84 2.2 - 3.2 2,70
FZZG 600*65-15 537 812 84 2,000 15,0 3RU1116-1KB1 537 247 84 9.0 - 12.0 11,50
FZZG 600*65-27 537 738 84 2,000 27,0 3RU1116-1JB1 537 246 84 7.0 - 10.0 8,60
FZZCQU 600x65-50 538 766 84 2,000 50,0 3RU1116-1HB1 537 245 84 5.5 - 8.0 6,30
FZZG 600*65-100 537 855 84 2,000 100,0 3RU1116-1FB1 537 243 84 3.5 - 5 4,50
FZZG 600*65-220 537 775 84 2,000 220,0 3RU1116-1DB1 537 241 84 2.2 - 3.2 3,00
FZDCQU 500x65-25 538 767 84 2,400 25,0 3RU1116-1KB1 537 247 84 9.0 - 12.0 9,80
FZDG 500*65-51 534 626 84 2,400 51,0 3RU1116-1HB1 537 245 84 5.5 - 8.0 6,90
FZDG 500*65-100 537 856 84 2,400 100,0 3RU1116-1FB1 537 243 84 3.5 - 5 4,90
FGFG 310 0502-9 537 813 84 2,500 9,0 3RU1126-4BB1 537 249 84 14.0 - 20.0 16,70
FZDG 600*65-51 535 966 84 3,000 51,0 3RU1116-1JB1 537 246 84 7.0 - 10.0 7,70
FZDG 600*65-68 537 857 84 3,000 68,0 3RU1116-1HB1 537 245 84 5.5 - 8.0 6,60
FZDG 600*65-120 537 776 84 3,000 120,0 3RU1116-1FB1 537 243 84 3.5 - 5 5,00
FZVCQU 500x65-50 538 768 84 3,200 50,0 3RU1116-1JB1 537 246 84 7.0 - 10.0 8,00
FGFG 310 0702-8.4 537 814 84 3,500 8,4 3RU1126-4DB1 537 251 84 20.0 - 25.0 20,40
FGF 310 0702-15 534 632 84 3,500 15,4 3RU1126-4BB1 537 249 84 14.0 - 20.0 15,10
FGF 310 0702-33 534 629 84 3,500 33,0 3RU1116-1KB1 537 247 84 9.0 - 12.0 10,30
FZZG 800*85-100 535 975 84 3,700 100,0 3RU1116-1HB1 537 245 84 5.5 - 8.0 6,10
FGFKQU 310 0804-10 538 769 84 4,000 10,0 3RU1126-4CB1 537 250 84 17.0 - 22.0 20,00
FZDG 600*85-51 535 967 84 4,000 51,0 3RU1116-1JB1 537 246 84 7.0 - 10.0 8,90
Tab. 290
214 716 44/200710
20) Please also note that the thermal overload relays are only suitable for operation of the braking resistor on inverters with a max. line voltage of
500 V.
21) Braking resistors with the additional designation "Fx..Qx" (e.g. FAQ…) feature a thermal contact for monitoring and protection against overload
196 in the braking resistor.
Qty. Type 23) Order no. Scope Resistive Qty. Type Order no. Setting range Setting
value value
[kW] [Ohm] [A] [A]
FGFKQU 310 0904-50 538 770 84 4,500 50,0 3RU1116-1KB1 537 247 84 9.0 - 12.0 9,50
FGFG 311 1002-6,8 537 817 84 5,000 6,8 3RU1136-4EB1 537 252 84 22.0 - 32.0 27,10
FGFG 311 1002-8,2 537 816 84 5,000 8,2 3RU1136-4EB1 537 252 84 22.0 - 32.0 24,70
FGF 311 1002-10 534 638 84 5,000 10,0 3RU1136-4FB1 537 253 84 28.0 - 40.0 22,40
FGF 311 1002-15 534 633 84 5,000 15,0 3RU1126-4CB1 537 250 84 17.0 - 22.0 18,30
FGF 311 1002-33 534 630 84 5,000 33,0 3RU1126-4AB1 537 248 84 11.0 - 16.0 12,30
FGFG 311 1002-33 537 858 84 5,000 33,0 3RU1126-4AB1 537 248 84 11.0 - 16.0 12,30
FGFL 311 1202-4,7 537 818 84 6,000 4,7 3RU1136-4FB1 537 253 84 28.0 - 40.0 35,70
FGFG 311 1202-6 538 600 84 6,000 6,0 3RU1136-4FB1 537 253 84 28.0 - 40.0 31,60
FGFKQU 311 1204-10 538 773 84 6,000 10,0 3RU1136-4EB1 537 252 84 22.0 - 32.0 24,50
FGF 311 1202-14 534 634 84 6,000 14,4 3RU1126-4CB1 537 250 84 17.0 - 22.0 20,40
FGFKQU 311 1204-25 538 772 84 6,000 25,0 3RU1126-4BB1 537 249 84 14.0 - 20.0 15,50
FGFG 311 1202-47 537 833 84 6,000 47,0 3RU1116-1KB1 537 247 84 9.0 - 12.0 11,30
FGFKQU 311 1204-50 538 771 84 6,000 50,0 3RU1116-1KB1 537 247 84 9.0 - 12.0 11,00
FGFG 311 1202-68 537 778 84 6,000 68,0 3RU1116-1JB1 537 246 84 7.0 - 10.0 9,40
FGFL 311 1302-4,3 537 819 84 6,500 4,3 3RU1136-4GB1 537 254 84 36.0 - 45.0 38,90
FGFG 312 1402-33 537 859 84 7,000 33,0 3RU1126-4BB1 537 249 84 14.0 - 20.0 14,60
FGFG 311 1402-56 537 848 84 7,000 56,0 3RU1126-4AB1 537 248 84 11.0 - 16.0 11,20
FGF 312 1502-10 534 639 84 7,500 10,0 3RU1136-4EB1 537 252 84 22.0 - 32.0 27,40
FGF 312 1502-15 534 635 84 7,500 15,0 3RU1126-4DB1 537 251 84 20.0 - 25.0 22,40
FGF 312 1502-33 534 631 84 7,500 33,0 3RU1126-4BB1 537 249 84 14.0 - 20.0 15,10
FGFL 312 1602-4 537 820 84 8,000 4,0 3RU1136-4HB1 537 255 84 40.0 - 50.0 44,70
FGFG 312 1602-27 537 860 84 8,000 27,0 3RU1126-4BB1 537 249 84 14.0 - 20.0 17,20
FGFL 312 1802-2.7 537 822 84 9,000 2,7 3RU1146-4JB1 537 256 84 45.0 - 63.0 57,70
FGFG 312 1802-22 727 002 46 9,000 22,0 3RU1126-4CB1 537 250 84 17.0 - 22.0 20,20
FGFL 312 1902-4,2 537 821 84 9,500 4,2 3RU1136-4HB1 537 255 84 40.0 - 50.0 47,60
FGFKQU 312 2004-8 538 776 84 10,000 8,0 3RU1136-4FB1 537 253 84 28.0 - 40.0 35,40
FGFKQU 312 2004-10 538 775 84 10,000 10,0 3RU1136-4FB1 537 253 84 28.0 - 40.0 31,60
FGFG 312 2002-33 537 849 84 10,000 33,0 3RU1126-4BB1 537 249 84 14.0 - 20.0 17,40
FGFKQU 312 2004-50 538 774 84 10,000 50,0 3RU1126-4AB1 537 248 84 11.0 - 16.0 14,10
FGF 312 2202-15 534 636 84 10,500 15,0 3RU1136-4EB1 537 252 84 22.0 - 32.0 26,50
FGFL 312 2202-2.7 537 823 84 11,000 2,7 3RU1146-4KB1 537 257 84 57.0 - 75.0 63,80
FGFG 312 2202-22 727 003 46 11,000 22,0 3RU1126-4DB1 537 251 84 20.0 - 25.0 22,40
FGF 312 2402-3,8 537 261 84 12,000 3,8 3RU1146-4JB1 537 256 84 45.0 - 63.0 56,20
FGFKQU 312 2404-8 538 778 84 12,000 8,0 3RU1146-4JB1 537 256 84 45.0 - 63.0 38,70
FGFG 313 2402-13,4 537 835 84 12,000 13,4 3RU1136-4FB1 537 253 84 28.0 - 40.0 29,90
FGFKQU 312 2404-50 538 777 84 12,000 50,0 3RU1126-4BB1 537 249 84 14.0 - 20.0 15,50
FGFL 313 2502-3 537 824 84 12,500 3,0 3RU1146-4KB1 537 257 84 57.0 - 75.0 64,50
FGF 313 2502-10 534 641 84 12,500 10,0 3RU1136-4FB1 537 253 84 28.0 - 40.0 35,40
FGFG 313 2802-28 537 850 84 14,000 28,0 3RU1136-4EB1 537 252 84 22.0 - 32.0 22,40
FAQU 313 3004-4 538 606 84 15,000 4,0 3RU1146-4JB1 537 256 84 45.0 - 63.0 61,20
FGFL 313 3002-6 537 837 84 15,000 6,0 3RU1146-4JB1 537 256 84 45.0 - 63.0 50,00
Tab. 291
214 716 44/200710
500 V.
in the braking resistor. 197
Qty. Type 25) 26) Order no. Scope Resistive Qty. Type Order no. Setting range Setting
value value
[kW] [Ohm] [A] [A]
FGFL 313 3002-8 537 836 84 15,000 8,0 3RU1136-4GB1 537 254 84 36.0 - 45.0 43,30
FGF 313 3002-10 534 642 84 15,000 10,0 3RU1136-4GB1 537 254 84 36.0 - 45.0 38,70
FGFKQU 313 3004-10 538 781 84 15,000 10,0 3RU1136-4GB1 537 254 84 36.0 - 45.0 38,70
FGF 314 3202-15 534 637 84 15,000 15,0 3RU1136-4FB1 537 253 84 28.0 - 40.0 31,60
FGFG 313 3002-24.6 727 005 46 15,000 24,6 3RU1136-4EB1 537 252 84 22.0 - 32.0 24,70
FGFKQU 313 3004-25 538 780 84 15,000 25,0 3RU1136-4EB1 537 252 84 22.0 - 32.0 24,50
FGFKQU 313 3004-50 538 779 84 15,000 50,0 3RU1126-4BB1 537 249 84 14.0 - 20.0 17,30
FGFKQU 313 3204-8 538 782 84 16,000 8,0 3RU1136-4HB1 537 255 84 40.0 - 50.0 44,70
FGFG 313 3402-27 537 851 84 17,000 27,0 3RU1136-4EB1 537 252 84 22.0 - 32.0 25,10
FGF 314 3802-15 535 568 84 19,000 15,0 3RU1136-4FB1 537 253 84 28.0 - 40.0 35,60
FA 314 4002-1,6 537 828 84 20,000 1,6 LRD-33676 538 503 84 95.0 - 120.0 111,80
FGFL 314 4002-2 537 826 84 20,000 2,0 LRD-33676 538 503 84 95.0 - 120.0 100,00
FGFKQU 314 4004-4 538 784 84 20,000 4,0 3RU1146-4KB1 537 257 84 57.0 - 75.0 70,70
FGF 314 4202-7.5 534 648 84 20,000 7,5 3RU1146-4JB1 537 256 84 45.0 - 63.0 51,60
FGFKQU 314 4004-10 538 783 84 20,000 10,0 3RU1136-4HB1 537 255 84 40.0 - 50.0 44,70
FGFL 314 4402-14 537 838 84 22,000 14,0 3RU1136-4GB1 537 254 84 36.0 - 45.0 39,60
FGFKQU 314 4404-25 538 785 84 22,000 25,0 3RU1136-4FB1 537 253 84 28.0 - 40.0 29,70
FA 322 4802-8 537 839 84 24,000 8,0 3RU1146-4JB1 537 256 84 45.0 - 63.0 54,80
FA 323 4802-10 534 644 84 24,000 10,0 3RU1146-4JB1 537 256 84 45.0 - 63.0 49,00
FAQ 323 5004-1,7 537 829 84 25,000 1,7 27)
FAQU 323 5004-4 538 787 84 25,000 4,0 3RU1146-4LB1 537 258 84 70.0 - 90.0 79,10
FAQU 323 5004-10 538 786 84 25,000 10,0 3RU1146-4JB1 537 256 84 45.0 - 63.0 50,00
FA 323 5002-15 535 968 84 25,000 15,0 3RU1136-4GB1 537 254 84 36.0 - 45.0 40,80
FA 323 5202-14 537 840 84 26,000 14,0 3RU1136-4HB1 537 255 84 40.0 - 50.0 43,10
FA 323 5402-10 534 645 84 27,000 10,0 3RU1146-4JB1 537 256 84 45.0 - 63.0 52,00
2* FGFL 313 3002-6 537 837 84 30,000 3,0 LRD-33676 538 503 84 95.0 - 120.0 100,00
2* FGFL 313 3002-8 537 836 84 30,000 4,0 3RU1146-4LB1 537 258 84 70.0 - 90.0 86,60
FA 323 6002-6 537 841 84 30,000 6,0 3RU1146-4KB1 537 257 84 57.0 - 75.0 70,70
FAQ 323 6404-1,6 537 830 84 32,000 1,6 27)
FA 3236 402-2.7 538 601 84 32,000 2,7 LRD-33676 538 503 84 95.0 - 120.0 108,90
FAQU 323 6404-4 538 790 84 32,000 4,0 3RU1146-4LB1 537 258 84 70.0 - 90.0 89,40
FAQU 323 6404-8 538 789 84 32,000 8,0 3RU1146-4KB1 537 257 84 57.0 - 75.0 63,20
FAQU 323 6404-10 538 788 84 32,000 10,0 3RU1146-4JB1 537 256 84 45.0 - 63.0 56,60
FAQ 324 7004-1,4 537 831 84 35,000 1,4 27)
FAQ 324 7504-8 537 842 84 37,500 8,0 3RU1146-4KB1 537 257 84 57.0 - 75.0 68,50
FAQU 324 7504-16 538 799 84 37,500 16,0 3RU1146-4JB1 537 256 84 45.0 - 63.0 48,40
FAQU 324 8004-4 538 792 84 40,000 4,0 LRD-33676 538 503 84 95.0 - 120.0 100,00
FAQU 324 8004-8 538 791 84 40,000 8,0 3RU1146-4KB1 537 257 84 57.0 - 75.0 70,70
FAQU 324 8004-16 538 800 84 40,000 16,0 3RU1146-4JB1 537 256 84 45.0 - 63.0 50,00
FAQ 324 8404-4 537 843 84 42,000 4,0 LRD-33676 538 503 84 95.0 - 120.0 102,50
FAQU 324 8404-10 538 793 84 42,000 10,0 3RU1146-4KB1 537 257 84 57.0 - 75.0 64,80
Tab. 292
214 716 44/200710
500 V.
in the braking resistor.
26) For resistors of type 2*F…, two resistors with the specified part no. are required and have to be connected in parallel.
198 27) No thermal overload relay available for amperage. Resistors must be provided with thermal contacts that are to be evaluated.
Qty. Type 29) 30) Order no. Scope Resistive Qty. Type Order no. Setting range Setting
value value
[kW] [Ohm] [A] [A]
FAQ 324 8804-1.5 537 832 84 44,000 1,5 31)
FAQ 324 8804-8 537 844 84 44,000 8,0 3RU1146-4LB1 537 258 84 70.0 - 90.0 74,20
FAQU 333 9004-4 538 794 84 45,000 4,0 LRD-33676 538 503 84 95.0 - 120.0 106,10
FAQ 333 0004-4 537 845 84 50,000 4,0 LRD-33676 538 503 84 95.0 - 120.0 111,80
FAQ 334 0804-3.6 538 602 84 54,000 3,6 31)
FAQ 334 0804-6 537 847 84 54,000 6,0 LRD-33676 538 503 84 95.0 - 120.0 94,90
FAQ 334 0804-8 537 846 84 54,000 8,0 3RU1146-4LB1 537 258 84 70.0 - 90.0 82,20
2* FA 323 6002-6 537 841 84 60,000 3,0 2* 3RU1146-4KB1 537 257 84 57.0 - 75.0 70,70
FAQU 334 2004-4 538 797 84 60,000 4,0 31)
FAQU 334 2004-8 538 796 84 60,000 8,0 3RU1146-4LB1 537 258 84 70.0 - 90.0 86,60
FAQU 334 2004-10 538 795 84 60,000 10,0 3RU1146-4LB1 537 258 84 70.0 - 90.0 77,50
FAQU 334 2004-16,2 538 610 84 60,000 16,2 3RU1146-4KB1 537 257 84 57.0 - 75.0 60,90
FAQ 334 3204-3.4 538 604 84 66,000 3,4
31)
FAQU 334 3204-4 538 798 84 66,000 4,0
FAQU 334 3204-8.2 538 608 84 66,000 8,2 3RU1146-4LB1 537 258 84 70.0 - 90.0 89,70
FAQU 334 3204-16 538 611 84 66,000 16,0 3RU1146-4KB1 537 257 84 57.0 - 75.0 64,20
2* FAQ 324 7504-8 537 842 84 75,000 4,0 2* 3RU1146-4KB1 537 257 84 57.0 - 75.0 68,50
2* FAQU 324 7504-16 538 799 84 75,000 8,0 LRD-33676 538 503 84 95.0 - 120.0 96,80
FAQ 344 6004-2,7 538 603 84 80,000 2,7 31)
FAQ 344 6804-3.4 538 605 84 80,000 3,4

31)
FAQU 344 6004-4 538 609 84 80,000 4,0
FAQ 344 6004-6 538 607 84 80,000 6,0 LRD-33676 538 503 84 95.0 - 120.0 115,50
2* FAQU 324 8004-16 538 800 84 80,000 8,0 LRD-33676 538 503 84 95.0 - 120.0 100,00
FAQU 344 6004-8 538 612 84 80,000 8,0 LRD-33676 538 503 84 95.0 - 120.0 100,00
2* FAQ 324 8804-8 537 844 84 88,000 4,0 2* 3RU1146-4LB1 537 258 84 70.0 - 90.0 74,20
2* FAQ 333 0004-4 537 845 84 100,000 2,0 2* LRD-33676 538 503 84 95.0 - 120.0 111,80
2* FAQ 334 0804-3.6 538 602 84 108,000 1,8 31)
2* FAQ 334 0804-6 537 847 84 108,000 3,0 2* LRD-33676 538 503 84 95.0 - 120.0 94,90
2* FAQ 334 0804-8 537 846 84 108,000 4,0 2* 3RU1146-4LB1 537 258 84 70.0 - 90.0 82,20
2* FAQU 334 2004-4 538 797 84 120,000 2,0 31)
2* FAQU 334 2004-8 538 796 84 120,000 4,0 2* 3RU1146-4LB1 537 258 84 70.0 - 90.0 86,60
2* FAQU 334 2004-16,2 538 610 84 120,000 8,1 2* 3RU1146-4KB1 537 257 84 57.0 - 75.0 60,90
2* FAQ 334 3204-3.4 538 604 84 132,000 1,7
31)
2* FAQU 334 3204-4 538 798 84 132,000 2,0
2* FAQU 334 3204-8.2 538 608 84 132,000 4,1 2* 3RU1146-4LB1 537 258 84 70.0 - 90.0 89,70
2* FAQU 334 3204-16 538 611 84 132,000 8,0 2* 3RU1146-4KB1 537 257 84 57.0 - 75.0 64,20
2* FAQ 344 6804-3.4 538 605 84 160,000 1,7
31)
2* FAQU 344 6004-4 538 609 84 160,000 2,0
2* FAQU 344 6004-8 538 612 84 160,000 4,0 2* LRD-33676 538 503 84 95.0 - 120.0 100,00
Tab. 293
214 716 44/200710
500 V.
in the braking resistor.
30) For resistors of type 2*F…, two resistors with the specified part no. are required and have to be connected in parallel.
31) No thermal overload relay available for amperage. Resistors must be provided with thermal contacts that are to be evaluated. 199
22.7.5 Braking resistor dimensions
22.7.5.1 Cement-coated single, double and triple-tube fixed resistors
Fig. 98
1 PG 13.5 cable dia.8 – 14 mm

2 Rating plate
Finish:
Cement-coated fixed resistors wired to two connections (porcelain terminal), with cover and terminal box of galvan‐
ized steel and perforated sheet.
Type of enclosure: IP 20 (requires uninterrupted mounting plate).
Permissible mounting position:

● on vertical surfaces, terminal (box) below
● on horizontal surfaces
214 716 44/200710
200
Braking resistor Electrical values Dimensions
Type Order no. Weight Output32) Resistive Min. cross- Terminal 33) b1 b2 h l l1 l2
value section
[kg] [kW] [Ohm] [mm²] [mm²] [mm] [mm] [mm] [mm] [mm] [mm]
FZG 300*45-100 535 970 84 1,2 0,285 100,0 1,5 FK 2,5-10² 48 75 87 300 389 360
FZG 300*65-51 515 696 84 1,8 0,430 51,0 1,5 FK 2,5-10² 92 64 120 300 386 326
FZG 400*65-470 537 852 84 2,3 0,500 470,0 1,5 FK 2,5-10² 92 64 120 400 486 426
FZG 500*65-56 537 735 84 2,8 0,800 56,0 1,5 FK 2,5-10² 92 64 120 500 586 526
FZECQU
538 764 84 4,0 50,0 1,5 G10 92 80 120 600 749 630
600x65-50
FZG 600*65-51 534 625 84 3,4 51,0 1,5 FK 2,5-10² 92 64 120 600 686 626
1,000
FZG 600*65-100 535 973 84 3,4 100,0 1,5 FK 2,5-10² 92 64 120 600 686 626
FZG 600*65-220 537 853 84 3,4 220,0 1,5 FK 2,5-10² 92 64 120 600 686 626
FZG 600*65-470 537 773 84 3,4 470,0 1,5 FK 2,5-10² 92 64 120 600 686 626
FZZG 400*65-33 537 736 84 4,3 1,200 33,0 1,5 FK 2,5-10² 185 150 120 400 486 426
FZZG 500*65-15 537 811 84 5,2 15,0 1,5 FK 2,5-10² 185 150 120 500 586 526
FZZG 500*65-27 537 737 84 5,2 27,0 1,5 FK 2,5-10² 185 150 120 500 586 526
FZZCQU
538 765 84 5,8 1,600 50,0 1,5 G10 185 150 120 500 649 530
500x65-50
FZZG 500*65-120 537 854 84 5,2 120,0 1,5 FK 2,5-10² 185 150 120 500 586 526
FZZG 500*65-220 537 774 84 5,2 220,0 1,5 FK 2,5-10² 185 150 120 500 586 526
FZZG 600*65-15 537 812 84 6,2 15,0 1,5 FK 2,5-10² 185 150 120 600 686 626
FZZG 600*65-27 537 738 84 6,2 27,0 1,5 FK 2,5-10² 185 150 120 600 686 626
FZZCQU
538 766 84 6,7 2,000 50,0 1,5 G10 185 150 120 600 749 630
600x65-50
FZZG 600*65-100 537 855 84 6,2 100,0 1,5 FK 2,5-10² 185 150 120 600 686 626
FZZG 600*65-220 537 775 84 6,2 220,0 1,5 FK 2,5-10² 185 150 120 600 686 626
FZDCQU
538 767 84 8,0 25,0 1,5 G10 275 240 120 500 649 530
500x65-25
2,400
FZDG 500*65-51 534 626 84 7,5 51,0 1,5 FK 2,5-10² 275 240 120 500 586 526
FZDG 500*65-100 537 856 84 7,5 100,0 1,5 FK 2,5-10² 275 240 120 500 586 526
FZDG 600*65-51 535 966 84 8,8 51,0 1,5 FK 2,5-10² 275 240 120 600 686 626
FZDG 600*65-68 537 857 84 8,8 3,000 68,0 1,5 FK 2,5-10² 275 240 120 600 686 626
FZDG 600*65-120 537 776 84 8,8 120,0 1,5 FK 2,5-10² 275 240 120 600 686 626
FZVCQU
538 768 84 10,3 3,200 50,0 1,5 G10 185 150 210 500 649 530
500x65-50
FZZG 800*85-100 535 975 84 13,0 3,700 100,0 1,5 FK 2,5-10² 230 190 145 800 890 830
FZDG 600*85-51 535 967 84 15,0 4,000 51,0 1,5 FK 2,5-10² 340 300 145 600 690 630
Tab. 294
214 716 44/200710
32) Technicaldata for max. 40°C ambient temperature.

33) FK
= flat terminal, BK = stud terminal, G10 = inverter terminal G10 (10 mm²). FK 2,5-10 = flat terminal for max. 4 mm² flexible, 6 mm² solid and
10 mm² via cable lug 201
22.7.5.2 Steel-grid resistors of standard design
Fig. 99
1 Terminals
Finish:
Steel-grid resistors wired to two connections (stud terminals fitted in the front of the unit), with cover of galvanized
steel and perforated sheet
Type of enclosure: IP 20
Permissible mounting position: free standing

Type Order no. Weight Output34) Resistive Min. cross- Terminal 35) h l l2
value section
[kg] [kW] [Ohm] [mm²] [mm²] [mm] [mm] [mm]
FAQU 313 3004-4 538 606 84 43,0 15,000 4,0 10 BK M12-25 460 795 770
FA 314 4002-1,6 537 828 84 61,0 20,000 1,6 25 BK M10-16 460 995 970
FA 322 4802-8 537 839 84 56,0 8,0 10 BK M6-10 710 595 570
24,000
FA 323 4802-10 534 644 84 86,0 10,0 6 BK M6-10 710 795 770
FAQ 323 5004-1,7 537 829 84 80,0 1,7 25 BK M10-16 710 795 770
FAQU 323 5004-4 538 787 84 80,0 4,0 16 BK M8-16 710 795 770
25,000
FAQU 323 5004-10 538 786 84 80,0 10,0 10 BK M8-16 710 795 770
FA 323 5002-15 535 968 84 86,0 15,0 6 BK M6-6 710 795 770
FA 323 5202-14 537 840 84 80,0 26,000 14,0 6 BK M6-10 710 795 770
FA 323 5402-10 534 645 84 86,0 27,000 10,0 10 BK M6-10 710 795 770
FA 323 6002-6 537 841 84 80,0 30,000 6,0 16 BK M8-16 710 795 770
FAQ 323 6404-1,6 537 830 84 80,0 1,6 35 BK M10-16 710 795 770
FA 323 6402-2.7 538 601 84 78,0 2,7 25 BK M10-16 710 795 770
FAQU 323 6404-4 538 790 84 80,0 32,000 4,0 16 BK M8-16 710 795 770
FAQU 323 6404-8 538 789 84 80,0 8,0 10 BK M8-16 710 795 770
FAQU 323 6404-10 538 788 84 80,0 10,0 10 BK M8-16 710 795 770
214 716 44/200710
FAQ 324 7004-1,4 537 831 84 93,0 35,000 1,4 50 BK M10-16 710 995 970

35) FK
202 10 mm² via cable lug
Type Order no. Weight Output34) Resistive Min. cross- Terminal 35) h l l2
value section
FAQ 324 7504-8 537 842 84 93,0 8,0 10 BK M8-16 710 995 970
37,500
FAQU 324 7504-16 538 799 84 93,0 16,0 6 BK M8-16 710 995 970
FAQU 324 8004-4 538 792 84 93,0 4,0 25 BK M8-16 710 995 970
FAQU 324 8004-8 538 791 84 93,0 40,000 8,0 16 BK M8-16 710 995 970
FAQU 324 8004-16 538 800 84 93,0 16,0 10 BK M10-25 710 995 970
FAQ 324 8404-4 537 843 84 93,0 4,0 25 BK M8-25 710 995 970
42,000
FAQU 324 8404-10 538 793 84 93,0 10,0 10 BK M8-16 710 995 970
FAQ 324 8804-1.5 537 832 84 93,0 1,5 50 BK M10-25 710 995 970
44,000
FAQ 324 8804-8 537 844 84 93,0 8,0 16 BK M8-16 710 995 970
FAQU 333 9004-4 538 794 84 102,0 45,000 4,0 25 BK M8-16 960 795 770
FAQ 333 0004-4 537 845 84 102,0 50,000 4,0 25 BK M8-25 960 795 770
FAQ 334 0804-3.6 538 602 84 114,0 3,6 35 BK M10-16 960 995 970
FAQ 334 0804-6 537 847 84 126,0 54,000 6,0 25 BK M8-25 960 995 970
FAQ 334 0804-8 537 846 84 126,0 8,0 16 BK M8-25 960 995 970
FAQU 334 2004-4 538 797 84 126,0 4,0 25 BK M10-16 960 995 970
FAQU 334 2004-8 538 796 84 126,0 8,0 16 BK M8-16 960 995 970
60,000
FAQU 334 2004-10 538 795 84 126,0 10,0 16 BK M8-16 960 995 970
FAQU 334 2004-16,2 538 610 84 120,0 16,2 10 BK M12-25 960 995 970
FAQ 334 3204-3.4 538 604 84 126,0 3,4 35 BK M10-25 960 995 970
FAQU 334 3204-4 538 798 84 126,0 4,0 35 BK M10-25 960 995 970
66,000
FAQU 334 3204-8.2 538 608 84 126,0 8,2 16 BK M12-25 960 995 970
FAQU 334 3204-16 538 611 84 126,0 16,0 10 BK M12-25 960 995 970
FAQ 344 6004-2,7 538 603 84 148,0 2,7 50 BK M10-25 1210 995 970
FAQ 344 6804-3.4 538 605 84 152,0 3,4 50 BK M10-25 1210 995 970
FAQU 344 6004-4 538 609 84 148,0 80,000 4,0 35 BK M12-25 1210 995 970
FAQ 344 6004-6 538 607 84 148,0 6,0 25 BK M10-16 1210 995 970
FAQU 344 6004-8 538 612 84 148,0 8,0 25 BK M12-25 1210 995 970
Tab. 295
214 716 44/200710
203
22.7.5.3 Steel-grid resistors of compact design
Fig. 100
1 PG 13.5 cable dia.8 – 14 mm

2 for FGF / FGFG / FGFL 312 to 314
Finish:
Steel-grid resistors wired to two connections, with cover and terminal box (up to 36 A) of galvanized steel and
perforated sheet.
● up to 35 A to a 2-pole flat terminal (fitted in terminal box) = FK terminal
● from > 35 A to 115 A to stud terminals (fitted in the front of the unit) = BK terminal
Type of enclosure: IP 20 (requires uninterrupted mounting plate).
Permissible mounting position:

● on vertical surfaces, terminal (box) below, perforated sheet above and below
● on horizontal surfaces

Type Order no. Weight Output36) Resistive val‐ Min. cross- Terminal 37) l l1 l2
ue section
FGFG 310 0502-9 537 813 84 7,5 2,500 9,0 1,5 FK 2,5-10² 330 295 270
FGFG 310 0702-8.4 537 814 84 8,5 8,4 1,5 FK 2,5-10² 330 295 270
FGF 310 0702-15 534 632 84 9,0 3,500 15,4 1,5 FK 2,5-10² 330 295 270
FGF 310 0702-33 534 629 84 9,0 33,0 1,5 FK 2,5-10² 330 295 270
214 716 44/200710
FGFKQU 310 0804-10 538 769 84 9,0 4,000 10,0 1,5 G10 355 295 270

37) FK
204 10 mm² via cable lug
ue section
FGFKQU 310 0904-50 538 770 84 9,5 4,500 50,0 1,5 G10 355 295 270
FGFG 311 1002-6,8 537 817 84 13,0 6,8 2,5 FK 2,5-10² 430 395 370
FGFG 311 1002-8,2 537 816 84 13,0 8,2 2,5 FK 2,5-10² 430 395 370
FGF 311 1002-10 534 638 84 11,0 10,0 2,5 FK 2,5-10² 430 395 370
5,000
FGF 311 1002-15 534 633 84 11,0 15,0 1,5 FK 2,5-10² 430 395 370
FGF 311 1002-33 534 630 84 11,0 33,0 1,5 FK 2,5-10² 430 395 370
FGFG 311 1002-33 537 858 84 11,0 33,0 1,5 FK 2,5-10² 430 395 370
FGFL 311 1202-4,7 537 818 84 12,0 4,7 4 BK M6-6 - 395 370
FGFG 311 1202-6 538 600 84 12,0 6,0 4 FK 2,5-10² 430 395 370
FGFKQU 311 1204-10 538 773 84 12,0 10,0 2,5 G10 455 395 370
FGF 311 1202-14 534 634 84 12,0 14,4 1,5 FK 2,5-10² 430 395 370
6,000
FGFKQU 311 1204-25 538 772 84 12,0 25,0 1,5 G10 455 395 370
FGFG 311 1202-47 537 833 84 13,0 47,0 1,5 FK 2,5-10² 430 395 370
FGFKQU 311 1204-50 538 771 84 12,0 50,0 1,5 G10 455 395 370
FGFG 311 1202-68 537 778 84 12,0 68,0 1,5 FK 2,5-10² 430 395 370
FGFL 311 1302-4,3 537 819 84 12,0 6,500 4,3 4 BK M6-6 - 395 370
FGFG 312 1402-33 537 859 84 13,0 33,0 1,5 FK 2,5-10² 630 595 570
7,000
FGFG 311 1402-56 537 848 84 13,0 56,0 1,5 FK 2,5-10² 430 395 370
FGF 312 1502-10 534 639 84 17,0 10,0 2,5 FK 2,5-10² 630 595 590
FGF 312 1502-15 534 635 84 17,0 7,500 15,0 2,5 FK 2,5-10² 630 595 590
FGF 312 1502-33 534 631 84 17,0 33,0 1,5 FK 2,5-10² 630 595 590
FGFL 312 1602-4 537 820 84 18,0 4,0 6 BK M6-6 - 595 570
8,000
FGFG 312 1602-27 537 860 84 16,0 27,0 1,5 FK 2,5-10² 630 595 570
FGFL 312 1802-2.7 537 822 84 22,0 2,7 10 BK M8-16 - 595 570
9,000
FGFG 312 1802-22 727 002 46 22,0 22,0 1,5 FK 2,5-10² 630 595 590
FGFL 312 1902-4,2 537 821 84 22,0 9,500 4,2 6 BK M6-10 - 595 570
FGFKQU 312 2004-8 538 776 84 20,0 8,0 4 G10 655 595 570
FGFKQU 312 2004-10 538 775 84 20,0 10,0 4 G10 655 595 570
10,000
FGFG 312 2002-33 537 849 84 18,0 33,0 1,5 FK 2,5-10² 630 595 570
FGFKQU 312 2004-50 538 774 84 20,0 50,0 1,5 G10 655 595 570
FGF 312 2202-15 534 636 84 22,0 10,500 15,0 2,5 FK 2,5-10² 630 595 590
FGFL 312 2202-2.7 537 823 84 22,0 2,7 10 BK M8-16 - 595 570
11,000
FGFG 312 2202-22 727 003 46 22,0 22,0 2,5 FK 2,5-10² 630 595 590
FGF 312 2402-3,8 537 261 84 22,0 3,8 10 FK 2,5-10² 630 595 570
FGFKQU 312 2404-8 538 778 84 22,0 8,0 4 G10 655 595 570
12,000
FGFG 313 2402-13,4 537 835 84 33,0 13,4 4 FK 2,5-10² 830 795 770
FGFKQU 312 2404-50 538 777 84 22,0 50,0 1,5 G10 655 595 570
FGFL 313 2502-3 537 824 84 33,0 3,0 10 BK M8-16 - 795 770
12,500
FGF 313 2502-10 534 641 84 33,0 10,0 4 FK 2,5-10² 830 795 770
FGFG 313 2802-28 537 850 84 33,0 14,000 28,0 2,5 FK 2,5-10² 830 795 770
FGFL 313 3002-6 537 837 84 33,0 6,0 10 BK M6-10 795 795 770
FGFL 313 3002-8 537 836 84 33,0 8,0 6 BK M6-10 795 795 770
FGF 313 3002-10 534 642 84 33,0 10,0 4 BK M6-6 830 795 770
FGFKQU 313 3004-10 538 781 84 31,0 10,0 4 G10 855 795 770
15,000
FGF 314 3202-15 534 637 84 33,0 15,0 4 FK 2,5-10² 1030 995 970
FGFG 313 3002-24.6 727 005 46 31,0 24,6 2,5 FK 2,5-10² 830 795 770
FGFKQU 313 3004-25 538 780 84 31,0 25,0 2,5 G10 855 795 770
FGFKQU 313 3004-50 538 779 84 31,0 50,0 1,5 G10 855 795 770
FGFKQU 313 3204-8 538 782 84 32,0 16,000 8,0 6 G10 855 795 770
FGFG 313 3402-27 537 851 84 33,0 17,000 27,0 2,5 FK 2,5-10² 830 795 770
FGF 314 3802-15 535 568 84 42,0 19,000 15,0 4 FK 2,5-10² 1030 995 970
214 716 44/200710
FGFL 314 4002-2 537 826 84 44,0 2,0 25 BK M8-25 - 995 970
FGFKQU 314 4004-4 538 784 84 42,0 4,0 16 G10 1055 995 970
20,000
FGF 314 4202-7.5 534 648 84 44,0 7,5 10 BK M6-16 1055 995 970
FGFKQU 314 4004-10 538 783 84 42,0 10,0 6 G10 1055 995 970
205
ue section
FGFL 314 4402-14 537 838 84 44,0 14,0 6 BK M6-10 - 995 970
22,000
FGFKQU 314 4404-25 538 785 84 42,0 25,0 4 G10 1055 995 970
Tab. 296
22.7.5.4 Compact resistors type PWR
Fig. 101

Type Order no. Weight Output38) Resistive value Min. cross-section A B
[kg] [kW] [Ohm] [mm²] [mm] [mm]
PWR R 200 537 730 84 0,208 220,0 1,5 94 105
PWR R 200 537 729 84 0,208 0,200 330,0 1,5 94 105
PWR R 200 537 728 84 0,208 470,0 1,5 94 105
PWR R 400 537 732 84 0,400 120,0 1,5 189 200
0,400
PWR R 400 537 731 84 0,400 150,0 1,5 189 200
PWR R 600 537 734 84 0,635 68,0 1,5 309 320
0,600
PWR R 600 537 733 84 0,635 100,0 1,5 309 320
Tab. 297
214 716 44/200710
206 38) Technical data for max. 40°C ambient temperature.

22.8 Line reactors and line filters
22.8.1 Assignment
22.8.1.1 General
Depending on the external components used, the following limit values for cable-bound interference transmission
are maintained.
Please note for the assignment:

● Further information ⇒ "Line reactor electrical data", Page 214
● Typically modulation frequencies of 2 and 4 Hz are used.
● ND = line reactor; NF = line filter
● It may be necessary to use the line reactor to protect the link 39) as well as to maintain the EMC limit value 40)
22.8.1.2 "Footprint" and "Book" format line filters
Fig. 102
1 "Footprint" format A Frequency inverter

2 "Book" format B Line filter
3 Mounting bracket
Two different types of line filter ("Footprint" (1) format and "Book" (2) format) are available for frequency inverters
up to 40 A .
● The combination of Dedrive Compact fitted on footprint line filters does not satisfy vibration resistance require‐
ments to IEC 68-2-6 (max. 5g).
● For increased vibration resistance demands, Dedrive Compact units must be fitted next to the line filter on the
mounting panel.
● Line filters cannot be used in IT systems.
The total mounting depth is increased (inverter depth + line filter depth) when the line filters are fitted as a base.
214 716 44/200710
39) The line reactor is used to maintain the EMC limit value
40) The line reactor is used to protect the link 207
22.8.1.3 Limit value class B
Limit value class B is achieved by means of the following components.
"Book" format line filters
Dedrive Modulation fre‐ CDF Components for motor cable length

Compact quency to 10 m 10 to 25 m 25 to 50 m 50 to 100 m
DIC-4-xxx [kHz] [%] Order no. Order no. Order no. Order no.
002 2…16 ≤100 ND 537 739 84 41) NF 537 888 84 NF 537 888 84
≤60 ND 537 739 84 41) NF 537 888 84 NF 537 888 84
003 2…12 ND 537 739 84 42) ND 537 739 84 42)
>60 ND 537 739 84 41) 42)
004 NF 537 888 84 NF 537 888 84
16 ≤100 ND 537 739 84 41) NF 537 888 84 NF 537 888 84
006 2…16 ≤100 ND 537 740 84 41) NF 537 888 84 NF 537 888 84
≤60 ND 537 741 84 41) NF 537 889 84 NF 537 889 84
007 2…12 ND 537 741 84 42) ND 537 741 84 42)
>60 ND 537 741 84 41) 42)
009 NF 537 889 84 NF 537 889 84
16 ≤100 ND 537 741 84 41) NF 537 889 84 NF 537 889 84
014 2…16 ≤100 ND 537 742 84 41) NF 537 889 84 NF 537 889 84
≤60 ND 537 743 84 41) NF 537 890 84 NF 537 890 84
2…12 ND 537 743 84 42) ND 537 743 84 42) No information availa‐
017 >60 ND 537 743 84 41) 42)
NF 537 890 84 NF 537 890 84 ble
16 ≤100 ND 537 743 84 41) 42) NF 537 890 84 NF 537 890 84
025 2…16 ≤100 NF 537 890 84 NF 537 890 84 NF 537 890 84
≤60 NF 537 891 84 NF 537 891 84 NF 537 891 84
2…12 ND 537 745 84 42) ND 537 745 84 42) ND 537 745 84 42)
032 >60
NF 537 891 84 NF 537 891 84 NF 537 891 84
16 ≤100 NF 537 891 84 NF 537 891 84 NF 537 891 84
ND 537 753 84 42) ND 537 753 84 42) ND 537 753 84 42)
040 2…16 ≤100
NF 537 891 84 NF 537 891 84 NF 537 891 84
045 2…8 ≤100 NF 537 891 84
≤60 NF 537 892 84
No information availa‐ No information availa‐
060 2…8 ND 537 193 84 42)
>60 ble ble
NF 537 892 84
075 2…8 ≤100 NF 537 893 84
≤60 NF 537 894 84 NF 537 894 84 NF 537 894 84 NF 537 894 84
090 2…8 ND 537 195 84 42) ND 537 195 84 42) ND 537 195 84 42) ND 537 195 84 42)
>60
NF 537 894 84 NF 537 894 84 NF 537 894 84 NF 537 894 84
≤60 NF 537 894 84 NF 537 894 84 NF 537 894 84 NF 537 894 84
110 2…8 ND 537 196 84 42) ND 537 196 84 42) ND 537 196 84 42) ND 537 196 84 42)
>60
NF 537 894 84 NF 537 894 84 NF 537 894 84 NF 537 894 84
Tab. 298
214 716 44/200710
208 42) The line reactor is used to protect the link
"Footprint" format line filters

002 2…16 ≤100 ND 537 739 84 43) NF 537 748 84 NF 537 748 84
≤60 ND 537 739 84 43) NF 537 748 84 NF 537 748 84
003 2…12 ND 537 739 84 44) ND 537 739 84 44)
>60 ND 537 739 84
004 NF 537 748 84 NF 537 748 84
16 ≤100 ND 537 739 84 43) NF 537 748 84 NF 537 748 84
006 2…16 ≤100 ND 537 740 84 43) NF 537 748 84 NF 537 748 84
≤60 ND 537 741 84 43) NF 537 748 84 NF 537 748 84
007 2…12 ND 537 741 84 44) ND 537 741 84 44)
>60 ND 537 741 84
009 NF 537 748 84 NF 537 748 84
16 ≤100 ND 537 741 84 NF 537 748 84 NF 537 748 84
014 2…16 ≤100 ND 537 742 84 43) NF 537 749 84 NF 537 749 84 No information
available
≤60 ND 537 743 84 43) NF 537 749 84 NF 537 749 84
2…12 ND 537 743 84 44) ND 537 743 84 44)
017 >60 ND 537 743 84
NF 537 749 84 NF 537 749 84
16 ≤100 ND 537 743 84 43) NF 537 749 84 NF 537 749 84
025 2…16 ≤100 NF 537 747 84 NF 537 750 84 NF 537 750 84
≤60 NF 537 747 84 NF 537 750 84 NF 537 750 84
2…12 ND 537 745 84 44) ND 537 745 84 44) ND 537 745 84 44)
032 >60
NF 537 747 84 NF 537 750 84 NF 537 750 84
16 ≤100 NF 537 747 84 NF 537 750 84 NF 537 750 84
ND 537 753 84 44) ND 537 753 84 44) ND 537 753 84 44)
040 2…16 ≤100
NF 537 747 84 NF 537 750 84 NF 537 750 84
Tab. 299
214 716 44/200710
22.8.1.4 Limit value class A group 1
Limit value class A group 1 is achieved by means of the following components.

002 2…16 ≤100 --- NF 537 888 84 NF 537 888 84
≤60 --- NF 537 888 84 NF 537 888 84
003 2…12 ND 537 739 84 45) ND 537 739 84 45)
>60 ND 537 739 84 45) 46)
004 NF 537 888 84 NF 537 888 84
16 ≤100 --- ND 537 739 84 46) ND 537 739 84 46)
006 2…16 ≤100 --- NF 537 888 84 NF 537 888 84
≤60 --- NF 537 889 84 NF 537 889 84
007 2…12 ND 537 741 84 45) ND 537 741 84 45)
>60 ND 537 741 84 45)
009 NF 537 889 84 NF 537 889 84
16 ≤100 --- NF 537 889 84 NF 537 889 84
2…8 ≤100 --- --- NF 537 889 84
014
12…16 ≤100 NF 537 889 84 NF 537 889 84 NF 537 889 84 No information avail‐
≤60 --- --- NF 537 890 84 able
2…12 ND 537 743 84 45)
017 >60 ND 537 743 84 45) ND 537 743 84 45)
NF 537 890 84
16 ≤100 NF 537 890 84 NF 537 890 84 NF 537 890 84
025 2…16 ≤100 NF 537 890 84 NF 537 890 84 NF 537 890 84
≤60 NF 537 891 84 NF 537 891 84 NF 537 891 84
2…12 ND 537 745 84 45) ND 537 745 84 45) ND 537 745 84 45)
032 >60
NF 537 891 84 NF 537 891 84 NF 537 891 84
16 ≤100 NF 537 891 84 NF 537 891 84 NF 537 891 84
≤60 NF 537 891 84 NF 537 891 84 NF 537 891 84
040 2…16 ND 537 753 84 45) ND 537 753 84 45) ND 537 753 84 45)
>60
NF 537 891 84 NF 537 891 84 NF 537 891 84
045 2…8 ≤100 NF 537 891 84 NF 537 891 84 NF 537 891 84 NF 537 891 84
≤60 NF 537 892 84 NF 537 892 84 NF 537 892 84 NF 537 892 84
060 2…8 ND 537 193 84 45) ND 537 193 84 45) ND 537 193 84 45) ND 537 193 84 45)
>60
NF 537 892 84 NF 537 892 84 NF 537 892 84 NF 537 892 84
075 2…8 ≤100 NF 537 893 84 NF 537 893 84 NF 537 893 84 NF 537 893 84
≤60 NF 537 894 84 NF 537 894 84 NF 537 894 84 NF 537 894 84
090 2…8 ND 537 195 84 45) ND 537 195 84 45) ND 537 195 84 45) ND 537 195 84 45)
>60
NF 537 894 84 NF 537 894 84 NF 537 894 84 NF 537 894 84
≤60 NF 537 894 84 NF 537 894 84 NF 537 894 84 NF 537 894 84
110 2…8 ND 537 196 84 45) ND 537 196 84 45) ND 537 196 84 45) ND 537 196 84 45)
>60
NF 537 894 84 NF 537 894 84 NF 537 894 84 NF 537 894 84
Tab. 300
214 716 44/200710
45) The line reactor is used to protect the link

210 46) The line reactor is used to maintain the EMC limit value

2…8 ≤100 --- --- NF 537 748 84
002
12…16 ≤100 --- NF 537 748 84 NF 537 748 84
≤60 --- --- NF 537 748 84
2…8 ND 537 739 84 47)
>60 ND 537 739 84 47) ND 537 739 84 47)
NF 537 748 84
003
≤60 --- NF 537 748 84 NF 537 748 84
004
12 ND 537 739 84 47) ND 537 739 84 47)
>60 ND 537 739 84 47)
NF 537 748 84 NF 537 748 84
16 ≤100 --- ND 537 739 84 NF 537 748 84
2 ≤100 --- --- NF 537 748 84
006
4…16 ≤100 --- NF 537 748 84 NF 537 748 84
≤60 --- --- NF 537 748 84
2 ND 537 741 84 47)
>60 ND 537 741 84 47) ND 537 741 84 47)
NF 537 748 84
007
≤60 --- --- NF 537 748 84
009
4…12 ND 537 741 84 47) ND 537 741 84 47)
>60 ND 537 741 84 47)
NF 537 748 84 NF 537 748 84
16 ≤100 --- NF 537 748 84 NF 537 748 84 No information avail‐
2 ≤100 --- --- --- able
014 4…8 ≤100 --- --- NF 537 749 84
12…16 ≤100 NF 537 749 84 NF 537 749 84 NF 537 749 84
≤60 --- --- NF 537 749 84
2…8 ND 537 743 84 47)
>60 ND 537 743 84 47) ND 537 743 84 47)
NF 537 749 84
017 ≤60 --- --- NF 537 749 84
12 ND 537 743 84 47)
>60 ND 537 743 84 47) ND 537 743 84 47)
NF 537 749 84
16 ≤100 NF 537 749 84 NF 537 749 84 NF 537 749 84
025 2…16 ≤100 NF 537 747 84 NF 537 750 84 NF 537 750 84
≤60 NF 537 747 84 NF 537 750 84 NF 537 750 84
2…12 ND 537 745 84 47) ND 537 745 84 47) ND 537 745 84 47)
032 >60
NF 537 747 84 NF 537 750 84 NF 537 750 84
16 ≤100 NF 537 747 84 NF 537 750 84 NF 537 750 84
≤60 NF 537 747 84 NF 537 750 84 NF 537 750 84
040 2…16 ND 537 753 84 47) ND 537 753 84 47) ND 537 753 84 47)
>60
NF 537 747 84 NF 537 750 84 NF 537 750 84
Tab. 301
214 716 44/200710

22.8.1.5 Limit value class A group 2
Limit value class A group 2 is achieved by means of the following components.

002 2…16 ≤100 --- --- NF 537 888 84
≤60 --- --- NF 537 888 84
003 2…12 ND 537 739 84 48)
>60 ND 537 739 84 48) 49) ND 537 739 84 48) 49)
004 NF 537 888 84
16 ≤100 --- --- NF 537 888 84
006 2…16 ≤100 --- --- NF 537 888 84
≤60 --- --- NF 537 889 84
007 2…12 ND 537 741 84 48)
>60 ND 537 741 84 48) ND 537 741 84 48)
009 NF 537 889 84 No information availa‐
16 ≤100 --- --- NF 537 889 84 ble
014 2…16 ≤100 --- --- ---

≤60 --- --- ---
2…12
017 >60 ND 537 743 84 48) ND 537 743 84 48) ND 537 743 84 48)
16 ≤100 --- --- ---
025 2…16 ≤100 ND 537 744 84 49) ND 537 744 84 49) ND 537 744 84 49)
032 2…16 ≤100 ND 537 745 84 48) 49) ND 537 745 84 48) 49) ND 537 745 84 48) 49)
040 2…16 ≤100 ND 537 753 84 48) 49) ND 537 753 84 48) 49) ND 537 753 84 48) 49)
045 2…8 ≤100 NF 537 891 84 NF 537 891 84 NF 537 891 84 NF 537 891 84
≤60 NF 537 892 84 NF 537 892 84 NF 537 892 84 NF 537 892 84
060 2…8 ND 537 193 84 48) ND 537 193 84 48) ND 537 193 84 48) ND 537 193 84 48)
>60
NF 537 892 84 NF 537 892 84 NF 537 892 84 NF 537 892 84
075 2…8 ≤100 NF 537 893 84 NF 537 893 84 NF 537 893 84 NF 537 893 84
≤60 NF 537 894 84 NF 537 894 84 NF 537 894 84 NF 537 894 84
090 2…8 ND 537 195 84 48) ND 537 195 84 48) ND 537 195 84 48) ND 537 195 84 48)
>60
NF 537 894 84 NF 537 894 84 NF 537 894 84 NF 537 894 84
110 2…8 ≤100 ND 537 196 84 48) 49) ND 537 196 84 48) 49) ND 537 196 84 48) 49) ND 537 196 84 48) 49)
Tab. 302
214 716 44/200710
48) The line reactor is used to protect the link

212 49) The line reactor is used to maintain the EMC limit value

2…4 ≤100 --- --- ND 537 739 84 50)
002
8…16 ≤100 --- --- NF 537 748 84
≤60 --- --- ND 537 739 84 50)
2…4
>60 ND 537 739 84 51) ND 537 739 84 51) ND 537 739 84
003 ≤60 --- --- NF 537 748 84
004 8…12
51) 51) ND 537 739 84
>60 ND 537 739 84 ND 537 739 84
NF 537 748 84
16 ≤100 --- --- NF 537 748 84
2…4 ≤100 --- --- ND 537 740 84 50)
006
8…16 ≤100 --- --- NF 537 748 84
≤60 --- --- ND 537 741 84 50)
2…4 No information avail‐
>60 ND 537 741 84 51) ND 537 741 84 51) ND 537 741 84
able
007 ≤60 --- --- NF 537 748 84
009 8…12 ND 537 741 84 51)
>60 ND 537 741 84 51) ND 537 741 84 51)
NF 537 748 84
16 ≤100 --- --- NF 537 748 84
014 2…16 ≤100 --- --- ---
≤60 --- --- ---
2…12
017 >60 ND 537 743 84 51) ND 537 743 84 51) ND 537 743 84 51)
16 ≤100 --- --- ---
025 2…16 ≤100 ND 537 744 84 50) ND 537 744 84 50) ND 537 744 84 50)
032 2…16 ≤100 ND 537 745 84 50) ND 537 745 84 50) ND 537 745 84 50)
040 2…16 ≤100 ND 537 753 84 50) ND 537 753 84 50) ND 537 753 84 50)
Tab. 303
22.8.1.6 Definition of the environments and categories
Environment
1. Environment Environment that contains residential areas as well as devices that are connected direct to a low-voltage
network without an intermediate transformer and which are used to supply the residential building.
(Residential and commercial environment)
2. Environment Devices that are not connected direct to a low-voltage network to supply residential areas. (Industrial
environment)
Tab. 304
Power Drive System (PDS) categories
Category C1 PDS
● PDS with a rated voltage < 1000 V for use in the first environment.
Category C2 PDS
● PDS for use in the first environment that satisfy all of the following criteria:
- Rated voltage < 1000 V,
- Not connected by plug-in devices,
- Not mobile,
- Connected and put into service önly by people who have an understanding of technical EMC requirements.
This is a product in category C2 according to EN 61800-3. This product may cause high-frequency interference in
residential areas which can require interference suppression measures.
214 716 44/200710
Category C3 PDS
● PDS with a rated voltage < 1000 V for use in the second environment. It is not designed to be operated in the
first environment.
This PDS is not designed to be connected to the public power supply network. EMV interference may occur if it is
connected to such power supply systems.
Category C4 PDS
● PDS for connection in the second environment that satisfy at least one of the following criteria:
- Rated voltage > 1000 V,
- Rated current > 400 A,
- Connection to IT systems,
- The required dynamic properties are not achieved as a result of EMC filter measures.
Accordingly, Dedrive Compact units may be classified in categories C1 to C4 depending on the application and
the external components used.
Example:
● Category C2 limit values must be met
- For use in the 1st environment,
- not connected by plug-in devices,
- not mobile,
- installed by qualified personnel.
22.8.1.7 Comparison of the limit values
EMC product standard for electrical power drive systems:
EN 61800-3: 2004. Adjustable speed electric power drive systems. Part 3: EMC product standard
EN 61800-3 EN 55011
Category C1 (first environment) Class B
Category C2 (first environment) Class A Group 1
Category C3 (second environment) Class A Group 2
Category C4 (second environment) Class A Group 2
Tab. 305
22.8.2 Line reactor technical data
22.8.2.1 Line reactor electrical data
Input voltage: 3 AC 50/60Hz ± 10%; 380 V to 480 V +10% -15%
Ambient temperature: 45 °C
Type of enclosure: IP00
IN L Uk Ploss
Order no. Code no. Type
[A] [mH] [%] [W]
537 739 84 184 420 004 DK 302/4 4,00 7,32 4 20
537 740 84 184 420 006 DK 303/6 6,00 4,88 4 25
537 741 84 184 420 008 DK 304/8 8,00 3,66 4 30
537 742 84 184 420 015 DK 306/15 15,00 1,95 3,7 45
537 743 84 184 420 018 DK 307/18 18,00 1,63 4 70
537 744 84 184 420 025 DK 307/25 25,00 1,17 4 70
214 716 44/200710
537 745 84 184 420 034 DK 307/34 34,00 0,86 4 85

537 753 84 184 420 050 DK 922/50 50,00 0,59 3,6 100
537 193 84 184 420 060 DK 921/60 60,00 0,49 4 100
537 194 84 184 420 075 DK 922/80 75,0 0,37 3,7 110
214
IN L Uk Ploss
Order no. Code no. Type
[A] [mH] [%] [W]
537 195 84 184 420 090 DK 923/90 90,0 0,32 4 120
537 196 84 184 429 115 DK 927/115 115,0 0,25 4 140
Tab. 306
22.8.2.2 Line reactor mechanical data and dimensions
PE U1 U2 V1 V2 W1 W2
c
d
n2
n1
a b
43203844_xml.eps
Fig. 103 Line reactor mechanical data and dimensions
Dimensions in mm Weight Connection

Order no.
a b c n1 n2 d [kg] [mm2] [Nm] PE
537 193 84 190 110 220 58 170 8 9,0 2,5 - 35 2,5 - 5,0 M5
537 194 84 190 120 250 68 170 8 12,0 25 - 50 3,0 - 6,0 M6
537 195 84 190 130 250 78 170 8 12,0 25 - 50 3,0 - 6,0 M6
537 196 84 210 140 280 82 180 8 14,0 50 - 95 6,0 - 12,0 M6
537 739 84 80 65 95 37 55 4 0,8 0,75 - 2,5 1,0 - 1,2 4 mm2/M4
537 740 84 100 65 115 39 60 4 1,0 0,75 - 2,5 1,0 - 1,2 4 mm2/M4
537 741 84 100 75 115 48 60 4 1,5 0,75 - 2,5 1,0 - 1,2 4 mm2/M4
537 742 84 125 85 135 55 100 5 3,0 0,75 - 4,0 1,5 - 1,8 4 mm2/M4
537 743 84 155 90 135 57 130 8 4,0 0,75 - 4,0 1,5 - 1,8 4 mm2/M4
537 744 84 155 100 160 57 130 8 4,0 0,75 - 10 4,0 - 4,5 4 mm2/M4
537 745 84 155 100 190 57 130 8 4,5 2,5 - 16 2,0 - 4,0 M5
537 753 84 190 105 210 68 170 8 4,5 2,5 - 16 2,0 - 4,0 M5
Tab. 307
214 716 44/200710
215
22.8.3 Line filter technical data
22.8.3.1 Electrical data
Input voltage: 3 AC 50/60 Hz ± 10%; 380 V to 480 V +10% -15%
Part no. Code no. Type IN Ploss

[A] [W]
537 747 84 185 609 040 40 35
537 748 84 185 661 008 8 3,2
537 749 84 185 601 018 18 20
537 750 84 185 601 040 40 35
537 888 84 52002 FS 21858-7-44 7,7 3,8
537 889 84 52004 FS 21858-16-44 17,5 6,1
537 890 84 52006 FS 21858-30-33 33 12
537 891 84 52008 FS 21858-55-34 60 26
537 892 84 52010 FS 21858-75-34 82 32
537 893 84 52012 FS 21858-100-35 109 35
537 894 84 52014 FS 21858-130-35 142 43
Tab. 308
214 716 44/200710
216
22.8.3.2 Mechanical data and dimensions of line filters
"Footprint" format line filters 537 747 84, 537 749 84 and 537 750 84
Fig. 104 Dimensions of line filters 537 747 84, 537 749 84 and 537 750 84
1 Line connection
2 Front view
Order no. Dimensions in [mm] 52) Weight Connections

Input terminals output
x y z [kg] [mm2] 53) [Nm] PE 54) [mm2] 53)
537 747 84 60 90 125 0,5 - 16 2,0 – 2,3 16
537 749 84 35 76 100 3,5 0,2 - 6 1,5 – 1,8 M6 4
537 750 84 60 90 125 0,5 - 16 2,0 – 2,3 16
Tab. 309
● Line filters 537 747 84, 537 749 84 and 537 750 84 can be used as a base below the Dedrive Compact unit.
214 716 44/200710
52) Other dimensions see drawing

53) 3x flexible lead; length 300 mm with ferrules
54) Threaded pin 217
"Footprint" line filter 537 748 84
30 PE
200
17,5
160
10,4
3 2
240
315
280
340
351
M6
5,5 2
45
62
1
33
50
Fig. 105 Dimensions of line filter 537 748 84
1 Line connection 3 Screening braid

2 Load connection; flexible 1,5 mm2 with lettering 4 Lettering
L1, L2, L3
Order no. Weight Connections

Input (terminals) Output (cable)
[kg] [mm2] [Nm] PE [mm2]
537 748 84 1,5 4 0,5 M4 1,5
Tab. 310
● Line filters 537 748 84 can be used a base below the Dedrive Compact.
214 716 44/200710
218
A mounting bracket is included in the line filter scope of supply. It must
be fitted to the top of the Dedrive Compact unit if the line filter is used as
a base.
Fig. 106
214 716 44/200710
219
"Book" format line filters 537 888 84 to 537 894 84
Fig. 107 Dimensions of line filters 537 888 84, 537 889 84, 537 890 84, 537 891 84, 537 892 84, 537 893 84 and 537 894 84,
Order no. Dimensions in [mm] Weight Connections

A B C D E F G H I J K L [kg] [mm²] [Nm]
537 888 84 190 40 70 160 180 20 4,5 1 22 M5 20 29,5 0,5 6 1,5
537 889 84 250 45 70 220 235 25 5,4 1 22 M5 22,5 29,5 0,8 6 1,5
537 890 84 270 50 85 240 255 30 5,4 1 25 M5 25 39,5 1,2 10 1,5
537 891 84 250 85 90 220 235 60 5,4 1 39 M6 42,5 26,5 2,0 25 4,0
537 892 84 270 85 135 240 255 60 6,5 1,5 39 M6 40 70,5 2,7 25 4,0
537 893 84 270 90 150 240 255 65 6,5 1,5 45 M10 45 64 4,3 50 7,0
537 894 84 270 90 150 240 255 65 6,5 1,5 45 M10 45 64 4,5 50 7,0
Tab. 311
214 716 44/200710
220
22.9 Output filters (du/dt)
22.9.1 Assignment and electrical data
Input voltage: 400 V / 500 V
Modulation frequency: 2-4 kHz
Output filter Electrical values

Dedrive IN L fmax uk Ploss
Compact
DIC - 4 - xxx Order no. Code no. 400V / 500V
[A] [mH] [Hz] [%] [W]
002 537 757 84 182 421 002 3/* 2,2 60 0,90 15
537 758 84 182 422 002 2,1 / * 2,3 200 0,66 15
003 / 004 537 759 84 182 421 004 4/* 1,2 60 0,65 15
537 760 84 182 422 004 4/* ?? 200 ?? ??
006 537 763 84 182 421 005 5,5 / * 0,87 60 0,65 15
537 764 84 182 422 005 5,5 / * 0,87 200 0,65 25
007 537 765 84 182 421 008 8/* 0,8 60 0,87 20
537 766 84 182 422 008 8/* 0,8 200 0,87 30
009 537 767 84 182 421 010 10 / * 0,65 60 0,88 20
537 768 84 182 422 010 10 / * 0,65 200 0,88 40
014 537 154 84 182 624 014 14 / 11 0,6 87 1,14 40
537 171 84 182 622 014 14 / 11 0,6 200 1,14 50
017 537 155 84 182 624 018 18 / 14 0,45 87 1,10 40
537 172 84 182 622 018 18 / 14 0,5 200 1,22 70
025 537 156 84 182 624 025 25 / 20 0,34 87 1,16 70
537 173 84 182 622 025 25 / 20 0,35 200 1,19 90
032 537 157 84 182 624 034 34 / 27 0,28 87 1,30 70
537 174 84 182 622 034 34 / 27 0,25 200 1,16 100
040 / 045 537 158 84 182 624 045 45 / 36 0,22 87 1,35 100
537 175 84 182 622 045 45 / 36 0,2 200 1,22 110
060 537 159 84 182 624 060 60 / 48 87 110
537 176 84 182 622 060 60 / 48 200 120
075 537 160 84 182 624 075 75 / 60 87 110
537 177 84 182 622 075 75 / 60 200 150
090 537 161 84 182 624 090 90 / 72 87 140
537 178 84 182 622 090 90 / 72 200 170
110 537 162 84 182 624 115 115 / 92 87 140
537 179 84 182 622 115 115 / 92 200 190
Tab. 312
* Only 400 V operation.

214 716 44/200710
221
22.9.2 Mechanical data and dimensions
a b
43204344_xml.eps
Fig. 108 Dimensions of output filters 537 757 84 … 537 760 84, 537 763 84, 537 765 84 and 537 767 84
1 Mounting on a top-hat rail
Dimensions Fastening Connection
Order no. a b c Snap-on de‐ Weight Phase PE Mtighten

vice for top-
mm mm mm kg mm2 mm2 Nm
hat rail
537 757 84 130 90 90 TS 35; 1,0 0,75-2,5 0,2-1,5 1,0-1,2
7,5 mm
537 758 84 130 90 90 TS 35; 1,0 0,75-2,5 0,2-1,5 1,0-1,2
7,5 mm
537 759 84 130 90 90 TS 35; 1,0 0,75-2,5 0,2-1,5 1,0-1,2
7,5 mm
537 760 00 130 90 90 TS 35; 1,0 0,75-2,5 0,2-1,5 1,0-1,2
7,5 mm
537 763 84 130 90 90 TS 35; 1,0 0,75-2,5 0,2-1,5 1,0-1,2
7,5 mm
537 765 84 130 90 90 TS 35; 1,0 0,75-2,5 0,2-1,5 1,0-1,2
7,5 mm
537 767 84 130 90 90 TS 35; 1,0 0,75-2,5 0,2-1,5 1,0-1,2
7,5 mm
Tab. 313
214 716 44/200710
222
Fig. 109 Dimensions of output filters 537 154 84 … 537 162 84, 537 171 84 … 537 179 84 , 537 764 84, 537 766 84 and 537 768 84
Dimensions Mounting dimensions Connection

Order no. a b c n2 n1 d Weight Phase PE Mtighten
mm mm mm mm mm mm kg mm2 mm2 Nm
537 154 84 125 100 190 100 45 5 3,0 0,5-6 0,2-4 0,8-1,0
537 155 84 125 100 190 100 45 5 3,0 0,5-6 0,2-4 0,8-1,0
537 156 84 155 110 220 130 57 8 4,3 2,5-16 0,5-10 1,2-1,4
537 157 84 155 110 220 130 57 8 4,3 2,5-16 0,5-10 1,2-1,4
537 158 84 190 110 255 70 58 8 9,0 2,5-35 M5 2,5-5,0
537 159 84 190 140 260 170 68 8 10 2,5-35 M5 3,2-3,7
537 160 84 190 140 260 170 68 8 10 2,5-35 M5 3,2-3,7
537 161 84 210 160 280 170 82 8 14 25-50 M6 3,2-3,7
537 162 84 210 160 280 180 82 8 14 16-70 M6 6,0-7,0
537 171 84 125 110 190 100 55 5 3,0 0,5-6 0,2-4 0,8-1,0
537 172 84 155 110 220 130 57 8 4,3 0,5-10 0,2-4 1,2-1,4
537 173 84 155 120 220 130 72 8 7,0 2,5-16 0,2-4 1,2-1,4
537 174 84 190 110 255 170 58 8 9,0 2,5-16 M5 1,2-1,4
537 175 84 190 125 255 170 68 8 10 2,5-35 M5 2,5-5,0
537 176 84 190 140 260 170 68 8 12 2,5-35 M5 3,2-3,7
537 177 84 190 140 260 170 68 8 15 25-50 M5 3,2-3,7
537 178 84 210 160 280 180 82 8 16 25-50 M6 3,2-3,7
537 179 84 210 160 280 180 82 8 20 16-70 M6 6,0-7,0
537 764 84 100 110 170 60 38 4 1,0 0,75-2,5 0,2-1,5 1,0-1,2
537 766 84 100 110 170 60 48 4 1,2 0,75-2,5 0,2-1,5 1,0-1,2
537 768 84 125 120 195 100 45 5 2,5 0,75-2,5 0,2-2,5 1,0-1,2
Tab. 314
22.9.3 Motor cable lengths
⇒ "Motor connection", Page 42

214 716 44/200710
223
23 Project engineering
23.1 General
Dedrive Compact frequency inverters are suitable for use with cylindrical and conical rotor motors.
For the maximum currents of the frequency inverters and deratings which may become necesary, please refer to
the tables and diagrams in section ⇒ "Technical data", Page 21.
23.2 Selecting the motor according to the drive requirement

● Determine the required torque for the drive and select the motor(s) from the motor lists. Remember that the
maximum acceleration and deceleration torque should generally be limited to 1.6 times the rated torque when
asynchronous motors are used with the frequency inverter. Torque and current increases are approximately
proportional up to this value. If higher torques are required, the increase of the current which determines the
inverter size may be disproportionately high.
● Determine whether the motors are to be used on the frequency inverter up to the motor rated frequency, e.g. 50
Hz (frequency for rated speed) or at a higher frequency. Note: Higher frequency provides
- greater speed control range, therefore
- better positioning accuracy
- possibly more power.
● Consider the following when selecting the motor:
- Pay attention to suitability of the motor for inverter operation (winding inter-phase insulation, fit output filters
and thermal protection, if required).
- Motor voltage ≤ inverter output voltage ≤ inverter input voltage
● Motors with 4 and 6 poles are most suitable for frequency-inverter feed.
● The field-oriented regulation without encoders is suitable for travel drives with one or several motors in the range
above ± 3 Hz.
● The field-oriented regulation may be used for hoist or travel drives with cylindrical rotor motors and speed feedback
from 0 Hz onwards.
● The V/f characteristic process is suitable for travel drives with one or several motors (without speed feedback) in
the range above ± 3 Hz.
23.3 Speed range of the selected motor

Determine the planned motor speed range.
The following applies for constant torque:
It must be possible to vary the motor voltage in direct proportion to the frequency, even when the frequency is boosted
beyond the rated point up to the transition frequency. This transition frequency (change-over to field-weakening
operation) is therefore determined by the maximum available line voltage.
Consider the maximum permissible voltage and speed of the motor.
fmax = maximum possible frequency

UAC fmot = rated motor frequency
fmax = ∙ fMot
UMot Umot = rated motor voltage
UAC = line voltage
Tab. 315
The following examples show how the maximum frequency for motors can be determined.
Example 1
Line voltage 400 V 400 V

Connection Star Delta
Motor data see type plate 400 V / 6,2 A / 50 Hz 230 V / 10,7 A / 50 Hz
214 716 44/200710
fmax = (400 V / 400 V) ·50 Hz = 50 Hz (400 V / 230 V) ·50 Hz = 87 Hz

Tab. 316
Example 2
224
fmax = (500 V / 400 V) ·50 Hz = 62,5 Hz (500 V / 230 V) ·50 Hz = 108 Hz
Tab. 317
Example 3 Special motor

fmax = (400 V / 230 V) ·50 Hz = 87 Hz (400 V / 133 V) ·50 Hz = 150 Hz
Tab. 318
23.4 Field weakening operation

The motor can be operated at speeds greater than the transition speed, this is generally referred to as field weakening
operation.
Reduced torque
Field weakening is used to operate the motor over an extended speed range with as constant an output as possible.
Field weakening operation occurs when the frequency alone is increased without exceeding the max. inverter output
voltage. The magnetic flux and torque decrease at an approximately inversely proportional ratio to the increase in
the frequency; however, the breakdown torque, a further characteristic of asynchronous motors, decreases accord‐
ing to a square-law function. This results in a limitation of the possible frequency increase and/or reduced output,
since the torque must remain smaller than the breakdown torque to ensure safe operation.
If field weakening is to be used for hoist applications, the ProHub function must be used, ⇒ "ProHub function", Page
112.
The maximum possible frequency in the field weakening range is limited by the following influencing factors:
● Mechanical features, such as
- Motor
- Gearboxes
- Brake
- Installation design, etc.
● Maximum inverter output frequencies:
- 200 Hz at 2 kHz modulation frequency,
- 300 Hz at ≥ 4 kHz modulation frequency
● Motor characteristic values
For design reasons, Demag sliding-rotor motors are suitable for field weakening operation only under certain con‐
ditions.
Please refer to your Demag drive specialists for the conditions.
23.5 Static torque for speed values of approx. "0 rpm"

Operation of the motor at speed values of approx. "0 rpm" when fed by the Dedrive frequency inverter is only possible
with field-oriented regulation and encoder feedback.
If the motor is operated at speeds below the rated speed and, in particular, when the motor shaft is at standstill, the
cooling effect of the fan connected to the rotor is reduced. Therefore, the application must be checked to determine
whether a fan is needed when the motor is operated below the rated speed over long periods of time.
As an alternative to forced-air cooling, the on-time of the motor can be reduced or the motor power rating must be
increased.
214 716 44/200710
225
24 Block wiring diagram
24.1 Circuit diagram

8
PWM +
PWM -
7
GND
X210B: 1 2 3 4 5 6 7
ANA 1
MFI
+ 24V
0V
+ 10V
MFO1
S1 OUT
X210B: 2 3 4 5 6 7
GND
3
S6 IND
2
X10:1
9
X210A: 1
4
_ 3,3k0hm
S3 IND
3 4 5
X210B: 2 3 4 5 6 7
S2 IND S5 IND
X210A: 1 2 6 7
6
S1 IND S4 IND
T1
F2
K1
K2
R>
+ 24 V 180 mA GND
X210A: 1
+ 24 V
Rb1 Rb2
R1
F2
PE
W2
W1
W
PE
PE
PE
PE
W1
T1
W1
W2
L3
L3
V1
V2
V
V1
5
M
3~
V1
V2
L2
L2
U1
U2
U2
U1
L1
X1: L1
X2: U
U1
K2 2
K1
F1
Z1
Z2
L1
3
1
43204644_xml.eps
Fig. 110
1 Brake control 7 PWM-analogue inverter

2 Motor contactor only for KB motors 8 DEMAG-DSE/DST PWM module
214 716 44/200710
3 Brake (option) 9 Relay

4 Rotary encoder (option) Normally open: 240 V AC / 5 A; 24 V DC / 5 A (ohmic)
Normally closed: 240 V AC / 3 A; 24 V DC / 1 A (ohmic)
5 Line connection Response time approx. 40 ms
6 Analogue reference value
Tab. 319
226
24.2 Pulse generator connection to the Dedrive Compact DIC-4-xxx
24.2.1 General
The Dedrive Compact offers several possibilities for evaluating a rotary encoder.
● Evaluation in the basic unit
In the basic unit 2 channels (A and B channel) with a signal level of 24 V can be evaluated. The encoder channels
are connected to the digital inputs.
● Evaluation with EM – UNI-01 extension module
The EM – UNI-01 extension module can be used to evaluate 2 channels with inverted signals (A+ , A- and B+ ,
B- channel) with a signal level of 24 V or 5 V.
24.2.2 Selection of the pulse generator and interface electronics
24.2.2.1 General
Demag Cranes & Components offers different pulse generators depending on the type of motor and mounting.
Different electronic interface modules are available for each pulse generator.
The following sections give an overview of the possible applications of the pulse encoders and interfaces on the
Dedrive Compact.
24.2.2.2 EG integral pulse generator with 30 pulses per revolution
Application:
● Conical rotor motors KBx, KDF 63, KMF, SBx
● Cylindrical rotor motors KLA, KLF
Available interfaces:
Power supply: UB = 5.5 to 30 V DC

Current consumption: IB= 50 mA (at UB=24 V)
Signal level: Ulevel = ~UB
S1
Evaluation on the DIC basic unit (rotary encoder 1): See ⇒ „S1 electrical protection on the Dedrive Compact“,
electrical protection
Page 229
Evaluation on the DIC with EM – UNI-01 (rotary encoder): Level encoder 2 495 :
2 - Unipolar with resistors ⇒ „S1 electrical protection on the
Dedrive Compact“, Page 229
Power supply: UB = 24 V DC
Electronics Signal level: Ulevel = 5 V
S 31
Evaluation on the DIC basic unit (rotary encoder 1): Not possible
Evaluation on the DIC with EM – UNI-01 (rotary encoder Level encoder 2 495 :
2): 0 - Push-pull
Tab. 320
214 716 44/200710
227
24.2.2.3 EGS integral pulse generator with 30 pulses per revolution
Application:
● Cylindrical rotor motors Zxx
Current consumption: IB= 70 mA
Interface Signal level: Ulevel = 5 V - RS 422 (TTL)
EGS 1
2): 0 - Push-pull
Power supply: UB = 10 to 30 V DC
Interface Signal level: Ulevel = 5 V - RS 422 (TTL)
EGS 2
2): 0 - Push-pull
Interface Signal level: Uhigh >= UB-3 V; Ulow <= 2 V
EGS 3
Evaluation on the DIC basic unit (rotary encoder 1): Only signals A and B
2): 2 - Unipolar
Tab. 321
24.2.2.4 AG external pulse generator with 1024 pulses per revolution
Application:
● External fitting to motors
Current consumption: IB= 100 mA
Signal level: Ulevel = 5 V - RS 422 (TTL)
Interface Manufacturer's code: Hengstler: .41DD
AG 1 Wachendorff: -I05-
2): 0 - Push-pull
Signal level: Ulevel = 5 V - RS 422 (TTL)
Interface Manufacturer's code: Hengstler: .41RD
AG 2 Wachendorff: -245-
2): 0 - Push-pull
Signal level: Uhigh >= UB-3V; Ulow <= 2 V
Interface Manufacturer's code: Hengstler: .41ID
AG 3 Wachendorff: -I24-
Evaluation on the DIC basic unit (rotary encoder 1): Only signals A and B
2): 2 - Unipolar
Tab. 322
214 716 44/200710
228
24.2.3 Electrical connection/terminal assignment
Basic unit terminal assignment
Control terminal X210A Connection Electrical data Explanation/Use

1 Voltage output 24 V, Imax = 180 mA
Supply voltage
2 Ground / GND 0V
6 Digital input S4IND Rotary encoder channel B
7 Digital input S5IND Rotary encoder channel A
Tab. 323
See also ⇒ "Control terminals", Page 47
EM – UNI-01 terminal assignment
Control terminal X410A Connection Electrical data Explanation/Use

1 EM – ENC A+ Rotary encoder channel A
2 EM – ENC A- Rotary encoder channel A inverted
3 EM – ENC B+ Rotary encoder channel B
4 EM – ENC B- Rotary encoder channel B inverted
5 Voltage output 24 V, Imax = 200 mA
Supply voltage
6 Ground / GND 0V
Tab. 324
Refer also to the EM – UNI-01 extension module operating instructions
24.2.4 S1 electrical protection on the Dedrive Compact
Fig. 111 Connection diagram for integral pulse generator with S1 electrical protection on the Dedrive Compact
1 Pulse generator connector socket 4 1,2 kOhm pull-up resistors

2 S1 electrical protection cable socket 5 Dedrive Compact
3 Pulse track
When the integral pulse generator is connected to the digital input of the Dedrive Compact by means of S1 electrical
protection (pulse output => open collector switching against GND), a 1,2 kOhm pull-up resistor must be connected
214 716 44/200710
between +24 V and the digital input.
229
230
214 716 44/200710
214 716 44/200710
231
The current addresses of the sales offices in Germany and the subsidiaries and agencies worldwide
can be found on the Demag Cranes & Components homepage at
www.demagcranes.com/Contact and Demag worldwide
Brief operating instructions
Dedrive Compact frequency inverter DIC-4-002 to DIC-4-110
42565444.jpg
Valid from software version 4.2.4/050-6 with DIC-4-xxx-E-0000-01 hardware
250909 enEN 214 708 44 720 IS 922

Drives
P.O box 67 · D-58286 Wetter
Telephone (+49/2335) 92-0 · Telefax (+49/2335) 927298
www.drives.demagcranes.com
Accompanying documents
Documents Ident. no.

DE EN FR ES
Dedrive Compact frequency inverter brief operating instructions 214 707 44 214 708 44 214 709 44 214 710 44
Dedrive Compact frequency inverter application guidelines/operating instructions 214 715 44 214 716 44 214 717 44 214 718 44
Operating instructions for Z motor range 214 227 44 214 228 44 214 229 44 214 230 44
CD
CD ROM Dedrive DIC documentation with, e.g., application guidelines/operating instruc-

213 136 44
tions and operating instructions of option modules
Contents
0 Foreword 4
0.1 Copyright 4
0.5 Definitions 5
1 Safety 6
1.1 Symbol description 6
1.2 Intended use 6
1.3 Prohibited practises, improper use 6
2 Scope of delivery, transportation and storage 8
2.1 Scope of delivery 8
2.1.1 DIC-4-002 to 009 frequency inverters 8
2.2 Transportation and storage 10
3 Product description 10
214708k1.indd/250909
4 Applications 10
2
Contents
5 Assembly/installation 11
5.1 Check the scope of delivery 11
5.2 Fitting the hardware modules 11
5.3 Check the installation location 11
5.4 Mechanical installation 12
5.5 Electrical installation 15
5.5.1 Conditions for connection 15
5.5.2 EMC notes 16
5.5.3 Block diagram 17
5.5.4 Information on the pulse generator 18
5.5.5 Connection to the electrical supply 18
5.5.5.1 DIC-4-002 to 009 frequency inverters 19
5.5.6 Motor connection 21
5.5.7 Control terminals 24
6 Commissioning 26
6.1 Programming parameters with the KP500 operating unit 27
6.1.1 Actual value menu 28
6.1.2 Parameter menu 29
6.1.3 Controlling the motor via the operating unit 30
6.2 Programming parameters with the Parcom Compact software 31
6.2.1 General 31
6.2.2 Window layout 31
6.3 Commissioning in practice 32
6.3.1 Switching on the power supply 32
6.3.2 Setup 32
7 Parameters/functions 39
7.1 Introduction 39
7.2 Reset 39
7.3 Brake application time 40
7.4 Error acknowledgement 41
7.5 Digital inputs and outputs 42
7.5.1 Function assignment of the digital inputs 42
7.5.2 Function assignment of the relay and digital inputs 42
7.6 Creating setpoint values in steps (SOST) 43
7.7 Creating stepless setpoint values with memory function (SOSP) 45
7.8 Encoders 47
7.8.1 Encoder 1 operation mode 47
7.8.2 Encoder 2 operation mode 47
7.8.3 Division marks encoder 1 48
7.8.4 Encoder filter time constant 48
7.9 Frequency switch-off limit 48
7.10 Max. frequency deviation 48
8 Diagnosis 49
8.1 Status message 49
8.2 Warning message 49
8.3 Fault signal 50
9 Maintenance 51
10 Technical data 52
10.1 DIC-4-002 to 009 frequency inverters 52
214708k1.indd/250909

10.4 Operating diagrams 55
10.5 Accessories 56
11 Parameters 58
12 Schematic circuit diagram 59 3
0 Foreword
You have purchased a Demag product. This equipment was manufactured in

accordance with state-of-the-art engineering principles.
maintaining and repairing our frequency inverters and their additional equipment must
have read and understood
• the safety regulations
The operating instructions must be available to the operating personnel at all times
in order to prevent operating errors and to ensure smooth and trouble-free operation
of our products.
0.1 Copyright These operating 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.
specific prior consent. Infringements are an offence resulting in obligatory compen-
satory damages.
0.2 After-sales service 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.
0.3 Liability for defects These operating instructions must be read carefully before installing and putting
the product into operation.
We assume no liability for any damage and malfunctions resulting from failure to
comply with the operating instructions.
Demag.

214708k1.indd/250909
4
0.4 Limitations of liability 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
further development of the frequency inverters which are the subject of these
operating instructions.
The information, illustrations and descriptions contained in these operating
instructions are therefore only intended for information purposes.
The descriptions and illustrations contained in these operating instructions do
not necessarily correspond to the scope of delivery or any subsequent spare part
delivery, either; the drawings and illustrations are not to scale.
We assume no liability for defects, damage and malfunctions caused as a result of
operating errors, non-compliance with these operating instructions or omitted and/
or inappropriate repairs and maintenance.
proved by us may be used. Accordingly, this also applies to other manufacturers’
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 Cranes & Components from any liability for
damages resulting therefrom.
With the exclusion of any further claims, our liability for defects and liability
obligations for any defects pertaining to the products supplied or faults in the
documentation delivered or any negligence on our part are exclusively based on
the stipulations of 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.

Owners (employer, company) are defined as persons who own the product and
who use it appropriately or allow it to be operated by suitable persons.
Operating personnel
Operating personnel are defined as persons assigned by the owner of the product
to operate the product.
Specialist personnel are defined as persons assigned by the owner to carry out
specific 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 the product and electrical installations
as well as knowledge of the relevant standards, codes of practice and regula-
tions, are able to assess the tasks given to them and to identify and eliminate
potential hazards.
• Trained person
for the tasks assigned to them and on the possible hazards resulting from in-
correct 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.
training and experience, have sufficient knowledge of the product and are fa-
miliar with the relevant national industrial safety regulations, codes of practice,
accident prevention regulations, directives and generally accepted engineering
214708k1.indd/250909
standards (e.g. EC Directives, German VDE and VBG regulations) enabling

them to judge the safe operating condition of frequency inverters.
5
1 Safety
1.1 Symbol description The following symbols and instructions are used to warn against potential safety
hazards or causes of damage or provide useful information.
Hazard warning
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 frequency
inverters including any associated equipment and the power supply.
In addition to the safety instructions, observe all general safety regulations and fac-
tory accident prevention regulations at all times.
Warning against dangerous electrical voltage

and enclosures) marked with this sign may only be opened by qualified electricians.
Before opening, all relevant operating, control, feed or other voltages must be
disconnected.

plied with, may result in damage to the frequency inverter, the installation or the
goods to be transported.
Information
This symbol indicates tips and useful information.
1.2 Intended use Frequency inverters are electrical drive components which are intended to be
incorporated into electrical installations or machines. Availability of frequency
inverters is limited, they are components exclusively intended for professional
use in the sense of standard EN 61000-3-2. The unit must not be put into
operation (i.e. designated/intended operation must not commence) until it has
been established that the machinery complies with the provisions of EC Directive
98/37/EEC (Machinery Directive) and with the provisions of EN 60204. The fre-
quency inverters are marked with the CE symbol and thus meet the requirements
of the Low Voltage Directive 73/23/EEC and comply with the standard EN 50178 /
DIN VDE 0160.
The user is responsible for compliance with EMC directive 89/336/EEC. With the
UL approval symbol according to UL508c the requirements of the CSA standard
C22.2-No. 14-95 are also met.
1.3 Prohibited practises, Refer to the rating plate and documentation for the technical data and information
on connecting these units; these conditions and data must not be exceeded.
improper use
Under certain conditions, operation of frequency inverters is prohibited as this
could result in malfunctions, equipment failure or hazard to life and limb, e.g. in the
case of:
• Acidic, corrosive air as coolant

• Operation outside the permitted temperature range
• Operation beyond the normal air pressure
• Operation under conditions of high humidity or splashwater
• Manipulation of electrical modules.
Safety devices must not be rendered inoperable or modified or used in any way
214708k1.indd/250909
other than that for which they have been designed.
6
1.4 Safety The relevant national accident prevention regulations and the general safety
conditions must always be observed when our products are operated in order to
instructions avoid accidents and damage to machinery. If the safety instructions given in these
operating instructions are not observed in any way, personal injury or even death
can result.
Dangerous voltage
The frequency inverter is connected to a mains power supply. Any contact with live
parts can lead to very serious injury or even death.
Only carry out maintenance and installation work,

• if the frequency inverter is at zero voltage,
• if the frequency inverter is secured against accidental restoration of the power
supply,
• if all cables, motor terminals and capacitors are at zero potential (establish with
a voltmeter).
• with insulated tools.
To ensure that the inverters are switched off independently of the mains supply, a
circuit interrupter or a line contactor must be installed between the power supply
and inverter.
Control, power supply and motor leads must be laid separately.
If the light emitting diodes go out or fail, this does not indicate that the
frequency inverter is de-energized.
According to current legislation, the owner of an installation must fulfil certain
obligations with a view to protecting personnel. These are:
• Ensuring proper instruction of personnel

• Ensuring that the operating instructions are available for reference at the point
of application of the equipment
• Compliance with additional instructions including supervisory and reporting ob-
ligations, making allowance for particular operational aspects, e.g. with respect
to work organization, operational sequences, personnel employed
• Review of personnel to ensure that they are aware of the safety requirements
and hazards involved in the work and the associated operating instructions
• Ensuring that frequency inverters are operated only when in perfect operating
condition and that all relevant safety requirements have been allowed for.
• Immediate shut-down of the frequency inverter as soon as a defect or irregularity
is established.
Commissioning the frequency Do this only

inverter
• if you have read the operating instructions – in particular the warning informa-
tion in chapter 6 – and the owner has instructed you in all details,
• if these operating instructions are available for reference at the place where
frequency inverters are in operation,
• if you are qualified specialist personnel,
• if you are not under the influence of drugs, alcohol or medication that can ad-
versely affect your ability to react,
• if the general accident prevention, operating and installation regulations (e.g.
DIN-VDE 0100/0113/prEN50178) have been observed.
214708k1.indd/250909
7
2 Scope of delivery, transportation and storage
2.1 Scope of delivery Due to the modular hardware components frequency inverters can easily be in-
tegrated into the automation concept. The scope of delivery described can be
supplemented with optional components and adapted to customer-specific require-
ments. The plug-in connection terminals ensure reliable functioning and efficient
installation.
Check any goods you have received immediately for quality, quantity and type.
Notice of obvious defects as e.g. external damage to the packing or unit, must be
given to the sender within seven days for assurance reasons.
2.1.1 DIC-4-002 to 009 frequency

inverters A H B C D
X1
X10
X210B
X2
X210B
F E G
42553645.jpg
Item Designation Make Type

A Frequency inverter
Terminal strip X1
B Phoenix ZEC 1,5 / ...ST 7,5
Plug-in terminals for the mains connection and DC link
Terminal strip X10
C Phoenix ZEC 1,5 / 3 ST 5,0
Plug-in terminals for the relay output
D Standard fasteners for mounting on a wall panel
E Brief operating instructions, this document
Terminal strip X2
F Phoenix ZEC 1,5 / ...ST 7,5
Plug-in terminals for braking resistor and motor connection
Control terminals X210A / X210B
G Wieland DST 85 / RM 3,5
Plug-in terminals to connect the control signals
H CD-ROM documentation 213 136 44
214708k1.indd/250909
8
A H B C
inverters
X10
X210B
X210B
D E
42553745.jpg

Terminal strip X10
B Phoenix ZEC 1,5 / 3 ST 5,0
C Standard fasteners for mounting on a wall panel
D Brief operating instructions, this document
E Wieland DST 85 / RM 3,5
H CD-ROM documentation 213 136 44

A B C H
inverters
X10
X210B
X210B
E
42687745.jpg

Terminal strip X10
B Phoenix ZEC 1,5 / 3 ST 5,0
214708k1.indd/250909

C Standard fasteners for mounting on a wall panel
D Brief operating instructions, this document
E Wieland DST 85 / RM 3,5
H CD-ROM documentation 213 136 44 9
2.2 Transportation Transport and storage must be carried out appropriately in the original packaging.
The frequency inverter must be stored in dry places protected against dust and
and storage moisture with only minor temperature fluctuations. Observe the climatic conditions
according to EN 50178 and the symbols on the packing.
The duration of storage without the unit being connected to the permissible rated
voltage must not exceed the period of one year.
3 Product description
For further information, see application guidelines / operating instructions.
4 Applications
If you have any problem applications when configuring or dimensioning your

drives, please consult your local Demag area office for advice from the team of
drive specialists. Should you have any questions, do not hesitate to contact our
team of specialists.

214708k1.indd/250909
10
5 Assembly/installation
5.1 Check the scope of Check the scope of delivery as described in section 2.1.
delivery
5.2 Fitting the CM communications modules and EM expansion modules are supplied pre-as-
sembled in an enclosure. They are fitted into slots B and C. See also section 5.5.6
hardware modules (Hardware modules).
Wait 5 minutes after The inverter must be disconnected from the power supply before any hardware is
disconnecting from fitted. Modules must not be fitted when the inverter is connected to a power supply
the power supply as the inverter and/or the hardware modules will otherwise be destroyed.
The circuit board visible on the rear must not be touched, as parts may be
damaged.
Expansion module EM Remove the cover before fitting the expansion module into slot C.
CM communication module A PE spring is also included to connect the PE conductor (screen).
e
c
d
42657145.tif 42657245.tif 42657345.tif
CM communication module
1. Remove the covers.
2. The slot for the module sub-assem-
bly is accessible.
3. First install the PE spring included
in the delivery using the screw fit-
ted in the unit. The spring must be
centred when fitted.
4. The unit can now be fitted and
f g secured to the PE spring using the

spring on the module.
5. Break out the pre-stamped opening
in the cover for connector X310 and
refit the cover.
42657444.tif 42657544.tif
5.3 Check the installation • Frequency inverters as chassis units are designed to be mounted vertically on
a panel in a switchgear cabinet and feature IP20 enclosure. Ventilation/cooling
location must be ensured.
• Ensure that the installation location is clean and free of dust and grease as well
214708k2.indd/250909
as free of coarse and fine-grain dirt.

• Ensure that foreign bodies do not enter the unit.
• It is advisable to install the unit in such a way that it is easily accessible, e.g. for
inspection and maintenance purposes.
11
5.4 Mechanical Standard frequency inverters of the IP20 type of enclosure are designed for fitting
in the switchgear cabinet. For fitting the installation and safety regulations as well
installation as the specification of the devices must be observed.
The frequency inverters only comply with type of enclosure IP20 once the covers
are properly in place and the terminals connected up. Only then operation is per-
mitted.
The combination of Dedrive Compact fitted on line filters as base does not satisfy
vibration resistance requirements to IEC 68-2-6 (max. 5 g). For increased vibration
resistance demands, Dedrive Compact units must be fitted next to the line filter on
the mounting panel.
For all sizes:

If the KP500 operating unit is fixed on the frequency inverter, the depth dimension
is increased by 19 mm.
5.4.1 DIC-4-002 to 009 frequency Installation is done with the standard fasteners onto the installation plate, see figure
inverters below.
The inverter is fitted on the line filter on the upper side by means of the mounting
tab included in the line filter scope of supply.
x ≥ 100 mm
42553845.jpg
Installation is done by inserting the long side of the fastening sheet into the heat
sink and fixing it to the installation plate with screws.
The dimensions and installation dimensions given are for the standard unit without
any optional components.
Mounting dimensions in mm
Frequency inverter a a1 a2 b b1 c c1
Size 1 DIC-4-002 ... 004 190 210 ... 230 255 60 30 180 130
Size 2 DIC-4-006 ... 009 250 270 ... 290 315 60 30 180 130
214708k2.indd/250909
The units must be fitted with sufficient clearance, so that the cooling air can circu-
late without any hindrance. Ensure that air pollution from sources such as dust,
greases, aggressive gases, etc., is avoided.
12
5.4.2 DIC-4-014 to 040 frequency Installation is done with the standard fasteners onto the installation plate, see figure
inverters below.
x ≥ 100 mm
42553945.jpg
Installation is done by fixing the two angle brackets with the heat sink of the
frequency inverter onto the installation plate with screws.
The frequency inverters of sizes 3 and 4 are supplied with angle brackets which are
fixed on the heat sink by means of four screws, each. The upper angle brackets are
fixed with M4 x 20 screws, the lower angle brackets with M4 x 60 screws.
The dimensions and installation dimensions given are for the standard unit without
any optional components.
Size 3 DIC-4-014 ... 017 250 270 ... 290 315 100 12 200 133
Size 4 DIC-4-025 ... 040 250 270 ... 290 315 125 17,5 200 133
The units must be fitted with sufficient clearance, so that the cooling air can circulate
without any hindrance. Ensure that air pollution from sources such as dust, greases,
aggressive gases, etc., is avoided.
214708k2.indd/250909
13
inverters
x ≥ 100 mm 42687846.jpg
Size 5 Size 6
42696844.jpg
Size 5 and 6 frequency inverters are supplied with a mounting frame, which is
attached to the heat sink. It is fixed at the top and bottom by means of cheese-
head screws and by means of counter-sunk screws on the sides. See diagram.
M6 screws must be used for attaching size 5 units to the mounting plate, and M8
screws for size 6.
Size 5 DIC-4-045 ... 060 250 270 ... 290 315 200 20 265 165
Size 6 DIC-4-075 ... 110 400 430 ... 450 470 275 20 265 165
214708k2.indd/250909
The units must be fitted with sufficient clearance, so that the cooling air can circulate
without any hindrance. Ensure that air pollution from sources such as dust, greases,
aggressive gases, etc., is avoided.
14
5.5 Electrical installation The electrical installation must be carried out by qualified personnel according to
the general and regional safety and installation regulations. Safe operation of the
frequency inverter is ensured provided that the documentation and the specifica-
tion of the unit are complied with during installation and putting into service. Under
special application conditions, further regulations and guidelines may also have to
be considered.
The mains terminals, DC terminals and motor terminals can still have dangerous
voltages even after the frequency inverter has been properly disconnected. Work
on the unit may only be carried out after a few minutes have elapsed until the link
The mains fuses and cable cross-sections must be designed for the rated working
point of the frequency inverter according to EN 60204-1 or DIN VDE 0298, part 4.
According to UL/CSA approved copper cables of class 1 with a temperature range
of 60/75°C must be used for the cable lengths and the corresponding mains fuses.
The frequency inverters must be connected appropriately to earth with a large

surface area to ensure good conductivity. The leakage current of frequency invert-
ers may be > 3,5 mA, a fixed connection must be provided in accordance with
the EN 50178 standard. The protective earth conductor cross-section required for
earthing the installation surface must be at least 10 mm² or a second protective
earth conductor must be connected in parallel to the first. The cross-section in
these applications must correspond to the recommended cable cross-section.
Type of enclosure IP20 (EN60529) is only ensured with the plug-in terminals con-
nected.
5.5.1 Conditions for connection • The connection of frequency inverters with a phase current ≤ 16 A to the public
mains system (1st environment) is to be made with the recommended line choke
as per the stipulations of standard EN 61000-3-2. Devices used professionally
with a connection rating > 1 kW connected to the public mains system (1st envi-
ronment) and frequency inverters in industrial applications (2nd environment) only
require the recommended line choke if the ratio of active power (real power) to
the mains short-circuit power is < 1 %.
• Frequency inverters ≤ DIC-4-017 with a built-in line filter comply with the
emission limit values of the product standard EN 61800-3, for a motor cable
length of up to 10 m. Optional filters can be used to meet any customer-specific
requirements.
• Operation in a non-earthed system (IT system) is allowed after the Y capacitors
inside the unit have been disconnected. Instructions are available on request.
• Operation with fault current protective devices is only permissible in connection
with a pulsed current or universal current-sensitive fault current relay with leak-
age current separation. The value of the leakage current depends on the instal-
lation, the environment and the length of the motor cables. Operation is possible
with a fault current circuit breaker and a cable length of < 10 m (shielded). The
relevant standards and regulations must be complied with.

214708k2.indd/250909
15
5.5.2 EMC notes The frequency inverters are designed with an interference immunity (EMI) for op-
eration in industrial applications according to the requirements and limit values of
the product standard EN 61800-3. Electromagnetic interference must be avoided
by appropriate installation and compliance with the specific product information.
Measures • Take care for a good equipotential bonding within the system or installation.
Installation parts such as switchgear cabinets, control desks, machines frames
etc. must be connected with PE conductors with a large surface area to ensure
good conductivity.
• Ensure that the frequency inverter, the line choke, external filters and other
components are connected to each other via short cables with one earthing
point.
• When installing, excessive cable lengths and cables laid in free air must be
avoided.
• Contactors, relays and magnet valves in the switchgear cabinet must be pro-
vided with suitable interference suppression components.
• Cable shields must be earthed or connected to the unit with a low resistance
and a large surface area. Provide a 360° earth connection using appropriate
screen clamps.
• Unplaiting screens and making contacts by means of long single conductors
(so-called pig tails) must be avoided.
A B A Mains connection
Provided the maximum permissible voltage drop is considered, the mains supply
line can be of any length, but it must be laid separated from control, data and mo-
tor cables. We recommend screened cables be fitted between the line filter and
the frequency inverter if an external line filter is used. The screen of control cables
must be connected to earth on both sides with good conductivity over a large area
using screen clamps (360° earth connection).
B DC link connection
The frequency inverters are to be connected with the same mains potential or with
a direct voltage source for link connection.
C Control/signal connection
Ensure that EMC requirements are considered, particularly when laying
control and signal cables.
The control and signal cables must be laid spatially separated from the power
cables. The screen of control and signal cables must be connected to earth on
both sides with good conductivity over a large area using screen clamps (360°
earth connection). The screen of analogue signal cables must be connected to
earth at one end with the inverter.
D Motor connection
The shielded motor cable is to be connected to the motor with a metallic PG screw
fitting and to the frequency inverter with a suitable and highly conductive clip (360°
earth connection) with earth potential. The signal cable for monitoring the motor
temperature must be laid separately from the motor cable.
C D
42554045.jpg
The frequency inverters comply with the requirements of Low Voltage Directive
73/23/EEC and the requirements of EMC directive 89/336/EEC. EMC product
standard EN 61800-3 relates to the drive system. The documentation gives infor-
mation on how to comply with the standards to be applied if the frequency inverter
is one component of the drive system. The person setting up the drive system
must provide the declaration of conformity.
214708k2.indd/250909
16
5.5.3 Block diagram
B
C
D
E
42554144.jpg
A Relay output S3OUT

Change-over contact, response time approx. 40 ms
Normally open: 240 V AC, 5 A (ohmic and inductive);
24 V DC, 5 A (ohmic load);
Normally closed: 240 V AC, 3 A (ohmic and inductive);
24 V DC, 1 A (ohmic load)
B Digital input S1IND

Digital signal, response time approx.16 ms (On), 10 μs (Off),
Umax = 30 V, 10 mA at 24 V, PLC compatible
C Digital input S2IND ... S6IND
Digital signal, response time approx.16 ms, Umax= 30 V, 10 mA at 24 V,
PLC-compatible,
Frequency signal, 0 ... 30 V, 10 mA at 24 V, fmax = 150 kHz
D Digital output S1OUT
PLC-compatible, overload proof and short-circuit proof,
Digital signal, 24 V, Imax=40 mA
E Multi-function output MFO1
Digital signal, U=24 V, Imax=40 mA, PLC-compatible, overload proof and short-
circuit proof,
Analogue signal, U=24 V, Imax=40 mA, pulse width modulated, fPWM=116 Hz,
Frequency signal, U=24 V, Imax = 40 mA, fmax = 150 kHz
F Multi-function input MFI1
Analog signal, resolution 12 Bit, 0 ... 10 V (Ri = 70 kΩ), 0 ... 20 mA (Ri = 500 Ω),
Digital signal, response time approx.16 ms, Umax= 30 V, 0,4 mA at 24 V,
PLC-compatible
214708k2.indd/250909
17
5.5.4 Information on the pulse Only encoder cables which are fully screened enable fault-free signal transmission.
generator This must be taken into consideration for project drafting and ordering. Different
lengths of cable may be ordered.
Screened pulse encoder cables which are extended at a later date do not achieve
the quality of a complete cable. The open end of the screening is a weak point at
the interface between sections of the cable and can allow interference to be intro-
duced and may result in distorted signals. An additional potential connection to the
screen at the interface to the earth will result in earth loops and must always be
avoided.
The following points must be considered for correct electrical cabling and wiring:
1. Any interruption in the screen between the pulse encoder and the pulse encoder
evaluation should be avoided.
2. 360° screening clamps should be used for screening.
3. Depending on the pulse encoders used, earth loops should be avoided by
means of suitable measures (single-sided potential connection of the screen,
potential connection on both sides of the screen for simultaneous equipotential
bonding). The screen on an intermediate terminal must not be earthed.
5.5.5 Connection to the electrical The mains connection of the frequency inverters is made via terminals X1.
supply The mains fuses and cable cross-sections must be designed for the rated working
point of the frequency inverter according to EN 60204-1 or DIN VDE 0298, part 4.
According to UL/CSA approved copper cables of class 1 with a temperature range
of 60/75°C must be used for the cable lengths and the corresponding mains fuses.
The electrical installation must be carried out according to the specification of the
unit and to the standards and regulations to be applied.
Control, power supply and motor cables must be laid separately. The cables con-
nected to the frequency inverter must not be subjected to an insulation test at a
high test voltage without using special circuits.
Frequency inverters may only be connected to the line supply every 60 seconds.
Flick-switching of the line contactor is not permitted.
214708k2.indd/250909
18
5.5.5.1 DIC-4-002 to 009 frequency
inverters
X1
Phoenix ZEC 1,5 / ... ST 7,5
0,2 ... 1,5 mm²
AWG 24 ... 16
0,2 ... 1,5 mm²
AWG 24 ... 16
0,25 ... 1,5 mm²
AWG 22 ... 16
0,25 ... 1,5 mm²
AWG 22 ... 16
DIC-4-002 to 004 DIC-4-006 to 009

3 ph / 400 V AC 3 ph / 400 V AC 42554245.jpg
Plug-in terminal X1, which cannot be connected up with an incorrect polarity, may
only be connected when not live and after being disconnected. The mains and
DC terminals may carry dangerous voltages after the frequency inverter has been
disconnected safely. Work on the unit may only be carried out after a few minutes
have elapsed until the link capacitors have discharged.

inverters
X1
X1
3 ph / 400 V
DIC-4-014 to 017 DIC-4-025 to 040

WAGO series 745 / 6 mm² / RM7,5 WAGO series 745 / 16 mm² / RM10+15
0,2 ... 6 mm² 0,2 ... 16 mm²
AWG 24 ... 10 AWG 24 ... 6
0,2 ... 6 mm² 0,2 ... 16 mm²
AWG 24 ... 10 AWG 24 ... 6
0,25 ... 4 mm² 0,25 ... 10 mm²
AWG 22 ... 12 AWG 22 ... 8
0,25 ... 4 mm² 0,25 ... 10 mm²
AWG 22 ... 16 AWG 22 ... 8
42554344.jpg
The terminal X1 may only be connected when not live and after being disconnected.
The mains and DC terminals may carry dangerous voltages after the frequency
214708k2.indd/250909
inverter has been disconnected safely. Work on the unit may only be carried out after
a few minutes have elapsed until the link capacitors have discharged.
19
inverters X1
Phoenix MKDSP 25 / 6-15.00-F

0,5 ... 35 mm²
AWG 20 ... 2
0,5 ... 25 mm²
AWG 20 ... 4
1,0 ... 25 mm²
2,5 Nm AWG 18 ... 4
22 Ib-in
1,5 ... 25 mm²
3 ph / 400 V AC AWG 16 ... 4
42687944.jpg
The mains and DC terminals may carry dangerous voltages after the frequency
inverter has been disconnected safely. Work on the unit may only be carried out after
a few minutes have elapsed until the link capacitors have discharged.

inverters
X1
Threaded stud M8 x 25 10 Nm 3 ph / 400 V AC

Conductor cross section up to 70 mm² 89 Ib-in
42688044.jpg
The X1 connection studs may only be connected when not live and after being
disconnected. The connection studs and the DC terminals can still have dangerous
214708k2.indd/250909
voltages even after the frequency inverter has been properly disconnected. Work
on the unit may only be carried out after a few minutes have elapsed until the link
20
5.5.6 Motor connection The motor and braking resistor (Rb) are connected the frequency inverter via ter-
minals X2. The shielding of the motor cable is to be connected on both sides to
earth with good conductivity over a large area. Control, power supply and motor
cables must be laid separately. Note the limit values in accordance with the ap-
plication, the length of the motor cable and the modulation frequency. The general
requirements of product standard EN 61800-3 are complied with in the case of a
shielded motor cable of up to 50 m in length.
Frequency inverters ≤ DIC-4-017 with a built-in line filter comply with the emission
limit values of the product standard EN 61800-3, for a motor cable length of up to
10 m. Optional filters can be used to meet any customer-specific requirements.
Motor cable lengths without an out- Frequency inverter Unscreened cables Screened cables
put filter [m] [m]
DIC-4-002 to 007 50 25
DIC-4-009 to 040 100 50
DIC-4-045 to 110 150 100
Motor cable lengths with an output Frequency inverter Unscreened cables Screened cables
filter (du/dt) [m] [m]
DIC-4-002 to 007 75 50
DIC-4-009 to 040 150 100
DIC-4-045 to 110 300 150

inverters
X2
X2

0,2 ... 1,5 mm²
AWG 24 ... 16
0,2 ... 1,5 mm²
AWG 24 ... 16
0,25 ... 1,5 mm²
AWG 22 ... 16
0,25 ... 1,5 mm²
AWG 22 ... 16 42554445.jpg
Plug-in terminal X2, which cannot be connected up with an incorrect polarity, may
only be connected when not live and after being disconnected. The motor termi-
214708k2.indd/250909
nals and the terminals of the braking resistor may carry dangerous voltages after
the frequency inverter has been released for operation. Work on the unit may only
be carried out after a few minutes have elapsed until the link capacitors have dis-
charged.
21
inverters
X2
X2
DIC-4-014 to 017 DIC-4-025 to 040

WAGO series 745 / 6 mm² / RM7,5 WAGO series 745 / 16 mm² / RM10+15
0,2 ... 6 mm² 0,2 ... 16 mm²
AWG 24 ... 10 AWG 24 ... 6
0,2 ... 6 mm² 0,2 ... 16 mm²
AWG 24 ... 10 AWG 24 ... 6
0,25 ... 4 mm² 0,25 ... 10 mm²
AWG 22 ... 12 AWG 22 ... 8
0,25 ... 4 mm² 0,25 ... 10 mm²
AWG 22 ... 16 AWG 22 ... 8
42554546.jpg
The motor terminals and the terminals of the braking resistor may carry dangerous
voltages after the frequency inverter has been released for operation. Work on the
unit may only be carried out after a few minutes have elapsed until the link capaci-
tors have discharged.
214708k2.indd/250909
22
inverters
X2
Phoenix MKDSP 25 / 6-15,00-F

0,5 ... 35 mm²
AWG 20 ... 2
0,5 ... 25 mm²
AWG 20 ... 4
1,0 ... 25 mm²
2,5 Nm
AWG 18 ... 4
22 Ib-in
1,5 ... 25 mm²
AWG 16 ... 4 42688144.jpg
The motor terminals and the terminals of the braking resistor may carry dangerous
voltages after the frequency inverter has been released for operation. Work on the
unit may only be carried out after a few minutes have elapsed until the link capaci-
tors have discharged.

inverters
X2
10 Nm
Threaded stud M8 x 25 89 Ib-in
Conductor cross section up to 70 mm² 42688244.jpg
214708k2.indd/250909
X2 threaded studs may only be connected when not live and after being
disconnected. The motor terminals and the terminals of the braking resistor may
carry dangerous voltages after the frequency inverter has been released for
operation. Work on the unit may only be carried out after a few minutes have
elapsed until the link capacitors have discharged. 23
5.5.7 Control terminals The control and software functions can be freely configured to ensure safe and
efficient operation. In the brief operating instructions, the factory settings are
described.
The control inputs and outputs, which cannot be connected up with an incorrect
polarity, may only be connected when not live and after being disconnected.
Control terminals
Wieland DST85 / RM3,5

0,14 ... 1,5 mm²
AWG 30 ... 16
0,14 ... 1,5 mm²
AWG 30 ... 16
0,25 ... 1,0 mm²
AWG 22 ... 18 0,2 ... 0,3 Nm
0,25 ... 1,0 mm² 1,8 ... 2,7 Ib-in
AWG 22 ... 18
42554645.jpg
Control terminals X210A

Terminal Connection Electrical data Explanation/Use (factory setting)
1 Voltage output 24 V, Imax = 180 mA Supply voltage
2 Ground / GND 0V
3 Digital input S1IND Controller release / acknowledge fault
4 Digital input S2IND programmable, SW-step 1+
5 Digital input S3IND programmable, SW-step 1-
Umax = 30 V, 10 mA at 24 V PLC-compatible Configuration 210: Encoder track B 1)
6 Digital input S4IND
Configuration 110, 410: programmable, free
Configuration 210: Encoder track A 1)
7 Digital input S5IND
Configuration 110, 410: programmable, free
Control terminals X210B

1 Digital input S6IND Umax = 30 V, 10 mA at 24 V PLC-compatible programmable, (SOST) step 2 / (SOSP) Accelerate
2 Ground / GND 0V
3 Digital output S1OUT overload proof programmable, Ready for operation (digital message)
Multi-function output U = 24 V, Imax = 40 mA and short-circuit
4 proof programmable, Error (digital message)
MFO1
5 Reference output U = 10 V, Imax = 3 mA Supply, reference value potentiometer
6 Multi-function input MFI1 12 Bit 0 ... + 10 V, Ri = 70 kΩ programmable, analog setpoint voltage value
7 Ground / GND 0V
214708k2.indd/250909
1) The level must be 24 V. For configurations, see section 6.3.2.

Please note section 5.5.4 for the encoder cable.

24
Relay output The relay output that can be programmed as desired is linked with the release
brake function in the factory setting.

0,2 ... 1,5 mm²
X10 AWG 24 ... 16
0,2 ... 1,5 mm²
AWG 24 ... 16
0,25 ... 1,5 mm²
AWG 22 ... 16
0,25 ... 1,5 mm²
AWG 22 ... 16
X10 S3OUT
42554744.jpg
Control terminals X10

1 NO:
Relay output, 240 V AC, 5 A (ohmic and inductive);
2
Change-over contact, response time 24 V DC, 5 A (ohmic load);
programmable, Release brake
approx. 40 ms NC:
3 floating 240 V AC / 3 A (ohmic and inductive);
24 V DC / 1 A (ohmic load);
Hardware modules Due to the modular hardware components frequency inverters can easily be in-
tegrated into the automation concept. The optional hardware modules are recog-
nized during initialization and the controller functionality is automatically adapted
to suit. The required information for installation and handling of the optional
expansions can be found in the Application notes/operating instructions.
A KP500 control unit (optional)

see section 6.1
A KP232 interface converter (optional)
see section 6.2
B B CM communications module (optional)
C EM expansion module (optional)

C
42555144.jpg
Only carry out installation and dismantling work on the hardware modules of sockets
B and C once the frequency inverter concerned has been disconnected. Work on
214708k2.indd/250909
the unit may only be carried out after a few minutes have elapsed until the link ca-
pacitors have discharged.
See also section 5.2 (Fitting the hardware modules).
25
6 Commissioning
Requirements Commissioning may only be performed by suitably qualified personnel in accord-

ance with VDE/IEC/ESD regulations.
Dangerous voltages may still be present for some time (wait at least 5 minutes)
after switching off the power supply.
Note:
Make sure that the inverter has been installed and wired in accordance with
the appropriate regulations.
Demag Cranes & Components accepts no liability for damage to the inverter or
other equipment caused by incorrect connection or parameterization.
For programming Dedrive Compact parameters via a KP-500 control unit or the
Parcom Compact parameter programming software, settings may be selected
which cause unintended start-up of the drive. This applies both for manual
parameter programming and for loading of a parameter file. These instructions
also apply to programming parameters via the CAN bus or Profibus.
In order to avoid unintended start-up of the drive, controller enable on input
S1IND MUST be de-activated while programming parameters.
Controller enable on input S1IND must only be activated after the “FUF” message
for the duration of parameter identification by the motor.
Take further suitable measures to avoid unintended start-up of the drive
or transmission of critical control commands between Dedrive Compact
and the installation. These may be, for example, disconnecting the control
terminals (e.g. X210A, X210B, X10 ...) or switching of the supply voltage for
the electrical brake.
Depending on the application, further additional safety devices must be
provided in order to avoid any hazard for persons and machinery.
Drive control The inverter is controlled via terminal strips X210A and X210B.
Implementation • Follow all safety precautions laid down for commissioning (e.g. easily and
rapidly accessible EMERGENCY STOP switch). Read carefully and ensure
compliance with the general safety instructions in section 1.
• Disconnect the motor, if possible, from the mechanical installation/facility.
When delivered, the inverter parameters are factory-preset.
See section 7 for a description of the parameters and functions.
For a list of all parameters, see application guidelines / operating instructions.
Check the
• Control signals (depending on the control mode)
• Motor thermo-contact
• Enable signal connection
• Motor – inverter configuration
• Direction of rotation
• Speeds (vmin, vmax)
• Ramps (acceleration and deceleration)
If the drive behaves according to the specifications of your installation, commis-

sioning is complete. If the drive operating characteristics must be corrected, adapt
the parameters in consultation with your project engineer.
The parameters of the inverter can either be programmed by using the KP500
control unit (see section 6.1) or by means of the Parcom Compact parameter
214708k2.indd/250909
programming software (see section 6.2).
26
6.1 Programming Please comply with the safety instructions in section 1.4 and chapter 6.
parameters with the
Parameters can be set and displayed and the frequency inverter can be controlled
KP500 operating unit by means of the optional KP500 operating unit.
The operating unit is not absolutely necessary for the operation of the frequency
inverter and can be plugged in during operation, if required.
A
B
C
42554844.jpg
Keys RUN Starts the drive unit and changes to the CTRL menu.
Pressing the RUN key branches into the motor potentiometer function.
STOP Changes to the CTRL menu and stops the drive unit.
Acknowledge fault.
Δ∇ Navigate in the menu structure and select parameters.
Increase and decrease parameter values.
ENT Call parameters or change within the menu structure.
Acknowledge the selected function or parameter.
ESC Exit parameters or return within the menu structure. Abort the function
or reset the parameter value.
FUN Change key functions and access special functions.
Display A Three-digit 7-segment display to show the parameter numbers

B One-digit 7-segment display of the active data set, direction of rotation etc.
Display the selected menu branch:

VAL Display actual values
PARA Select parameters and edit parameter values
CTRL Select functions which can be used via the operating unit:
SEtUP for commissioning
CtrL Motor potentiometer and jog function
(cannot be selected, when REM is active)
Status and operational messages:
WARN Warning against critical operating behaviour
FAULT Fault switching-off, with the associated message
RUN Flashing indicates ready for operation
Continuously on indicates operation and enable of the output stage
REM Active remote control via interface connection
(CtrL cannot be selected, when REM is active)
F Change of functions by means of FUN key
C Five-digit 7-segment display of the parameter value and sign

Physical unit of the displayed parameter value
Active acceleration or deceleration ramp
214708k2.indd/250909
Current direction of rotation of the drive unit
27
6.1.1 Actual value menu The operating unit displays a large number of actual values in the VAL menu
branch, depending on the selected configuration and installed options. The brief
instructions document a selection of parameters and the basic functions of the
software.
A
D
B C
42561944.jpg
A Use the cursor keys to select the required number from the actual values shown
in numeric order. The number is shown flashing with the active data set in the
display.
Keys
Δ+∇ Change to the actual value parameter when switching on
FUN , Δ Display last actual value parameter (highest number)
FUN , ∇ Display first actual value parameter (smallest number)
B By pressing the ENT key you select the actual value which is displayed with the
current parameter value, unit and active data set.
C It is possible to monitor a specific actual value parameter as part of commission-
ing and troubleshooting.
Keys
FUN , Δ Maximum actual value is continuously determined and displayed
FUN , ∇ Minimum actual value is continuously determined and displayed
FUN, ENT Mean value of the actual value during the monitoring period
D By pressing the ENT key, the selected actual value is stored as parameter when
switching on. The SEt message with the parameter number appears for a short
time. When switching on the frequency inverter, this actual value will automati-
cally be displayed.
E You can once again monitor and display the value when the parameters have
been saved. Press the ESC key to change to the parameter selection in the VAL
menu branch.
214708k2.indd/250909
28
6.1.2 Parameter menu The parameters that are queried during guided set-up are selected from known
applications and must be supplemented by additional settings in the PARA menu
branch as required. The brief instructions describe the basic parameters and the
basic functions of the software.
A
D
B C
42562044.jpg
A Use the cursor keys to select the desired number from the parameters shown in
numeric order. The parameter number is shown flashing with the active data set
in the display.
Keys
Δ+∇ Change to the last changed parameter
FUN , Δ Display last parameter (highest number)
FUN , ∇ Display first parameter (smallest number)
B By pressing the ENT key you select the parameter which is displayed with the
current parameter value, unit and active data set.
C The parameter value can be adapted using the arrow keys. Depending on the
parameter, the value must be changed or an operation mode be selected.
Keys
Δ+∇ Parameter is reset to the factory setting
FUN , Δ The parameter is set to the highest value.
FUN , ∇ The parameter is set to the smallest value.
FUN, ENT Change the data set in the case of switchable parameters
D Press the ENT key to save the parameter value. The SEt message is displayed
briefly with the parameter number and data set. Press the ESC key if you want
to quit the parameter without making any changes.
Messages
Err1: EEPrO Parameter could not be saved
Err2: StOP Parameter can only be read during operation
Err3: Error Other error
E When the parameter has been saved, you can change the value again or
change to parameter selection by pressing the ESC key.
214708k2.indd/250909
29
6.1.3 Controlling the motor via the The operating unit makes control of the connected motor in parallel to the ana-
operating unit logue and digital control signals possible.
Control of the drive unit via the operating unit requires the release of the power
component via the controller enable S1IND digital input. Avoid any risks of severe
personal injury or damage to valuable assets by ensuring that only suitably
qualified technicians work on the equipment. Qualified persons are those who
are familiar with the setting up, installation, commissioning and operation of fre-
quency inverters and have the corresponding qualifications to carry out such work.
Carefully read the documentation before starting the work and comply with the
safety instructions.
The CTRL menu branch can be reached by navigation within the menu structure.
The CtrL function includes sub-functions that are displayed according to the
operating point of the frequency inverter.
Press the RUN key to go from any point within the menu structure to motor
potentiometer function Pot or internal reference value int respectively.
Motor potentiometer function Pot

Use the cursor keys to set the output frequency of the frequency inverter from the
minimum frequency 418 up to the maximum frequency 419. The acceleration cor-
responds to the factory setting (2 Hz/s) of the parameter Ramp Keypad MPot 473.
The parameters Acceleration 420 and Deceleration 421 are considered at lower
values of acceleration.
Internal reference value int

The drive unit is in operation and the current actual value is displayed. Use the
cursor keys to go to motor potentiometer function Pot, which causes the current
value for the frequency to be accepted.
JOG frequency JOG

Press the FUN key to change from internal reference value int or motor
potentiometer function Pot respectively to the JOG frequency 489. The frequency
is set by using the cursor keys.
Key functions
ENT Changes over the direction of rotation, regardless of the control signal at
the SPV step 1+ or SPV step 1- terminals.
ESC Quit the function and go back in the menu structure.
FUN Press the key to go to JOG frequency and start the drive unit.
Releasing the key changes to the sub-function and stops the drive unit.
RUN Starts the drive unit; alternative to control signals SPV step 1+ or
SPV step 1-.
STOP Stops the drive unit; alternative to control signals SPV step 1+ or
SPV step 1-.
The ENT key produces a change in direction of rotation regardless of the signal
at the SPV step 1+ or SPV step 1- terminals.
If the minimum frequency 418 has been set to 0 Hz, a change in the sign of the fre-
quency reference value produces a change in direction of rotation of the motor.
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30
6.2 Programming Please comply with the safety instructions in section 1.4 and chapter 6.
parameters with
Parcom Compact
software
6.2.1 General As an alternative for configuring and programming the parameters of the inverter,
a PC with Parcom Compact parameter programming software, which is connected
to one of the optional RS 232 modules 537 769 84 or 537 723 84 via data cable
537 237 84 can be used.
Communication with the inverter is only possible when the unit is supplied
with power.
6.2.2 Window layout Parcom Compact software with its graphical user interface facilitates simple pro-
gramming of the inverter parameters. The mouse or the keyboard can be used.
1
2
1 Menu bar The width and height of the windows as well as the width of the columns in the
2 Toolbar parameter window can be changed by holding and dragging the separator with
214708k2.indd/250909
3 Directory window the pointer.

4 Parameter window
5 Status bar
42578345.bmp
31
6.3 Commissioning in Please comply with the safety instructions in section 1.4 and chapter 6.
practice
In the following, the procedure using the KP500 control unit is described.
For commissioning with Parcom Compact, the parameters must be called up
individually and processed.
6.3.1 Switching on the power Once the installation work has been completed, you should check all control and
supply power connections again before turning on the mains voltage.
If all the electrical connections are correct, it is necessary to ensure that you switch
off the controller enable of the frequency inverter (control input S1IND open). After
the mains is switched on, the frequency inverter carries out a self-test and reports
“Fault” during this short period.
The frequency inverter concludes the self-test after a few seconds.
When controller enable has been applied to control input S1IND, the frequency
inverter activates the “Ready” digital signal (to digital output S1OUT by default).
Guided set-up is called up automatically in the status as delivered and after reset-
ting to the factory settings. The control unit displays the “SEtUP” menu item from
the CTRL menu branch.
6.3.2 Setup The guided set-up of the frequency inverter determines all the relevant parameter
settings for the desired application. Selection from the available parameters is
made from known default applications for the drive unit technology. This makes it
easier to select the most important parameters, but it in no way replaces a subse-
quent check by the user. Once the SETUP routine has been successfully conclud-
ed, the actual value Actual frequency 241 is subsequently displayed from the VAL
menu branch in the control unit.
The guided set-up includes the function for parameter identification. The parameters
are determined by measurement and set accordingly. The motor should not have
been run before starting the measurement, since some of the motor data depends
on the operational temperature.
The commissioning “SetUP” appears automatically in the state as delivered.

Following successful set-up you can select the sub-menu CTRL in the main menu
and call up the “SEtUP” function again by means of the arrow keys.
Confirm the “SEtUP” display with the ENT key.
Parameter Configuration 30 appears. Enter the numbers 110, 210 or 410 with the
cursor keys (see the following section). End the input with the ENT key.
If the configuration has been changed, the hardware and software functions are
configured and the inverter is re-initialised. The guided “SEtUP“ starts again from
the beginning. Confirm the configuration with the ENT key.
Configuration Parameter Configuration 30 determines the control processes. The frequency

inverter software offers several configurations to choose from. The configurations
primarily differ in the way that the drive unit is controlled. The speed is input as a
frequency setpoint value.
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32
110 - U/f without encoder
Configuration 110 includes the functions for the variable speed control of a motor.
The motor speed is adjusted depending on the load and on the set reference fre-
quency.
210 - FOR speed control with encoder

May be used for hoist applications.
Configuration 210 includes the functions for speed-controlled field-oriented control
of a motor with encoder feedback. A separate regulation of the torque-forming and
the flux-forming current provides for a highly dynamic drive with a high load torque.
410 - FOR speed control without encoder

Factory setting, recommended for travel applications.
Possible min. frequency fmin = 5 Hz
Configuration 410 includes the functions for the field-oriented regulation of a
motor without encoder. The current motor speed is determined from the currents
and voltages at that moment in combination with the motor parameters. Parallel
switching of different motors is not possible in this configuration.
Data set After configuration, selection of the data set is displayed. Select the required Data
set ds with the cursor keys and confirm with the ENT key.
In data set 0 (factory setting), data sets 1 to 4 are saved with the same parameter
values. The standard application of the frequency inverter uses data set 1.
Motor data The motor data that is input in the following part of the guided set-up is to be taken
from the rating plate and the data sheet of the motor. The motor data set in the fac-
tory refer to the rated data of the frequency inverter. The other motor data required
for the control and regulation processes are calculated from the settings made
during the setup which are checked for plausibility.
Multi-motor drives can be operated with Dedrive Compact. Note that identical
motors must be used and that the motor cable lengths must be the same. The
sum of the motors must be entered for the rated current and rated output details
for multi-motor drives.
The rated values used in the factory settings must be checked and, if necessary,
changed by the user. Change the values with the cursor keys and confirm entry
with the ENT key.
Enter the lower of the two voltages for Demag ZBA motors with a wide voltage
range, e.g. 380 – 400 V.
Parameter no. Parameter name Unit Value Factory Description

Minimum Maximum setting
Motor data
370 Rated voltage V 60,0 800,0 U FUN
371 Rated current A Depends on type Depends on type I FUN
372 Rated speed min -1 96 60000 Depends on type
374 Rated cos (phi) - 0,01 1,00 Depends on type
375 Rated frequency Hz 10,00 1000,00 50,00
376 Rated Mech. Power kW Depends on type Depends on type P FUN
Only for configuration 2xx,
490 Operation Mode Encoder 1 - 1 - single 4 - quadruple 0 - off
see 7.7
491 Division marks encoder 1 - 1 8192 1024 Only for configuration 2xx
Only with extension module,
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493 Operation Mode Encoder 2 - 4x 104 x inverted 0 - off

see 7.7
494 Division marks encoder 2 - 1 8192 1024 Only with extension module
766 Source actual speed 1 – Rotary encoder 1 2 – Rotary encoder 2 2 – Rotary encoder 2 see 7.7
812 Cyclic duration factor - 40% 100% 100%
33
Plausibility check A check of the motor data should only be skipped by a suitably qualified and expe-
rienced user. The configurations include complex control procedures that depend
to a large extent on the correct motor data being entered. The warning and fault
messages displayed during the testing and checking should therefore be noted
carefully. If a critical state is detected during commissioning, this is displayed in the
control unit. In Parcom Compact, this is displayed in the parameter Status Motor
Parameter Identification 797. A warning or fault message is displayed according to
the deviation from the expected parameter value.
The warning message can be acknowledged with the ENT key and then commis-
sioning is continued. The parameter values that had been entered can be cor-
rected subsequently by pressing the ESC key.
Possible warning messages output during the plausibility check

SA000 There is no warning message. This message can also be read by an op-
tional communication card.
SA001 The rated voltage 370 is outside the FI nominal voltage range.
SA002 The rated current 371, the rated mech. power 376 and the rated voltage
370 must be checked. The calculated efficiency is within the limits for a
3-phase motor.
SA003 The rated cos phi 374 is outside the standard range (0,6 to 0,95).
SA004 The rated speed 372 and the rated frequency 375 must be checked. The
slip is within the limits for a 3-phase motor.
If a fault message appears, check and enter the parameterized rated data again.
Repeat commissioning until the rated values have been input without any faults.
Only experienced users should terminate commissioning prematurely by pressing
the ESC key, since some of the rated data is not correct.
Possible error messages output during the plausibility check

SF000 There are no error messages.
SF001 The rated current 371 that was entered is too low.
SF002 The rated current 371 is too high related to the rated mech. power 376 and
the rated voltage 370.
SF003 The rated cos phi 374 is wrong (more than 1 or less than 0,3).
SF004 The slip frequency calculated from the rated data is negative. The rated
speed 372 and the rated frequency 375 must be checked.
SF005 The rated speed 372 and the rated frequency 375 that were entered must
be checked, since the calculated slip frequency is too large.
SF006 The overall output calculated from the rated data of the drive unit it lower
that the figure that was entered for the rated output.
SF007 The configuration that was set is not supported by commissioning.
Configurations 110 and 410 are described in these brief instructions and
the unit must be set accordingly.
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34
Parameter identification The selected configuration requires the knowledge of additional motor data that
is not given on the motor rating plate. The parameter identification process can
detect the necessary motor data. The values measured while the drive unit is at
standstill can be entered directly or following calculation of the parameter. The
parameter identification sequence and duration varies according to the motor
connected and the unit rating and can take up to several minutes. The connected
motor is evaluated while the parameters are identified with the displayed signals.
During this procedure the motor may be braked firmly.
The commissioning sequence switches over to the functions for parameter
identification when the entered motor data have been checked.
Display “PAidE” must be confirmed by pressing the ENT key.
In Parcom Compact, the function is started with the parameter Motor
Parameter Identification 796 by selecting the value “10 – Self sett. Complete,
DS0”.
The frequency inverter safety functions prevent the power component from being
enabled unless digital input S1IND (controller enable) is connected.
If the controller enable signal is not applied to control input S1IND, the in-
verter reports “FUF” on the control unit. When the enable signal is applied,
the “FUF” message is deleted and the unit starts identifying the parameters.
The parameter identification of the frequency inverter requires the release of the
power module. Avoid any risks of severe personal injury or damage to valuable
assets by ensuring that only suitably qualified technicians work on the equipment.
Qualified persons are those who are familiar with the setting up, installation, com-
missioning and operation of frequency inverters and have the corresponding quali-
fications to carry out such work. Carefully read the documentation before starting
the work and comply with the safety instructions.
The concluding message “rEAdY” is to be confirmed with the ENT key.
For parameter identification any du/dt filter must be removed from the circuit
Parameter identification results in releasing the brake of a conical rotor

motor (Demag KB motor) without a torque being built up. Therefore, the
drive must always be secured against any unwanted movement.
During parameter identification, the “Release brake” function of the digital outputs
is not activated.
For further warning and error messages, see next page.

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35
Possible warning messages output during detection of the parameters
SA021 The stator resistance is very high. The following causes are possible:
SA022 The rotor resistance is very high. The following causes are possible:
SA041 The slip speed could not be correctly determined. Check the values
entered for the Rated speed 372 and Rated frequency 375 parameters.
Repeat identification of the parameters.
SA042 The slip speed could not be correctly determined. Check the values
entered for the Rated speed 372 and Rated frequency 375 parameters.
SA051 Motor data entered for star connection, but the motor is connected for
delta connection. Change the motor lead connections for operation with
star connection. Check the values entered for the rated motor values for
operation with delta connection.
SA052 Motor data entered for delta connection, but the motor is connected for
star connection. Change the motor lead connections for operation with
delta connection. Check the values entered for the rated motor values for
operation with star connection.
SA053 Measurements show asymmetric phases. Check the leads on the motor
and frequency inverter terminals for correct connection and check the
contacts (possibly corroded).
Possible error messages output during detection of the parameters
SF011 Measurement of main inductance has failed because the motor has high
slip. Correct the rated motor values in parameters 370, 371, 372, 374, 375
and 376.
SF012 Measurement of leakage inductance has failed because the motor has
high slip. Correct the rated motor values in parameters 370, 371, 372,
374, 375 and 376.
SF021 Measurement of the stator resistance provided no useful result. Check the
leads on the motor and frequency inverter terminals for correct connection
and check the contacts for corrosion and secure contact.
SF022 Measurement of the rotor resistance provided no useful result. Check the
leads on the motor and frequency inverter terminals for correct connection
and check the contacts for corrosion and secure contact.
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36
Cancelling the parameter identification sequence by pressing the ESC key or by
disabling the control release at the S1IND control input means that the values
will be incomplete. When the parameters have been identified, the “Read inverter
information” function must be performed in Parcom Compact.
Overview of control unit messages Control unit display Meaning

SEtUP Setup routine menu item;
CALC Plausibility check running;
PAidE Inverter is ready to identify parameters;
FUF No frequency inverter enable;
rEAdY Parameter identification completed;
End Commissioning routine finished;
rESEt Inverter is being reset
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37
Setpoint values The wide variety of applications for drive units, with the resulting parameter
settings, require additional parameters to be checked. The parameters that are
queried during the commissioning process are selected from known applications
and can be supplemented as required in the PARA menu.
Parameter no. Parameter name Unit Value Factory Explanation

setting
Minimum Maximum
Reference frequency channel
475 Drive control 10 = SOST 10 - SOST / 20 - SOSP (see 7.5 / 7.6)
Frequency limits
418 Minimum frequency Hz 0,00 300,00 3,50
419 Maximum frequency Hz 0,00 300,00 50,00
Frequency ramps
420 Acceleration Hz/s 0,00 999,99 10,00
421 Deceleration Hz/s 0,00 999,99 10,00
Setpoint steps
480 SOST step 1 Hz -300,00 300,00 5,00 Input (SOST) step 2 = 0
The control unit shows the End message that you should confirm with the ENT key.
Commissioning of the frequency inverter is concluded with a reset and initialization
of the frequency inverter. The Dedrive Compact reports a fault during initialization.
The parameter Actual frequency 241 that is defined in the factory settings is dis-
played in connection with fault-free initialization of the frequency inverter.
The commissioning process makes it easier for you to select the main parameters
and determines additional rated data for the motor. If the settings for the parameters
were determined via the optional operating software or the PARA menu branch of
the control unit, display of the selected actual value has to be activated manually.
The setup function appears when the frequency inverter is switched on, and you can
quit this by pressing the ESC key. Change to the VAL menu branch and select the
desired actual value to be displayed in future. Press the ENT key to display the value
of the parameter and press the ENT key again to select the actual value for a new
start.
Checking the direction of rotation The relationship between the reference value and the actual direction of rotation of
the drive unit must be checked. The check should be made as follows. Input a ref-
erence value of around 10 % and briefly switch on the release for the inverter (con-
trol inputs controller enable (S1IND) and SW step 1+ or controller enable (S2IND)
and SW step 1-). Check that the motor shaft is turning in the right direction as the
drive unit accelerates. In addition to checking the drive unit, the corresponding
actual values and the operational messages can be read with the aid of the control
unit. If the direction of rotation is wrong, for example, then swap over two of the
motor at the terminals of the frequency inverter, e.g., U and V. The connection of
the frequency inverter at the mains has no effect on the direction of rotation of the
drive unit.
Commissioning of the frequency inverter has been completed and can now be
supplemented by further settings in the PARA menu. The selected parameters are
adequate for commissioning in most cases. Testing and checking additional set-
tings that are relevant for the application is to be done on the basis of the operating
instructions.
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38
7 Parameters/functions
7.1 Introduction The following tables show the basic parameter values. If no other parameter infor-
mation is specified in the order, the unit is supplied with these standard settings.
For configuring and programming the parameters of the inverter, a PC with Parcom
Compact parameter programming software, which is connected to one of the op-
tional RS 232 modules 537 769 84 or 537 723 84 via data cable 537 237 84 can
be used.
Alternatively, the control unit can also be used to program the parameters.
In these operating instructions, control level 1 is described.

7.2 Reset The Program(ming) 34 parameter makes it possible to acknowledge an error mes-
sage and to restore the factory setting. The display of the operating unit shows the
message “dEFLt” or “rESEt” and the LEDs additionally indicate the status of the
frequency inverter.
Parameter no. Parameter name Value Function

A reset is carried out, an existing error is acknowledged.
123
The display of the operating unit shows the message “rESEt”.
34 Program(ming) The parameters set within the configuration selected are overwritten
4444 with the factory-set values. The display of the operating unit shows
the message “dEFLt”.
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39
7.3 Brake application time The inverter calculates an internal frequency cut-off value on the basis of the brake
application time and the deceleration ramp. This also considers a programmed DC
post-magnetization time parameter. At the moment the setpoint value is switched
off, the inverter compares the actual output frequency with the calculated cut-off
value. In principle, there are 3 possibilities as shown in cases 1 to 3.
Case 1: The brake application time is shorter than the remaining deceleration time
“Modulation on” signal
“Release brake” signal
“SPV step 1+” input
Output frequency
Calculated cut-off value
tB: Brake application time

tVZ: Deceleration time 42265444.jpg
In case 1, the brake application time is shorter than the remaining deceleration
time. The “Release brake” signal is switched off as soon as the value drops below
the cut-off value. The brake is no longer excited and the mechanical brake starts to
brake when its application time has elapsed. If the brake application time is cor-
rectly programmed, the ramp is at zero at the same moment and the modulation is
switched off.
Case 2: The brake application time is longer than the remaining deceleration time
Output frequency

tVZ: Deceleration time
tGS: DC post-magnetization time 42265544.jpg
In case 2, the brake application time is longer than the remaining deceleration
time. The “Release brake” signal is switched off immediately and the inverter cal-
culates a DC post-magnetization time. The output frequency decreases to zero
at the ramp and the modulation then remains switched on. For the calculated DC
post-magnetization time, the inverter outputs a DC. This causes the motor to ex-
hibit eddy-current braking characteristics until the mechanical brake engages.
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40
Case 3: The brake application time is interrupted by an integrator stop, for example
Integrator stop
Output frequency

tVZ: Deceleration time
tGS: DC post-magnetization time 42265644.jpg
Case 3 shows an interrupted brake application time. The cause of this may be
another valid setpoint or an integrator stop due to an overload. In both cases, the
calculation is restarted as in case 2. The DC post-magnetization time is extended
correspondingly.
Parameter Parameter name Unit Value Factory Description

no. setting
Minimum Maximum
Operating characteristics→ Brake control
825 Brake application time ms 0 2000 100
7.4 Error When an acknowledgement has been successfully completed, the “Error” message
is cancelled and the “Ready” message is set. If the cause of the error has not been
acknowledgement eliminated, the error is reported again.
All error information is saved in the error memory (see section 8). The information
from the error memory can help you and after-sales service personnel to eliminate
any errors.
The following error acknowledgement possibilities are available:
1. Briefly de-activating the digital input S1IND (factory setting of parameter 103)
2. Disconnect and restore the line power supply
The waiting time depends on the type of unit. If power is restored too soon,
the error will not be acknowledged. When the power is restored, the unit will
re-initialize.
Dedrive Compact inverters may only be connected to the line supply

every 60 seconds.
3. Actuating the stop key on the control unit
4. Setting the Program(ming) 34 parameter to value 123

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41
7.5 Digital inputs Please also consider the details relating to the technical data on the inputs
and outputs in section 5.5.6.
and outputs
7.5.1 Function assignment of the Depending on the required control mode, there are varying assignments of the
digital inputs digital inputs for setpoint value generation. In addition, there are also other unused
inputs that can be assigned additional functions.
Control modes The following functions can also be selected for the parameter Control 475:
No. of assigned
Designation of basic functions Description
digital inputs
2 direction signals (step 1) and 1 further
10 - SOST 3
speed (see section 7.4)
2 direction signals (step 1)
20 - SOSP 3
and acceleration (see section 7.5)
For further information and other control types, see application guidelines /
operating instructions.
Input functions The following functions can be assigned to the inputs:

Parameter no. Parameter name Unit Value Factory setting See section
Minimum Maximum
Control inputs/outputs→ Digital inputs
68 SPV-Step 1+ 71 - S2IND 7.5, 7.6
69 SPV-Step 1 - 72 - S3IND 7.5, 7.6
66 (SOST) Step 2 75 - S6IND 7.5
62 (SOSP) Acceleration 75 - S6IND 7.6
7.5.2 Function assignment of the The following are available:

relay and digital inputs 1 digital output with transistor output Mode of operation digital output 1 S1OUT 530
1 relay output with change-over contact Mode of operation digital output 3
S3OUT 532
1 multi-function output, digital assignment possible Mode of operation MFO1D 554
“Ready” message The inverter indicates it is ready for operation via a programmable output by
switching it to active mode. Setpoint values are only processed when the unit is in
Ready mode (factory setting Digital output 1 530 terminal S1OUT).
In the following situations, the inverter is not ready for operation:

• After the power supply has been switched on, during the initialization phase.
• When the internal supply voltage has dissipated (after approx. 0,5 to 5 seconds)
after the power supply has been switched off.
• If no enable signal is applied.
• When an error has been detected and the system is responding to the error.
214708k3.indd/250909
• When an error has not yet been acknowledged.
42
“Error” message When an error has occurred, the programmed output is activated. The output re-
mains activated until the error has been acknowledged (set in the factory to multi-
function output MF01).
“Setpoint value reached” message When the specified setpoint value is reached, this function activates the pro-
grammed output. The output remains activated until a new setpoint value initiates
acceleration or deceleration operations. The limitation function is also evaluated
as a setpoint value and a message is also output when the limitation frequency
is reached.
“Release brake” signal The inverter provides further parameters for synchronizing a separate brake.
Due to its higher voltage load rating up to 230 V, a power contactor for control of
the external brake can be controlled direct with relay 3 (set in the factory to relay
output S3OUT).
“Modulation on” signal The programmed output is activated when the inverter output is active.
7.6 Creating setpoint

values in steps (SOST)
Operating principle: All reference step functions are activated when current flows through the relevant
General information input. The input signals are filtered by the hardware and software.
To obtain a valid reference value, an edge from “off” to “on” must be created follow-
ing the ready for operation signal.
Edge evaluation is only possible if the inverter is ready for operation. Edge
signals given too early will not be detected and have to be repeated.
Reference value step function The steps do not work on the basis of summation. A lower value may be pro-
grammed to a higher step than for a lower one. The current reference value is
always specified by the highest step that is switched on.
When the first step SPV step 1+ 68 is applied, the inverter accelerates up the
Acceleration 420 ramp to the frequency value programmed for SOST step 1 480.
If a signal is applied to the (SOST) step 2 input in addition to SVP step 1+ 68, the
inverter accelerates or decelerates to the frequency value of parameter SOST
step 2 481. The signal must remain applied to the SPV-Step 1+ 68 input for acti-
vating higher steps.
If no signal is applied to the SPV step 1 + 68 input any longer, the inverter will
decelerate down Deceleration 421 ramp to 0 and will switch off the output stage.
If a signal is applied for the opposite direction SPV-step 1– 69 before zero is
reached, the inverter will accelerate in the opposite direction after reaching 0
without switching off the “Release brake” signal.
The setpoint value step function works in the “-” direction in the same way.
If both SPV step 1+ 68 and SPV step 1– 69 inputs are activated simultaneously,
the inverter will evaluate this status as an invalid setpoint value. It would respond
in the same way as if neither of the inputs were active.
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43
SOST input assignment The table below shows the assignment of the digital inputs as delivered. The as-
(factory setting) signment can be freely re-programmed.

no. setting
Minimum Maximum
Control inputs/outputs → Digital inputs
68 SPV-Step 1+ 71 - S2IND
69 SPV-Step 1 - 72 - S3IND
66 (SOST) Step 2 75 - S6IND
SOST Relevant parameters

no. setting
Minimum Maximum
Setpoint values → SOST parameter
The frequency limits and frequency ramps apply, see section 6.3.2 “Setpoint
values” table (page 29).
For further information (SOST step 3 and SOST step 4), see application
guidelines / operating instructions.
Setpoint value steps 2-step diagram
“(SOST) Step 2” input
Frequency value
“SOST step 2” 481
Frequency value
“SOST step 1” 480
Time
42267545.jpg
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44
7.7 Creating stepless setpoint
values with memory
function (SOSP)
Operating principle: All setpoint value memory functions are activated when current flows through the
General information relevant input. The input signals are filtered by the hardware and software.
To obtain a valid setpoint value, an edge from “off” to “on” must be created follow-
ing the ready for operation signal.
Edge evaluation is only possible if the inverter is ready for operation. Edge
signals given too early will not be detected and have to be repeated.
Setpoint value memory function This setpoint value creation function is specially designed for use with 2-stage
pushbuttons. A 2-stage pushbutton is required for each direction of rotation. The
first step actuates the SPV-step 1+ 68 or SPV-step 1– 69 input. The second step
actuates the relevant “(SOSP) Accelerate” input.
When the first step SPV-Step 1+ 68 is applied, the inverter accelerates up the
Acceleration 420 ramp to the value of parameter Min. frequency 418. If a signal is
applied to the “(SOSP) Accelerate” input in addition to the SPV step 1+ 68 input,
the inverter will continue to accelerate up the Acceleration 420 ramp. Acceleration
can be interrupted by switching off the signal at the “(SOSP) Accelerate” input. If
the signal remains applied to the SPV-Step 1+ 68 input, the inverter will save the
current frequency reference value to memory. The acceleration operation can be
continued at any time until the Max. frequency 419 parameter value is reached.
The signal applied to the SPV-Step 1+ 68 input must be switched off to start de-
celerating. The inverter will then reduce its frequency down the Deceleration 421
ramp. If the SPV-Step 1+ 68 input is activated once more, the inverter will save
the current frequency to memory, but only if it is still higher than the Min. frequency
418 parameter value. If the current value is lower than the Min. frequency 418
parameter value, the inverter will accelerate to the Min. frequency 418 parameter
value. Frequency values between 0 and Min. frequency 418 cannot be achieved
with this reference value control when stationary.
If the SPV-Step 1+ 68 signal remains switched off, the inverter will reach zero and
switch off the output stage.
If a signal is applied for the opposite direction SPV-step 1– 69 before zero is
reached, the inverter will accelerate in the opposite direction after reaching 0 with-
out switching off the “Release brake” signal.
The “–” direction of rotation works in the same way.
If both SPV-step 1+ 68 and SPV-step 1– 69 inputs are activated simultaneously,
the inverter will evaluate this status as an invalid setpoint value. It would respond
in the same way as if neither of the inputs were active.
214708k3.indd/250909
45
SOSP input assignment The table below shows the assignment of the digital inputs as delivered. The as-
(factory setting) signment can be freely re-programmed.

no. setting
Minimum Maximum
Control inputs/outputs → Digital inputs
68 SPV-Step 1+ 71 - S2IND
69 SPV-Step 1 - 72 - S3IND
62 (SOSP) Acceleration 75 - S6IND
SOSP The frequency limits and frequency ramps, see section 6.3.2 “Setpoint values”
Relevant parameters table (page 29) apply.
Reference value memory diagram
“(SOSP) Acceleration” input
Maximum frequency 419
Minimum frequency 418
Time
42267644.jpg 214708k3.indd/250909
46
7.8 Encoders The speed actual value needs to be measured continuously for the control and
regulation process for some of the available Configurations 30. The required
incremental encoder can be connected to digital control terminals S5IND (track A)
and S4IND (track B) of the frequency inverter.
Operating modes 490 and 493 for encoders 1 and 2 are deactivated by
default in Software 6.
In 2xx configurations, the user must activate the operating mode of the
encoder that is used and set Actual speed source 766 accordingly.
Please note section 5.5.4 for the encoder cable.
7.8.1 Encoder 1 operation mode Select Operation mode 490 for encoder 1 in accordance with the connected in-
cremental encoder. A unipolar encoder must be connected to the standard control
terminals.
Operation mode Encoder 1 490 Encoder 1

0 - Off (default setting) Speed detection is not active; the digital
inputs may be used for other functions.
1 - Single evaluation Double channel encoder with direction
of rotation detection via track signals A
and B; one signal flank is evaluated for
each division mark.
4 - Quadruple evaluation Double channel encoder with direction
of rotation detection via track signals A
and B; four signal flanks are evaluated
for each division mark.
11 - Single evaluation unsigned Single channel encoder via track sig-
nal A. The speed actual value is posi-
tive. One signal flank is evaluated for
each division mark. Digital input S4IND
may be used for other functions.
12 - Double evaluation unsigned Single channel encoder via track sig-
nal A. The speed actual value is posi-
tive. Two signal flanks are evaluated for
each division mark. Digital input S4IND
may be used for other functions.
101 - Single evaluation inverted As for operation mode 1. The speed
actual value is inverted. (Alternative to
swapping the track signals)
104 - Quadruple evaluation inverted As for operation mode 4. The speed
actual value is inverted. (Alternative to
swapping the track signals)
111 - Single evaluation negative As for operation mode 11. The speed
actual value is negative.
112 - Double evaluation negative As for operation mode 12. The speed
actual value is negative.
7.8.2 Encoder 2 operation mode A further encoder input is available when an extension module is fitted. It is pro-
grammed by means of the Encoder 2 operation mode 493 parameter.
The Actual speed source 766 parameter must be set accordingly.

For further details: see the extension module operating instructions
214708k3.indd/250909
Integrated encoders of KB motors with S31 electronics may only be operated

with an EM-ENC-02 extension module with a 24 V power supply if the terminating
resistor of the EM-ENC-02 unit is deactivated.
47
7.8.3 Encoder 1 division marks The parameter for the number of increments for the connected encoder must be
programmed via the Encoder 1 division marks 491 parameter. Select the division
mark for encoder 1 in accordance with the application speed range.
The maximum number of division marks Smax is defined by the limit frequency
fmax = 150 kHz of digital inputs S5IND (track A) and S4IND (track B).
60 s / min
Smax = 150 000 Hz x nmax = Max. speed of motor in rpm
nmax
To ensure good motor running characteristics, an encoder signal must be evalu-

ated at least every 2 ms (signal frequency f = 500 Hz). Based on this requirement,
the minimum division mark Smin of the incremental encoder can be calculated for
a required minimum speed nmin.
60 s / min nmin = Min. speed of motor in rpm

Smin = 500 Hz x
A x nmin A = Evaluation (1, 2, 4)

Motor data → Encoder 1
491 Encoder 1 division marks - 1 8192 1024
7.8.4 Encoder filter time constant The encoder signal can be filtered with parameter 815 Encoder filter time constant
to improve the control characteristics for small division marks.

Motor data → Encoder 1
815 Encoder filter time constant ms Off 128 Off
7.9 Frequency switch-off The maximum permissible output frequency of the frequency inverter must be
set with the Frequency switch-off limit 417 parameter. If this frequency limit is ex-
limit ceeded by Stator frequency 210, or Actual frequency 241, the frequency inverter
switches off and outputs error message “F1100”.
For configurations 110 “U/f characteristic” and 410 “FOR speed without encoder”,
encoder 1 can be activated by means of parameter Operation mode 490 for addi-
tional monitoring of the measured actual frequency.

Error/warning behaviour
417 Frequency switch-off limit Hz 0,00 999,99 100,00
7.10 Max. frequency The difference between the actual frequency and the integrator frequency is
monitored by this function. If the difference exceeds the value of the Maximum
deviation frequency deviation 429 parameter, the unit switches off and outputs error
message 1102 “Maximum frequency deviation”.
This function is only activated for configuration 210 when the unit leaves the
factory.
214708k3.indd/250909

Error/warning behaviour
429 Max. frequency deviation Hz 0,01 15,00 5,00
48
8 Diagnosis
Operation of the frequency inverter and the connected load is constantly moni-
tored.
For further information (Operation and fault diagnosis), see application

guidelines / operating instructions.
8.1 Status message
42554944.jpg
The red green LED’s provide information on the operational point of the frequency
inverter. If the control unit is plugged in, status messages are also displayed by
display elements RUN, WARN and FAULT.
Status display
Green LED Red LED Display Description
0 0 - No power supply
1 1 - Initialization and self-test
Flashes 0 RUN flashes with S1IND = LOW: Ready, no modulation
Flashes 0 RUN flashes with S1IND = HIGH: Ready for operation,
no modulation
1 0 RUN Operational message
1 Flashes WARN Operational message, current Warn-
ings 269
Flashes Flashes WARN Ready for operation, current Warnings 269
0 Flashes FAULT flashes Display: Current error 259 of the frequency
inverter
0 1 FAULT Display: Current error 259, error can be
reset. See section 7.3
8.2 Warning message The code that is read by the Warnings 269 parameter can be made up of several
different messages. For example, code A0088 is made up of the separate warning
messages A0008 + A0080. See section 6.3.2 for SAxxx and SFxxx messages.
Code Acronym Meaning

A0000 - No warning messages.
A0001 Ixt Frequency inverter overloaded, warning code A0002 or A0004.
A0002 IxtSt Frequency inverter overloaded (10 sec), check load behaviour.
A0004 IxtLt Overload (60 sec), check motor and application parameters
A0008 Tc Max. heat sink temperature reached, check the cooling and fan.
A0010 Ti Max. inside temperature reached, check the cooling and fan.
A0020 LIM Speed reference values are being limited by a controller.
A0040 LK Load spectrum: 90% of hoist duration of service elapsed.
A0080 PTC Max. motor temperature reached, check the motor and sensor.
A0001 Mains Mains phase failure, check the mains Fuse links and cable.
A0200 PMS Software motor circuit breaker.
A0400 Flim Limit frequency reached, the output frequency is limited.
214708k4.indd/250909
A0800 A1 MFI1A input signal is lower than 1 V / 2 mA.

A1000 A2 EM-S1INA input signal is lower than 1 V / 2 mA.
A2000 Sysbus A slave on the system bus has reported an error.
A4000 UDC DC link voltage has reached the minimum limit for that particular type.
A8000 Toggle bit Field bus monitoring reports bus system failure. 49
8.3 Error messages The fault code that is stored in parameter Last Fault 310 after a fault occurs makes
troubleshooting much easier. The fault code is made up of fault group FXX and the
following code number XX.
The fault message is cleared via the keys of the control unit, (see section 7.2.6).
See section 6.3.2 for SAxxx and SFxxx messages.
Error messages
Code Meaning
F00 00 No fault has occurred.
Overload
F01 02 Frequency inverter overloaded (60 sec), check the load behaviour.
03 Short-term overload (10 sec), check the motor and application pa-
rameters
Heat sink
F02 00 Heat sink temperature too high, check the cooling and fan
01 Temperature sensor defective or ambient temperature too low.
Inside temperature
F03 00 Inside temperature too high, check the cooling and fan.
01 Inside temperature too low, check the electrical cabinet heating.
Motor connection
F04 00 Motor temperature too high or sensor defective,
check motor thermo-contact connection.
01 The software motor circuit breaker has tripped.
03 Motor phase failure, check the motor and wiring.
Output current
F05 00 Overloaded, check the load relationships and ramps.
03 Short circuit or earth fault, check the motor and wiring.
05 Asymmetrical motor current, check the motor and wiring.
06 Motor phase current too high, check the motor and wiring.
07 Message from the phase monitoring, check the motor and wiring.
Link voltage
F07 00 DC link voltage too high, check the deceleration ramps and brake
resistor that is connected.
01 DC link voltage too low, check the mains voltage.
02 Mains failure, check the mains voltage and circuit.
03 Phase failure, check the mains fuse and voltage.
04 Mains voltage UDC too high when switching on, check the voltage.
05 Mains voltage BC too high when switching on, check the voltage.
06 Mains voltage MC too high when switching on, check the voltage.
Electronics voltage
F08 01 Electronics voltage 24 V too low, check the wiring of the terminals.
04 Electronics voltage too high, check the wiring of the terminals.
Optional components
F0B 13 The communications module at slot B was installed without discon-
nection from the mains supply, disconnect the mains supply.
214708k4.indd/250909
50
Output frequency
F11 00 Output frequency too high, check the control signals and settings.
01 Max. frequency reached by the controller, check the deceleration
ramps and brake resistor that is connected.
02 The value for the max. frequency deviation has been exceeded
See section 7.9.
Motor connection
F13 00 Earth fault at output, check the motor and wiring.
10 Min. current monitoring, check the motor and wiring.
Control connection
F14 01 Setpoint value signal at multifunction input 1 missing, check the
signal.
02 Setpoint value signal missing at analogue input EM-S1INA, check the
signal.
07 Overcurrent at multifunction input 1, check the signal.
30 Encoder signal is defective:
- Check connections S4IND and S5IND;
- Check connections on EM-xxx expansion module;
- Encoder 2 is active, but the expansion module is not fitted.
31 One encoder signal track missing, check the connections.
32 Incorrect direction of rotation from the rotary encoder, check
connections.
40 No encoder active (only from Software 6 and above).
Field bus communication
F20 xx Profibus
F21 xx System bus
F22 xx System bus
9 Maintenance
Ensure compliance with the safety instructions in section 1.4.
Maintenance:
Frequency inverters are largely maintenance-free.
Make sure that there is adequate ventilation, e.g. by:
• regular removal of dust deposits
• cleaning or replacing impermeable filters (such as door filter in switchgear
cabinet)
The storage period must not exceed 1 year.

Frequency inverters must be connected to a line power supply for a duration
of one hour before a year elapses. The storage period may then be extended
to a further year.
214708k4.indd/250909
51
10 Technical data
10.1 DIC-4-002 to 009 The following data are related to the nominal working point of the frequency inverter.
The nominal working point of the frequency inverter is defined for a permissible
frequency inverters mains voltage of 400 V and a modulation frequency of 2 kHz.
Size 1 2
Current code DIC-4-... 002 003 004 006 007 009
Motor-side output
Output current I A 2,4 3,2 3,8 5,8 7,3 9,0
Output voltage U V 3 x 0 ... Line voltage
1,5 for 60 s;
Overload capability at 2 kHz and 4 kHz - -
2,0 for 10 s (10 min. cycle)
0 ... 300 depending on modulation
Rotary field frequency f Hz
frequency
Modulation frequency f kHz 2 ... 16
Min. brake resistor R Ω 462 300 220 148 110 92
Line-side input
Line current 2) 3 ph / PE I A 2,4 2,8 1) 3,3 1) 5,8 6,4 1) 7,8 1)
Line voltage U V 3 x 380 to 480 +10% / -15%
Fuses 3 ph / PE I A 6 10
Mechanical equipment
Dimensions HxWxD mm 190x60x180 250x60x180
Connecting terminals A mm² 0,2 ... 1,5
Mounting arrangement - - vertical
Ambient conditions
Power loss P W 46 58 68 87 108 130
Coolant temperature Tn °C 0 ... 40 (3K3 DIN IEC 721-3-3)
Storage temperature TL °C -25 ... 55
Transport temperature TT °C -25 ... 70
Rel. humidity - % 15 ... 85, non-condensing
Depending on the customer-specific requirements the modulation frequency may

be increased, if the output current is reduced. The relevant standards and regula-
tions must be complied with for this working point.
Output current in A Hardware DIC-4-xxx-E-0000-01

and software from 4.2.4/050-6
Current code 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz
002 2,4 2,4 2,4 2,0 1,6
003 3,2 1) 3,2 1) 3,2 1) 2,7 1) 2,2
004 3,8 1) 3,8 1) 3) 3,8 1) 3) 3,2 1) 3) 2,6 3)
006 5,8 5,8 5,8 4,9 3,9
007 7,8 1) 7,8 1) 7,8 1) 6,6 1) 5,3
009 9,0 1) 9,0 1) 3) 9,0 1) 3) 7,6 1) 3) 6,1 3)
The modulation frequency may be automatically reduced as a function of the

214708k4.indd/250909
overload.
1) Line reactor required for a duty factor > 60% CDF

2) Mains current with a relative line impedance of 1% (see section 5)
52 3) Modulation frequency reduced in thermal limit range
Size 3 4
Current code DIC-4-... 014 017 025 032 040
Motor-side output
Output current I A 14 16,5 25 32 40
1,5 for 60 s; 1,4 for 60 s;
Overload capability at 2 kHz - - 2,0 for 10 s 1,6 for 10 s
(10 min. cycle)
1,5 for 60 s; 1,4 for 60 s; 1,3 for 60 s;
Overload capability at 4 kHz - - 2,0 for 10 s 2,0 for 10 s 1,6 for 10 s
(10 min. cycle)
Rotary field frequency f Hz 0 ... 300 depending on modulation frequency
Min. brake resistor R Ω 58 48 32 24 24
Line-side input
Line current 2) 3 ph / PE I A 14,2 14,5 1) 26 28,2 1) 35,6 1)
Fuses 3 ph / PE I A 16 20 35 50
Connecting terminals A mm² 0,2 ... 6 0,2 ... 16
Ambient conditions
Power loss P W 145 180 240 310 420


014 14,0 14,0 14,0 11,8 9,5
017 16,5 1) 16,5 1) 16,5 1) 13,9 1) 11,2
025 25,0 25,0 25,0 21,0 17,0
032 32,0 1) 32,0 1) 32,0 1) 26,9 1) 21,8
040 40,0 1) 38,3 1) 35,0 1) 29,4 1) 23,8 1)

214708k4.indd/250909
overload.

2) Mains current with a relative line impedance of 1% (see section 5) 53
Size 5 6
Current code DIC-4-... 045 060 075 090 110
Motor-side output
Output current I A 45 60 75 90 110
1,5 for 60 s;
Overload capability at 2 kHz and 4 kHz - -
2,0 for 10 s (10 min. cycle)
0 ... 300 depending on modulation frequen-
Rotary field frequency f Hz
cy
Min. brake resistor R Ω 15 7,5
Line-side input
Line current 2) 3 ph / PE I A 52 58 1) 72 86 1) 105 1)
Fuses 3 ph / PE I A 63 80 100 125
Weight (approx.) m kg 8 20
Connecting terminals A mm² 1,5 ... 25 Max. 70 (threaded studs)
Ambient conditions
Power loss P W 420 540 660 770 1060


045 45,0 45,0 45,0 - -
060 60,0 1) 60,0 1) 60,0 1) - -
075 75,0 75,0 75,0 - -
090 90,0 1) 90,0 1) 90,0 1) - -
110 110,0 1) 110,0 1) 110,0 1) - -

214708k4.indd/250909
overload.

54 2) Mains current with a relative line impedance of 1% (see section 5)
10.4 Operating diagrams The technical data for the frequency inverter relates to the nominal working point
that was selected for a wide range of applications. It is possible to apply a function-
ally safe and economical dimensioning (derating) of the frequency inverter via the
following diagrams for specific applications.
Power reduction (derating); Max. coolant temperature;

5% / 1000 m for more than 1000 m 3,3°C / 1000 m for more than 1000 m
above sea level; above sea level;
hmax = 4000 m
Coolant temperature in °C
Output current in %
Installation height in m above Installation height in m above

sea level sea level
Power reduction (derating); Power reduction (derating);

2,5% / K above 40°C; Tmax = 55 °C 0,22% / V above 400 V; Umax = 480V
Output current in %
Output current in %
Coolant temperature in °C Mains voltage in V
42555044.jpg
214708k4.indd/250909
55
10.5 Accessories
Line capaci-
Line fuses Line filter Notes
tors
D-close-tolerance bolt
Rated output at 2 kHz
Recommended fuses
Low leakage current

Dedrive Compact
10 m motor cable
50 m motor cable
10 m motor cable
D-fuse socket
D-screw cap
D-fuse T
Class B
Class B
Class B
3-pole
(1 off)
(1 off)
(1 off)
Type Part no. Part no. Part no. Part no. Part no. Part no. Part no. Part no.
DIC-4- [kW] [A] 1) 1) 1)
002 0,75
In
003 1,1 6 451 663 99 575 049 44 451 700 99 504 905 99 537 739 84 Internal 537 748 84
preparation
004 1,5
006 2,2 537 740 84
In
007 3 10 451 643 99 575 049 44 451 700 99 504 906 99 Internal 537 748 84
537 741 84 preparation
009 4
014 5,5 16 451 644 99 537 742 84 In
575 049 44 451 700 99 504 907 99 Internal 537 749 84
017 7,5 20 451 645 99 537 743 84 preparation
025 11 537 744 84
35 451 647 99 504 910 99 In
032 15 575 051 44 451 701 99 537 745 84 537 747 84 537 750 84
preparation
040 18,5 50 451 648 99 504 911 99
537 753 84
045 22 537 891 84 2) In
63 451 649 99 575 051 44 451 701 99 504 912 99 -
060 30 537 193 84 537 892 84 2) preparation
075 37 80 894 317 44 3) 537 893 84 2)
090 45 100 894 318 44 894 315 44 - - 537 195 84 - - NH00-fuse links
537 894 84 2)
110 55 125 894 319 44 537 196 84
1) 3 off each required for line supply protection.
2) Limit value also for 100 m cable length
3) Line reactor is not needed
Standard braking resistor Overcurrent relay Output filter Notes

Rated output at 2 kHz
Continuous rating
Dedrive Compact
Resistive value
Setting range
Setting value
Type
Type Part no. Part no. Part no.

max. output frequency
DIC-4- [kW] [Ω] [kW] [A] [A] 60 Hz 87 Hz 200 Hz
002 0,75 470 537 728 84 0,55 - 0,8 0,65 3RU1116-0HB1 537 751 84 537 757 84 537 758 84
003 1,1 330 0,2 537 729 84 0,78 -
0,7 - 1,0 3RU1116-0JB1 537 239 84 537 759 84 537 760 84
004 1,5 220 537 730 84 0,95
006 2,2 150 537 731 84 1,63 537 763 84 537 764 84
0,4 1,4 - 2,0 3RU1116-1BB1 537 240 84
007 3 120 537 732 84 1,83 537 765 44 - 537 766 44
009 4 100 0,6 537 733 84 2,2 - 3,2 2,45 3RU1116-1DB1 537 241 84 537 767 84 537 768 84
014 5,5 68 0,6 537 734 84 2,2 - 3,2 2,97 3RU1116-1DB1 537 241 84 537 154 84 537 171 84
-
017 7,5 56 0,8 537 735 84 3,5 - 5,0 3,78 3RU1116-1FB1 537 243 84 537 155 84 537 172 84
025 11 33 1,2 537 736 84 5,5 - 8,0 6,03 3RU1116-1HB1 537 245 84 537 156 84 537 173 84
032 15 1,6 537 737 84 7,70 537 157 84 537 174 84
27 7,0 - 10,0 3RU1116-1JB1 537 246 84
040 18,5 2,0 537 738 84 8,61 -
537 158 84 537 175 84
214708k4.indd/250909
045 22
15,4 3,5 534 632 84 14 - 20 15,00 3RU1126-4BB1 537 249 84
060 30 537 159 84 537 176 84
075 37 537 160 84 537 177 84
8,2 5,0 537 816 84 22 - 32 24,7 3RU1136-4EB1 537 252 84
090 45 - 537 161 84 537 178 84
56 110 55 8,0 10,0 538 776 84 28 - 40 35,4 3RU1136-4FB1 537 253 84 537 162 84 537 179 84
Option modules / Options Notes
Type Designation Part no.
DIC-4-
KP 232 interface converter 537 769 84
CM RS 232 communication module 537 723 84
CM RS 485 communication module 537 724 84
CM CAN-bus communication module 537 726 84
EM system bus expansion module 537 727 84
002 to 110
EM I/O-02 extension module (I/O extension) 537 867 84
1,8 m data cable 537 237 84
Parcom Compact CD parameter programming software 537 752 84
CM-PDP-24-Kit communication module (Profibus + external 24 V power supply) 537 898 84
EM ENC-02-24 extension module (rotary encoder evaluation) 537 899 84
KP CMK switchgear cabinet fitting accessories 537 869 84 for KP 232 and KP 500
002 to 004 DIC connector set size 1 538 008 33
006 to 009 DIC connector set size 2 538 009 33
002 to 110 DIC X210 connector set 538 010 33
002 to 009 Screen fitting set size 1/2 537 770 84
014 to 017 Screen fitting set size 3 537 771 84
The CM-PDP-24 communications module in kit 537 898 84 contains an additional

possibility for an external 24 V supply compared to CM Profibus communications
module 537 725 84.
The CM-PDP-24 Code 179-675 122 communications module in kit 537 898 84
must not be combined with the EM-ENC-02 extension module (537 868 84 / Code
179-675 021) when used with the external 24 V supply.
However, the CM-PDP-24 Code 179-675 122 communication module in kit

537 898 84 may be combined with the EM-ENC-02-24 extension module
(537 899 84 / Code 179-675 041).
The code number is clearly applied to the front of the modules.

214708k4.indd/250909
57
11 Parameters
Parameter no. Parameter name Unit Value Factory setting See section
Minimum Maximum
General inverter parameters
12 Inverter software version
28 Control Level
30 Configuration 110 410 410 - sensor-less FOR 6.3.2
33 Language 0 - German
62 (SOSP) Acceleration 75 - S6IND 7.6
66 (SOST) Step 2 75 - S6IND 7.5
68 SW-Step 1+ 71 - S2IND 7.5, 7.6
69 SW-Step 1 - 72 - S3IND 7.5, 7.6
370 Rated voltage V 60,0 800,0 U FUN 6.3.2
Depends on Depends on
371 Rated current A I FUN 6.3.2
type type
372 Rated speed min -1 96 60000 Depends on type 6.3.2
374 Rated cos (phi) - 0,01 1,00 Depends on type 6.3.2
375 Rated frequency Hz 10,00 1000,00 50,00 6.3.2
Depends on Depends on
376 Rated Mech. Power kW P FUN 6.3.2
type type
417 Frequency Switch-off Limit Hz 0,00 999,99 100,00 7.8
418 Minimum frequency Hz 0,00 300,00 3,50 6.3.2
419 Maximum frequency Hz 0,00 300,00 50,00 6.3.2
420 Acceleration Hz/s 0,00 999,99 10,00 6.3.2
421 Deceleration Hz/s 0,00 999,99 10,00 6.3.2
429 Max. frequency deviation Hz 0,01 15,00 5,00 7.9
473 Ramp keypad motorpoti Hz/s 0,00 300,00 2,00 6.1.3
475 Drive control 10 = SOST 6.3.2
480 SOST step 1 Hz -300,00 300,00 5,00 6.3.2, 7.5
481 SOST step 2 Hz -300,00 300,00 50,00 6.3.2, 7.5
490 Operation Mode Encoder 1 - 1 - single 4 - quadruple 0 - off 1) 7.7.1
491 Division marks encoder 1 - 1 8192 1024 7.7.3
493 Operation Mode Encoder 2 - 1 - single 4 - quadruple 0 - off 1) 7.7.2
494 Division marks encoder 2 - 1 8192 1024
530 Op. mode digital output 1 S1OUT 1 - Ready
532 Op. mode digital output 3 S3OUT 41 - Release brake
554 Op. mode digital MFO1D 3 - Error
1 – Rotary 2 – Rotary
766 Source actual speed 2 - Encoder 2 1)
encoder 1 encoder 2
796 Motor parameter identification
Status of motor parameter identifica-
797
tion
812 Cyclic duration factor - 40% 100% 100%
815 Encoder filter time constant ms Off 128 Off 7.7.3
825 Brake application time ms 0 2000 100 7.2
1) Operating modes 490 and 493 for encoders 1 and 2 are deactivated by default in Software 6.
In 2xx configurations, the user must activate the operation mode of the encoder that is used and set Source actual speed 766 accordingly.
For further information, see application guidelines / operating instructions

and option modules operating instructions.
214708k4.indd/250909
58
12 Schematic circuit diagram
Line connection (Analogue setpoint) (PWM analogue inverter)
PWM module
Demag DSE/DST
Relays
Normally open:
240 V AC / 5A; 24 V DC / 5 A (ohmic)
Normally closed:
240 V AC / 3 A; 24 V DC / 1 A (ohmic)
L1 Optional line reactor 1) Brake control

Z1 Optional line filter 2) Motor contactor only for KB motors
Z2 Optional output filter 3) Brake
4) Optional rotary encoder
42707244.jpg
214708k4.indd/250909
59
The current addresses of the sales offices in Germany and the subsidiaries and
agencies worldwide can be found on the Demag Cranes & Components homepage at
www.demagcranes.com ► Contact and Demag worldwide

Drives
P.O. Box 67 · 58286 Wetter / Germany
Telephone (+49-2335) 92-2922 · Telefax (+49-2335) 92-2406
Printed in Germany
E-mail drives@demagcranes.com
www.drives.demagcranes.de
Reproduction in whole or in part only with prior consent of Demag Cranes & Components, D-58286 Wetter Subject to change. Not liable for errors or omissions.
Operating/assembly instructions
DSE-10R control pendant
42360144.jpg
200110 enGB 214 795 44 719 IS 975

Manufacturer Demag Cranes & Components GmbH
P.O. Box 67 · 58286 Wetter / Germany
Telephone +49 (0) 2335 92-0 · Telefax +49 (0) 2335 927676
www.demagcranes.de
Contents
1 Foreword 4
1.1 Copyright 4
1.5 Definitions 6
2 Safety instructions 7
2.1 Symbols 7
2.2 Intended use 7
2.3 Inappropriate use 7
2.4 General safety information 8
2.5 Safety instructions for assembly and disassembly 9
2.6 Safety instructions when first putting the unit into service
after completing assembly 9
2.7 Safety instructions for operation 9
3 Technical data 10
3.1 Design features 10
3.2 Use 10
4 Design and installation information 11

4.1 Components 11
4.2 Fitting the silicone protective case and the bumper 12
4.3 Regulations 13
4.4 Resistance 13
4.5 Type of enclosure 13
4.6 Protective measures 13
4.7 Control cable union and strain relief 13
4.8 Switching elements 13
5 Using the unit for the first time 14

5.1 Casing seal/seal breakage 14
5.2 DSE-10R control pendant 14
6 Connecting the control cable 15

6.1 Assembly 15
7 Designations / symbols on the control pendant 17

8 DSE-10R control pendant operating elements 18
8.1 Operating functions 18
8.2 DSE-10R control pendant display 19
8.3 DSE-10R control pendant operating statuses 21
8.4 Operating mode/operating functions 22
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2
9 DSE-10R control pendant information menu 23
9.1 Activating the Information menu 23
9.2 Selecting the information source 23
9.3 Information menu data 24
10 Fault elimination 25
EC conformity declaration 26
DSE-10R control pendant parameter programming

(for authorized personnel only) 27
1 Menu for programming DSE-10R control pendant parameters 28
1.1 Activating the menu 28
1.2 Displaying the current parameters 28
1.3 Changing between display and entry mode 29
1.4 Entry mode 29
1.5 CAN Baud rate 29
1.6 Setting the control pendant node ID 30
1.7 Reserve 30
1.8 Displaying the main controller 12 software version 31
1.9 Displaying the control pendant hardware version 31
1.10 Displaying the date of the main controller 12 software version 31
1.11 Displaying the time of the main controller 12 software version 31
1.12 Displaying the monitoring controller software version 31
1.13 Activating display information 32
1.14 Activating IrDA information 33
1.15 Activating CAN bus information 34
2 Self-test 35
2.1 Activating the self-test routine 35
3 Demag service and Demag parameter menu in connection

with DSE-10R units 37
3.1 Activating the menus 37
3.2 Selecting the information source 37
3.3 Start screen 37
3.4 Navigating in the menu 37
3.5 Menu data 38
3.6 IrDA interface 38
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3
1 Foreword
You have purchased a Demag product/system.

These assembly/operating instructions are designed to provide the owner with ap-
propriate instructions for safe and correct operation and for maintenance.
Every individual given the task of transporting, installing, commissioning, operat-
ing, maintaining and repairing our products and systems must have read and un-
derstood
• the assembly/operating instructions
The assembly/operating instructions must be available to the operating personnel
at all times in order to prevent operating errors and to ensure smooth and trouble-
free operation of our products/systems.
1.1 Copyright These assembly/operating instructions must be treated confidentially. They should
only be used by authorized personnel. They may only be entrusted or made avail-
able to third parties with the prior written consent of Demag.
All documents are protected within the sense of copyright law.
specific prior consent. Infringements are an offence resulting in obligatory compen-
satory damages.
1.2 After-sales service 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 centres, the relevant representative or the head office in Wetter.
Kindly quote the serial or order number (see test and inspection booklet, load ca-
pacity plate on the crane) in any correspondence or for spare part orders.
Specifying these data ensures that you receive the correct information or the re-
quired spare parts.
21479544.indd/200110
4
1.3 Liability for defects These assembly/operating instructions must be read carefully before assembly
and putting the system into operation.
We assume no liability for any damage and malfunctions resulting from failure to
comply with the assembly/operating instructions.
Demag.
1.4 Limitations of liability All technical information, data and instructions for operation contained in these
assembly/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
further development of the system which is the subject of these assembly/operat-
ing instructions.
The information, illustrations and descriptions contained in these assembly/operat-
ing instructions are therefore only intended for information purposes.
The descriptions and illustrations contained in these assembly/operating instruc-
tions do not necessarily correspond to the scope of delivery or any subsequent
spare part delivery, either; the drawings and illustrations are not to scale.
We assume no liability for defects, damage and malfunctions caused as a result
of operating errors, non-compliance with these assembly/operating instructions or
omitted and/or inappropriate repairs and maintenance.
proved by us may be used. Accordingly, this also applies to other manufacturers‘
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 void 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.
21479544.indd/200110
5
Owners (employer, company) are defined as a person who owns such a system
and who uses it appropriately or allows it to be operated by suitable and instructed
persons.
Operating personnel/operator
Operating personnel or operators are defined as persons entrusted by the owner
of the system with the operation of the system.
Specialist personnel are defined as persons assigned by the owner of the system
to carry out special tasks such as installation, setting-up, maintenance and fault
elimination.
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
for the tasks assigned to them and on the possible hazards resulting from incor-
rect handling and who have been informed about the required protective devices,
training and experience, have sufficient knowledge of these systems 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 such systems.
21479544.indd/200110
6
2 Safety instructions
2.1 Symbols The following symbols and instructions warn against possible personal injuries or
damage to property and are intended to assist you in your work.
Hazard warning
This symbol appears in the assembly/operating instructions next to all instructions
relating to safety at work wherever a potential hazard to life and limb exists if the
instructions are not followed.
Pass on safety instructions to all persons entrusted with working on the product
including the power supply.
In addition, observe all general safety regulations at all times.

Contact with live parts can result in immediate death. Protective covers (e.g. cov-
ers and enclosures) marked with this sign may only be opened by qualified electri-
cians. Before opening, all relevant operating, control, feed or other voltages must
be disconnected.

This symbol in the assembly/operating instructions indicates all warnings which, if
not complied with, may result in damage to the product.
2.2 Intended use The product may only be operated when in perfect working order by trained per-
sonnel in accordance with the relevant safety and accident prevention regulations.
This also includes compliance with operating and maintenance conditions speci-
fied in the assembly/operating instructions.
This product is designed as a control pendant switch suspended from its connec-
tion cable. It may only be used as intended as suspended equipment and must
always remain suspended, even when it is held in the operator’s hand.
This product is industrial equipment that is intended to be used with the rated volt-
age specified on the type plate.
The relevant main switches must be switched off when maintenance work is car-
ried out.
During operation or when the main switch is not switched off, electrical compo-
nents inside enclosures, motors, switchgear cabinets, terminal boxes, etc., carry
dangerous voltages. This voltage may cause fatal injuries.
Serious personal injury or damage to property may occur in the event of:
• unauthorized removal of covers,
• inappropriate use of the product,
• incorrect operation,
• insufficient maintenance,
• working on live parts.
2.3 Inappropriate use Certain work and practices are prohibited when using the product as they may
involve danger to life and limb and result in lasting damage to the product, e.g.:
• Manipluation of the electrical equipment.
• Connecting the unit to a power supply with a voltage or frequency other than
those specified on the type plate.
• Non-compliance with specified mounting positions.
• Non-compliance with the max. permissible operating temperature.
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• The control pendant switch must not be placed in or on transport containers, on

the load to be lifted, on workbenches, on any other objects or set down in any
other way
7
2.4 General safety infor- Persons under the influence of drugs, alcohol or medicines which affect reactions
must not install, operate, put into service, maintain, repair or disassemble the
mation products. Any conversions and modifications to the installation must comply with
the safety requirements. Work on electrical equipment may only be carried out by
specialists in accordance with electrical regulations. In the event of malfunctions,
the product must be stopped, switched off and the relevant main switches locked
immediately.
Malfunctions must be eliminated 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 assembly/operating instructions must be kept available at the place where the
product 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 appropri-
ately. Any non-compliance with the safety instructions may result in personal injury
or even death.
Observe general statutory and other obligatory regulations relating to accident
prevention and environmental protection and basic health and safety requirements
in addition to those included in these assembly/operating instructions.
Such requirements may also relate, for example, to the handling of hazardous
materials or the provision/wearing of personal protection equipment.
Comply with these regulations and general accident regulations relevant for the
place at which the product is used and follow the instructions therein when working
with the product.
The product may still constitute a danger to life and limb if it is installed, operated,
maintained or used inappropriately by personnel who have not been trained or
specially instructed.
The safety instructions must, if required, be supplemented by the owner with in-
structions and information (e.g. factory regulations) relating to organization of work,
working procedures, operating personnel, etc. Supervising and reporting obliga-
tions as well as special operating conditions must also be taken into consideration.
Personnel assigned to working with the product must have read the assembly/op-
erating instructions and the safety instructions.
All activities relating to the product which are not described in the assembly/operat-
ing instructions may only be carried out by specifically trained specialist personnel.
The owner must ensure that personnel work in a safety and hazard-conscious
manner in compliance with the assembly/operating instructions.
The owner must ensure that product is only operated when in proper working order
and that all relevant safety requirements and regulations are complied with.
The product must be taken out of service immediately if any functional 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 main-
tenance purposes, if damage is detected or after finishing work), the operator/ex-
perienced technician must carry out all prescribed safety measures or observe that
they are automatically carried out.
Personal protective clothing must be worn as necessary or as required by regula-
tions. Personnel must not wear any 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 the product, its access routes and mains con-
nection switches must be preserved completely and in legible condition.
Modifications, additions to and conversions of the product which might impair safe-
ty in any way must not be carried out without the approval of Demag.
Safety devices must not be rendered inoperative.
Only genuine Demag spare parts may be used. Observe prescribed deadlines or
21479544.indd/200110
those specified in the assembly/operating instructions for routine checks/inspec-

tions.
8
2.5 Safety instructions • Installation and disassembly work may only be performed by experienced tech-
nicians.
for assembly and
• Installation and disassembly work must be co-ordinated by the person carrying
disassembly out the work and the owner within the scope of their responsibility.
• The assembly zone must be made safe.
• The installation must be isolated in accordance with the relevant electrical regu-
lations.
• Customer-specific regulations must be observed.
• Only appropriate, tested and calibrated tools may be used.
2.6 Safety instructions • The working area must be made safe.

when first putting the • First check that the voltage and frequency specified on the type plates match
the owner‘s mains power supply.
unit into service after
• In the course of putting the product into service, it may be necessary to render
completing assembly safety devices or features inoperative when carrying out adjustments or function
checks.
• When putting the machine into service, it may be necessary to perform work in
the danger zone, therefore, it must be ensured that only appropriately trained
personnel are employed for this work.
2.7 Safety instructions for All instructions and measures described in the assembly/operating instructions
with regard to safe operation and items concerning general safety and accident
operation prevention which have to be observed before, during and after the product is put
into service must be strictly followed. Any failure to comply can lead to accidents
resulting in fatalities.
The product 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 the product when all protective devices and safety-relevant equip-
ment, e.g. movable protective devices and emergency-stop devices, are fitted and
fully functioning.
Switch off the product immediately in the event of damage to electrical devices and
cables as well as parts of the insulation.
Ensure that nobody is endangered by operation of the product before switching it
on or putting it into operation.
If the operator notices persons who may be exposed to a risk to health or personal
safety by operation of the equipment, he must suspend operation immediately and
may not resume operation again until the persons are outside the danger zone.
Before putting the product into operation, the operator must be satisfied that the
product is in safe and correct operating condition.
When work is finished or when the operator leaves the working area, the emergen-
cy-stop button on the control switch must be actuated. The emergency-stop button
is unlatched by turning it.
When work is finished, the power supply must also be switched off at the mains
connection or isolating switch.
Work on the product may only be carried out when instructions to this effect have
been issued, when operation and function of the equipment have been explained
and when the working and danger zone has been made safe.
Cooling devices, such as ventilation openings, may not be rendered permanently
inoperative (e.g. covered or closed). Special local conditions or special applica-
tions can lead to situations which were not known when this chapter was written. In
21479544.indd/200110
such cases, special safety measures must be implemented by the owner.
9
3 Technical data
42360244.jpg
3.1 Design features • The ergonomic curved housing design of the control pendant permits operators
to work in a natural position, reducing fatigue.
• No internal wiring is required in the pendant housing thanks to the PCB, which
has a central connection.
• An LCD display is integrated to display the load and service data.
• The housing is made of high-quality thermoplastic which is highly resistant to
impacts.
• Protective insulation to VDE 0100 part 410, section 6.2.
• Switching distances and forces to DIN 33 401, holding force < 8 N.
• IP 65 enclosure to DIN VDE 0470 T.1 and EN 60 529 as standard.
• The housing is non-flammable, climate and corrosion-proof.
• Largely resistant to fuels, salt water, grease, oils and lyes.
• Strain relief by means of control cable as standard.
• Standard impact protection against arduous ambient conditions.
3.2 Use Control pendants of the DSE-10R series are exclusively intended for use with rope
hoists of the DR series with CAN bus technology.
DSE-10R control pendants are supplied with 10 openings in a double-row arrange-
ment as standard.
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10
4 Design and installation information
4.1 Components The control pendant housings are made of high-quality thermoplastic which is
highly resistant to impacts. The housing upper section is RAL 1007 yellow, the
housing lower section is RAL 9005 black.
The control pendants are designed to meet ergonomic requirements. The shape of
the housing permits low-fatigue work, also when wearing gloves. The pushbuttons
feature a large contact surface and require only low actuating and holding forces.
The relevant manual holding force for switching is less than 8 N and therefore
complies with DIN 33 401.
The elliptical shape of the DSE-10R control pendant housing is a special feature. It
permits operators to work in a natural, comfortable position, reducing fatigue. The
ribbed rear side of the pendant prevents the operator‘s hand from slipping.
As standard, the control pendant is provided with an infra-red interface (IrDA) for
service purposes.
The designation labels are self-adhesive and resistant to abrasion. The arrow
symbols comply with the symbols defined by FEM (Fédération Européenne de la
Manutention) Section 9.941 and DIN 15012 (draft).
Colours: - Yellow symbol against black background
- Black symbol against yellow background
If the DSE-10R control pendant is used under particularly arduous ambient condi-
tions, the control pendant housing is additionally protected by means of a bumper.
2-stage button:
Emer-
gency Horn/limit switch test
stop
IrDA infrared interface

21479544.indd/200110
42360344.jpg
11
4.2 Fitting the silicone The silicone protective case and the bumper can also be fitted to assembled
control pendants. Fit the bumper at room temperature.
protective case and
the bumper
1 1. Turn the bumper through 90° and slide it over the control pendant from below.
Pay attention to the protruding emergency-stop button.
2. Turn the bumper into the correct position.
3. If you want to use the silicone protective case, slide the bumper upwards on
the control cable so that the control pendant lies completely open. Now pull the
silicone protective case over the control pendant from below.
4. Slide the control pendant into the bumper, as shown in the diagram, until it is
firmly located in the upper part of the bumper.
5. We recommend that a lubricant (e.g. washing-up liquid) be used for further as-
sembly. Fix the control pendant and the bumper at the top, stretch the lower part
of the bumper and slide it over the control pendant.
42324844.eps
42330744.eps
3 4
42777844.eps 42325844.eps
5
21479544.indd/200110
42324944.eps
12
4.3 Regulations The control pendants comply with the regulations for low voltage switchgear
DIN VDE 0660 and EN 60947, IEC publications 337-1 and 158-1 as well as the
CSA rules (Canada and USA).
4.4 Resistance The material of the control pendant housing is impact-resistant, non-flammable,
climate and corrosion-proof. It is largely resistant to fuels, greases, oils, salt water
and lyes. The materials used are suitable for high electrical and mechanical re-
quirements.
The maximum permissible operating temperatures for rubber and thermoplastic
parts are –25 °C to +70 °C.
4.5 Type of enclosure In suspended operating position, control pendants when ready for operation meet
the requirements of enclosure type IP 65 to DIN VDE 0470 T. 1 and EN 60529, i.e.
they are dust-proof and protected against hose-water from all directions.
4.6 Protective measures High level of electrical safety owing to protective insulation to DIN VDE 0100, part
410, section 6.2.
4.7 Control cable union For all types, strain relief is implemented via two vulcanised steel wire cords on the
control cable.
and strain relief
4.8 Switching elements Explanation of type designation

e.g.: DSE-10R V2V
D = Demag, S = Control pendant,E = Ergonomic
10 = Openings
R = for DR rope
Switching functions
V = infinitely variable
2 = 2-stage
Example for switching functions on the DSE-10R:

2V2
crane, 2-stage
trolley, infinitely variable
hoist, 2-stage
possible variants: 2V2, 2VV, VVV
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13
5 Using the unit for the first time
Note: The operator must observe BGV D6 regulations and instructions when
DSE-10R control pendant switches are used in crane installations.
All components are designed for operation in industrial environments.
The DSE-10R control pendant has been built in compliance with the rules and
regulations of BGV D 6 for cranes as well as EN 60204-32 and EN 954-1.
All units have been tested in accordance with the EMC directives and comply with
the relevant standards regarding interference emission and resistance to interfer-
ence for application in industrial environments.
5.1 Casing seal/ DSE-10R control pendant units are sealed in the factory.
seal breakage The equipment may only be opened by authorised parties for repair purposes.
Breaking a casing seal such as this will result in loss of all warranty rights.
5.2 DSE-10R control Demag DSE-10R control pendant switches are used to control rope hoists.
pendant Demag rope hoists are generally fitted with emergency limit switches and a (two-
stage) test button in the DSE-10R control pendant. The test button can be used to
by-pass the “lifting” operating limit switch to check the emergency limit switch. The
control pendant is fitted as described in section 6.1.1.
The control pendant should be suspended so that the bottom edge is approx. 1 m
above floor level.
The arrow symbols on the buttons must indicate the correct direction of the respec-
tive movement.
2-stage button:
The control pendant is generally of plug-in design, this ensures service and main-
Horn/limit switch tenance-friendly installation.
Emer- test
gency
stop
42360444.jpg
5.2.1 Principle The DSE-10R consists of an integrated mechatronics solution, i.e. the actuating
mechanical system acts on a magnet sensor system that evaluates the control
commands via an electronic system.
This makes stepless actuation of all three motion axes possible. The integrated DR
control system provides step or variable control in accordance with the optionally
selected drives.
5.2.2 Wiring The integrated DR control system features transmission of the control signals from
the DSE-10R control unit to the DR control system or to the crane control system
via a CAN bus. This makes it possible to reduce wiring requirements to a mini-
mum. The number of connection diagrams is reduced to one diagram.
5.2.3 IrDA infrared interface All DSE-10R control pendants are provided with an integrated infrared interface
(IrDA) for reading and transmitting the service data of the DR rope hoist.
5.2.4 Display In addition, information on the load value and the service data is available via the
standard display.
When the standard MGS load detector is used and the load is detected by means
of slip calculation, the load value trend is displayed.
The load is precisely displayed when the optional strain gauge carrier link is used
as a load detector.
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14
6 Connecting the control cable
6.1 Assembly Electrical installation work must only be carried out by a qualified
electrician, see also chapter 1 “Safety instructions”.
Control pendant suspension height approx. 1000 mm above floor
level.
Proceed as follows:
2 1. Slide protective sleeve (1) onto control cable (2).
2. Plug the control cable into the control pendant and turn the bayonet lock until it
is locked.
Ensure that
1
- the connector groove matches the swivel lock in the control pendant enclo-
sure and
- that the two pins on the control pendant enclosure match the bayonet lock.
3. Slide the protective sleeve over the control cable until the sleeve latches with
the housing lower section and the housing cap.
42360544.jpg
42682144.eps
21479544.indd/200110
15
6.1.1 Connection to the KBK
trailing cable trolley
42360744.jpg
42371444.eps 42371544.eps
Control pendant height adjustment:

The DSE-10R control pendant is supplied with a standard cable length of 6 m or
10 m. The height can be varied by approx. 4 m.
The suspension height can be adjusted at any time by means of a self-locking
clamping mechanism to suit individual requirements. The control pendant can be
adjusted to a different suspension height by unlocking clamping mechanism (1).
The excess control cable is accommodated in the cable collector (2) in a bundle.
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16
7 Designations / symbols on the control pendant
As standard, all keys on the control pendant are designated in the factory with the
relevant foil symbols.
If requested by the owner, it is also possible to apply other, for example, country-
specific symbols for the direction keys on the control pendant. The owner then has
to apply the symbols required by him over the existing symbols. Note that when
the control pendant is used in connection with a DR rope hoist, the functions of the
individual keys are pre-defined.
To replace the symbols, proceed as follows:
• The symbol field must be free from adhesive, dust and grease. Clean, as re-
quired, with spirit or alcohol.
Solvents, benzene, cold sprays, etc. may damage the housing

material. (see fig. 1 for hoist unit functions)
• Apply the symbol required for the assigned function in the symbol field.
DSE-10R control pendant
Emergency
stop 2-stage button:
Horn/limit switch test
Hoist unit
Cross travel
Long travel
F1 function key F2 function key
Fig. 1 42360544.jpg
21479544.indd/200110
17
8 DSE-10R control pendant operating elements
8.1 Operating functions
Display
Emergency 2-stage button:

stop Horn/limit switch test
F1 F2
42360644.jpg
Introduction In the following, the LCD display and its display functions are described. In addi-
tion, the various operating modes are also explained.
21479544.indd/200110
18
8.2 DSE-10R control The DSE-10R is provided with a display. All data important for operation of the
crane to be operated are shown on the display.
pendant display
8.2.1 Scope of the display
Bus status
Display of selected
travelling hoist(s) Service interval display
CAN
+
1st main row with large
2nd main row with alpha- S1 S2 icon or numerical dis-
numerical display
0145 play
Load reduction icon
Load-proportional Icons for switching statuses of Symbol safety function off

bar display universal outputs
42705944.eps
8.2.2 Display of selected travelling The display of the selected travelling hoists is only active if there are two travelling
hoist(s) hoists and both can be operated with one DSE-10R unit.
Symbol Meaning
I Travelling hoist 1 is selected
II Travelling hoist 2 is selected
I+II Travelling hoists 1 and 2 are selected
8.2.3 Service interval, IrDA and

internal error display
8.2.3.1 Service interval display This icon indicates that the Demag Service or a service company author-
ised by Demag must be called in for service work.
8.2.3.2 IrDA display Shows IrDA data transfer when parameters are being programmed.
8.2.3.3 Internal error display Indicates that there is an internal error in the control pendant
Icons in the first main row In the first main row, all icons important for operation are shown.
STOP symbol
STOP STOP indicates the STOP mode. The system is switched into the RUN
mode with the emergency stop button.
Warning icon
The warning icon is displayed in the event of a warning. The code of the
warning is displayed in the row below.
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19
Icons in the first main row Fault icon
The fault icon is displayed in the event of a fault.
The code of the fault is displayed in the row below. If there are several
faults at the same time, the code displayed changes in cycles.
Overload icon
The overload icon is displayed in the event of an overload. The load of the
selected travelling hoist(s) is also displayed in the row below if the hoist is
fitted with ZMS.
Brake icon
The brake icon is displayed if the additional brake has been applied.
“Universal output 1 switching status” icon

This icon is displayed when universal output 1 is active. The function of
this output can be programmed.
“Universal output 2 switching status” icon

This icon is displayed when universal output 2 is active. The function of
this output can be programmed.
“Important. Safety function de-activated” icon

This icon indicates that a function relevant for safety such as a reduced
load or by-pass control has been de-activated by the operator.
“Load reduction active” icon

The icon indicates that load reduction is active. Only a reduced load
(specified by a parameter) can be lifted when load reduction is active.
CAN This symbol indicates that there is a problem with connection of the con-
trol pendant.
Load-proportional bar display
The load-proportional bar display shows the load on the crane in five
increments of approx. 20 %. This display is independent of the travelling
hoist selection and always refers to the max. possible load.
21479544.indd/200110
20
8.3 DSE-10R control The function and display of the DSE-10R control pendant are determined by the
operating status of the control pendant. The operating status of the control pen-
pendant operating dant is transmitted to the crane control system. In addition to stop mode, operating
statuses mode is also possible:
Emergency-stop switch Stop mode

locked
Operating mode Emergency-stop switch

unlocked
8.3.1 Stop mode Stop mode is the basis for all operating statuses and menus. Travel motions are
not possible in stop mode. Key sequences are used to change to other operating
statuses or into other menus:
8.3.2 Changing into operating mode • Unlock emergency stop switch
8.3.3 Changing into the system • Lock emergency-stop switch

data menu • Actuate the horn key twice
• Actuate the horn key again and hold it down for 5 seconds
• Release the horn key
Note: The Horn key must not be pressed down completely but only to the first
stage.
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21
8.4 Operating mode/oper- In operating mode, the DSE-10R is fully functional and continuously exchanges
data with the DR rope hoist. Operating and moving the crane is only possible in
ating functions operating mode. The lift, lower, left, right, forward and reverse keys are used to
control the travel motions. All the other keys are functional, too:
8.4.1 F1 key Actuate the F1 key to change the travelling hoist selection if there are several trav-
elling hoists. The selection is incremented one step further every time the key is
actuated:
I -> II -> I+II -> I
The modified travelling hoist selection is shown in the display of the control pen-
dant. If there is only one travelling hoist, the F1 key has no function.
8.4.2 F2 key When the F2 key is actuated for 5 seconds, the current load value of the selected
travelling hoist(s) is saved as a tare value.
8.4.3 F1/F2 keys, additional The F1 and F2 keys can also be assigned optional additional functions
functions (e.g. grab, magnets, etc.).
8.4.4 Horn key, first stage When the first stage of the horn key is actuated, the horn in the travelling hoist
control system is activated.
8.4.5 Horn key, second stage When the second stage of the horn key is actuated and held down for more than 5
seconds, the limit switch test for hoist units with operating limit switch is activated.
8.4.6 Emergency -stop switch If the emergency-stop key is actuated in operating mode, this triggers several reac-
tions:
• The emergency-stop switch stops all travel motions as quickly as possible
(emergency stop), activates all brakes and switches off the crane contactor.
Since this may result in load sway, the emergency-stop switch must only be
actuated in dangerous situations or at standstill.
• The control pendant switches from operating mode to STOP mode.
• The “STOP” icon appears on the control pendant display.
Display
Emergency
2-stage button:
stop
Horn/limit switch test
F1 F2
21479544.indd/200110
42360644.jpg
22
9 DSE-10R control pendant information menu
This additional function of the DSE-10R control pendant switch can only be used in
connection with a DR rope hoist and CAN bus.
The information menu makes it possible to display information on the crane or the
travelling hoist(s). This information is stored in the form of a list by each DR control
system. One of these list elements is requested by the DSE-10R control pendant
and made available by the selected control system via the CAN bus.
9.1 Activating the • Actuate the emergency-stop switch

Information menu • Actuate stage 1 of the horn key twice
• Actuate stage 1 of the horn key again and hold it down for approx. 5 seconds
• Release the horn key again
9.2 Selecting the The polled control system is selected in the same way as for the travelling hoist .
Since the F1 key has no function in the information menu, the travelling hoist must
information source first be selected in Run operating mode:
Travelling hoist selection Information from
I Travelling hoist 1 control system
II Travelling hoist 2 control system
I+II Crane control system:
9.2.1 Start screen After switchover to the information menu, the start screen of the information menu
is shown in the display of the DSE-10R control pendant. This starting screen
shows information START II (since travelling hoist 2 has been selected) and code
888:
Information code
Information
(Start info travelling hoist II)
42360944.jpg
9.2.2 Navigating in the information Use the following keys to navigate in the information list:
menu Key Function
Right Continue to the next value in the list
Left Back to the previous value in the list
Lifting Exit the Information menu
21479544.indd/200110
23
9.3 Information menu data The following data can be displayed via the information menu:
Code Information
401 Remaining duration of service in % ( from load spectrum)
400 Operating hours
000 Permissible full load hours acc. to FEM classification
001 Gearbox transmission ratio
002 Drum diameter
003 Reeving factor
004 Control type (travelling hoist or crane control)
005 Solo travelling hoist (with/without crane control)
146 Customer number
147 Order number
148 Serial number
149 Year of manufacture
150 Hoist speed V1
151 Hoist speed V2
152 Lifting height
153 Reeving
155 Rope diameter
171 Country code
216 Serial number of control system
217 Hardware version
520 Software version of main controller
529 Software version of monitoring controller
The following additional information is available with the “Status analysis” option:
Code Information
402 K1 switching operations
403 Hoist brake switching operations
404 Travel path in m
416 Number of times slip limit is exceeded
417 Number of times max. speed is exceeded
418 Number of hoist brake errors
419 Number of times the overspeed brake is triggered
420 Number of overloads
421 Number of emergency stop actuations during motion of at least
one axis
448 Last error
449 Penultimate error
Sequence and quantity of information depend on the software and may be
changed.
The following example shows the remaining duration of service:

21479544.indd/200110
42361044.jpg
24
10 Fault elimination
Before taking any fault elimination measures on the DSE-10R control pendant,
check that the crane installation is supplied with power and is ready for operation
and has not been switched off by safety devices (mains connection switch, crane
isolating switch, emergency-stop switch, travel and lifting path limitation devices,
overload protective device, motor protective switch, etc.).
No. Problem Advertisements Possible causes Notes, section in this document
Power supply • Check 48 V AC power supply

• Replace control pendant
01 No function
Blue LED Off

Green LED Off
1)
• Cable connection to rope hoist • Check the cable connections
Demag interrupted • Check rope hoist electrical equip-
“Demag” display does
02 • Error in rope hoist electrical ment, see corresponding DR
not go off
equipment operating instructions
Blue LED
Green LED
1)
STOP
03 Crane does not respond
to key command STOP mode Unlock emergency stop switch
Blue LED
Green LED
1) Additional symbols may also be shown in the display field
Please contact Demag customer service if the measures above do not eliminate
the fault.
21479544.indd/200110
25
1 page(s) Page 1
EC conformity declaration Ident. no.
Demag DST, DSK, DSE, DSM5, DSC, DSM-C control pendants #
205 391 44
in accordance with EC directive 73/23/EEC, Annex III EN
Issue 0404
Hereby we,

declare that the product
Demag control pendants #
DST, DSK, DSE, DSM5, DSC, DSM-C 1)
of serial design is in conformity with the provisions of following relevant regula-

tions:
EC Low Voltage Directive 73/23/EEC

amended by 93/68/EEC
Applied harmonised standards:
EN 60529 Types of enclosure (IP code)

EN 60947-1 Low voltage switchgear
EN 60947-5-1 Control circuit devices and switching elements
Applied standards and technical specifications:
DIN VDE 0100 Part 410 Protection against electric shock

DIN VDE 0110 Insulation coordination for equipment with low-voltage
equipment
Wetter, 1 April 2004
Place and date of issue
#
ppa. Gersemsky ppa. Hoffmann
Technik HT GZ Handling-Technology
21479544.indd/200110
1) Application of CE symbol in accordance with EC Low Voltage Directive 73/23/EEC:

DST, DSK, DSM5 1995; DSE 1996; DSC, DSC-M 2004
# = Modifications compared Class. no.

Normung
previous issue 715 IS 951
26
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter (Germany) Subject to change. Not liable for errors or omissions.
(For authorized personnel only)
DSE-10R control pendant parameter programming
21479544.indd/200110
27
1 Menu for programming DSE-10R control pendant parameters
The “Control pendant parameter programming” menu is used by specially trained

personnel for programming parameters on the control pendant itself. The follow-
ing control pendant settings can be displayed and, if required, modified using this
menu:
Code Information
000 Control pendant transmission speed (Baud rate) on the CAN bus
001 Control pendant node ID
002 Reserved
003 Main controller 12 software version
004 Control pendant hardware version
005 Main controller 12 software date
006 Main controller 12 software time
007 Monitoring controller software version
008 Enable display information
009 Enable IrDA information
010 Enable CAN bus information
Note:
Parameters 000 to 001 are set in the factory and must not be changed without
prior agreement.
Attention:
Changes to the parameters of the control pendant may impair functioning of the
hoist unit.
1.1 Activating the menu • Actuate the STOP key

• Actuate the lower key
• Actuate the right key twice
• Actuate the lower key again and hold it down for approx. 5 seconds
• Release the lower key again
Every change into the “Control pendant parameter programming” menu is commu-
nicated to the crane control system.
1.2 Displaying the current Only parameters are displayed after the menu is first activated. The display starts
with parameter 000, the Baud rate used by the control pendant on the CAN bus, or
parameters the last parameter used. The colon following the parameter code 000 indicates the
display mode:
000:
125kBIT
42706244.eps
Use the left and right keys to select the parameter to be displayed. The lift key can
be used to quit the “Control pendant parameter programming” menu at any time.
21479544.indd/200110
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1.3 Changing between The displayed parameter can only be modified after the F1 key has been actuated
to switch from display mode to entry mode. The lift keys can be used to exit entry
display and entry mode and to return to display mode at any time.
mode
1.4 Entry mode In entry mode, the colon following the parameter code is replaced by an equals
symbol. Instead of the current value of a parameter, one of the possible values is
now displayed:
000=
010kBIT
42703244.eps
Use the left and right keys to scroll through the possible values. Actuate the F2 key
to accept the displayed value.
The parameter will remain unchanged if entry mode is exited with the lift key be-
fore the value is accepted with F2.
1.5 CAN Baud rate

1.5.1 Default setting Precondition: Parameter code 001 is activated
The default setting set in the factory is a transmission speed of 125 kbit.
1.5.2 Display mode The current Baud rate is shown on the display. Use the following keys to navigate:
Key Function
Right Change to display of parameter 001
Left Change to display of parameter 010
Lift Exit parameter programming menu
F1 Change to entry mode
1.5.3 Entry mode The current Baud rate appears in the display after the system is switched into entry
mode.
The following settings are possible 10 kBit
20 kBit
50 kBit
125 kBit
250 kBit
500 kBit
1000 kBit
Use the following keys to select and navigate:

Key Function
Right Display the next possible value
Left Display the previous possible value
Lift Exit entry mode
F2 Accept the displayed Baud rate
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29
1.6 Setting the control
pendant node ID
The default setting set in the factory is node ID 1.
1.6.2 Display mode The current node ID of the control pendant is shown on the display. Use the follow-
ing keys to navigate:
Key Function
1.6.3 Entry mode The current node ID appears on the display after the system is switched into entry
mode. Values 1 – 8 are permitted.
Key Function
F2 Accept the displayed node ID
1.7 Reserve
This parameter is reserved for future additions. 0 is shown as the parameter value.
1.7.2 Display mode Use the following keys to navigate:
Key Function
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30
1.8 Displaying the main
controller 12 software
version
1.8.1 Default setting Requirement: Parameter code 003 is activated
The software version of main controller 12 of the control pendant is shown on the
display. This display is only provided for information purposes and the displayed
value cannot be changed.
1.8.2 Display mode Use the following keys to navigate:
Key Function
1.9 Displaying the con- Precondition: Parameter code 004 is activated

trol pendant hard- The hardware version of the control pendant is shown on the display. This dis-
play is only provided for information purposes and the displayed value cannot be
ware version changed. Use the following keys to navigate:
Key Function
Lift Exit menu
1.10 Displaying the date of Precondition: Parameter code 005 is activated

the main controller 12 The creation date of the software version of main controller 12 is displayed with
parameter code 005. It is only provided for information purposes and cannot be
software version changed. Use the following keys to navigate:
Key Function
Lift Exit menu
1.11 Displaying the time of Precondition: Parameter code 006 is activated

the main controller 12 The creation time of the software version of main controller 12 is displayed with
software version changed. Use the following keys to navigate:
Key Function
Lift Exit menu
1.12 Displaying the moni- Precondition: Parameter code 007 is activated

toring controller soft- The software version of the monitoring controller is shown on the display with
ware version changed. Use the following keys to navigate:
Key Function
21479544.indd/200110

Lift Exit menu
31
1.13 Activating display
information
The display information is deactivated by default.
Control pendant error and status

messages
Display of selected
Service interval display
travelling hoist(s)
10
+
2. Main row with alpha- 0145
numerical display
Load-proportional bar
display
42706444.eps
Additional control pendant error status messages are output on the display when
the display information is activated.
1.13.2 Display mode The current enable setting for additional control pendant display information is
shown on the display.
Use the following keys to navigate:
Key Function
1.13.3 Entry mode The current display information status appears on the display after the system is
switched into entry mode.
The following settings are possible: 0 deactivated

1 activated.

Key Function
F2 Accept activation or deactivation
21479544.indd/200110
32
1.14 Activating IrDA
information
IrDA information is deactivated by default.
Control pendant status messages are output via the IrDA interface when IrDA infor-
mation is activated.
1.14.2 Display mode The current enable setting for additional control pendant IrDA information is shown
on the display.
Key Function
The current IrDA information status appears on the display after the system is

1 activated.
1.14.3 Entry mode Use the following keys to select and navigate:
Key Function
F2 Accept activation or deactivation
Note:
No other use of the IrDA interface (parameter programming) is possible when this
parameter is activated.
21479544.indd/200110
33
1.15 Activating CAN bus
information
CAN bus information is deactivated by default.
Control pendant status messages are output via the CAN bus interface when CAN
bus information is activated.
1.15.2 Display mode The current enable setting for additional control pendant CAN bus information is
shown on the display.
Key Function
The current CAN bus information status appears on the display after the system is

1 activated.
1.15.3 Entry mode Use the following keys to select and navigate:
Key Function
F2 Accept activation or deactivation.
21479544.indd/200110
34
2 Self-test
The control pendant is able to perform a self-test to ensure that the button and
display functions are working correctly. This function is carried out independently of
any connected peripheral devices, only the power supply voltage has to be provid-
ed. System safety is ensured throughout the entire test by transmitting “Emergency
stop” on the CAN bus, no travel motions are possible.
Only when a self-test has been completed, the control pendant is ready for opera-
tion again.
2.1 Activating the self-test • Actuate the emergency-stop switch

routine • Actuate the lower key
• Actuate the forwards key twice
• Actuate the lower key again and hold it down for at least 5 seconds
The key sequence must be actuated within a certain time, otherwise the sequence
is automatically interrupted if it is entered too slowly. The operator can see the sta-
tus of the key sequence on the bar diagram. The first step of the test is automati-
cally initiated when the key sequence has been successfully entered.
2.1.1 Display test step This test step is fully automatic and requires no interaction by the operator. The
display is filled with pixels (turns completely black) and is then deleted. This ena-
bles dead pixels to be seen.
2.1.2 Key test steps The individual key functions are tested during this step of the test. The display
shows the operator which key needs to be actuated, whereby care must be taken
to ensure that key is actuated slowly and smoothly until its end position is reached.
The load bar at the bottom edge of the display shows the progress of the tested
key. The individual steps of the test are explained in the following:
• Key test step 1:

The first step of the test checks that neither the first nor the second stage of the
relevant key is actuated. One load bar section is shown when the test is suc-
cessfully completed, otherwise no load bar is shown.
F2
42706544.eps
21479544.indd/200110
35
The second step of the test checks the first stage of the key. Two load bar sec-
tions are shown when the test is successfully completed, otherwise the value
remains unchanged. For keys with analogue control, the test continues with
step 3, otherwise with step 4.

The third step of the test checks whether the analogue value of the correspond-
ing key functions or not. Three load bar sections are shown when this test is
successfully completed, otherwise the value remains unchanged.

The fourth step of the test checks the second stage of the corresponding key.
Four load bar sections are shown when the test is successfully completed, oth-
erwise the value remains unchanged.

The fifth and final step of the test checks that both stages of the corresponding
key are no longer actuated. Five load bar sections are shown when the test is
successfully completed, otherwise the value remains unchanged.
If the self-test is not successfully completed, the control pendant can only
be returned to ready by disconnecting it from the power supply.
The control pendant must be replaced if it is unable to complete its self-test.
21479544.indd/200110
36
3 Demag service and Demag parameter menu in connection
with DSE-10R units
This additional function of the DSE-10R control pendant switch can only be used
in connection with a DR rope hoist and CAN bus.
The menus make it possible to display information on the crane or the travelling
hoist(s). This information is stored in the form of a list by each DR control system.
One of these list elements is requested by the DSE-10R control pendant and
made available by the selected control system via the CAN bus.
3.1 Activating the menus

3.1.1 Demag service menu • Actuate the emergency-stop switch
• Actuate stage 1 of the horn key twice
3.1.2 Demag parameter menu • Actuate the emergency-stop switch

• Actuate stage 1 of the horn key twice
3.2 Selecting the informa- Selection of the polled control system is analogue to travelling hoist selection.
Since the F1 key has no function in the menu, the travelling hoist must first be
tion source selected in Run operating mode:
Travelling hoist selection Information from
I Travelling hoist 1 control system
II Travelling hoist 2 control system
I+II Crane control system
3.3 Start screen The menu start screen is shown on the control pendant display after the cor-
responding menu is selected. This starting screen shows information START II
(since travelling hoist 2 has been selected) and code 888:
IrDA trans-
Information code mission
888:
Information
(Start info travelling START
hoist II)
42706644.eps
3.4 Navigating in the Use the following keys to navigate in the information list:
menu Key Function
Right Continue to the next value in the list
Left Back to the previous value in the list
Lift Exit menu
21479544.indd/200110
37
3.5 Menu data The data depend on the DR control system software version and may, therefore,
differ. The number of data items displayed differs in the two menus. The following
example shows the remaining duration of service.
IrDA trans-
mission
401:
14.6%
42706744.eps
3.6 IrDA interface The IrDA interface is enabled in the Demag service and Demag parameter menus.
The DR control system parameters can be read out and modified by means of a
connection with a PC/notebook with the corresponding IDAPSY software. To do
this, it is not necessary to access the DR control system; the information can be
read out directly via the easily accessible IrDA interface on the control pendant.
The following IDAPSY versions are available:
• IDAPSY Professional and Advanced Version (only for DCC Service).
• IDAPSY Basic (customer version). This can only be used to download data.
The IrDA transmission function can be used with any of these IDAPSY versions.
The standard notebook IrDA interface can be used as the counterpart to the DSE
unit with the IDAPSY Basic version.
Only the IDAPSY Professional and Advanced Version can be used to download
and upload DR control system parameters.
Please request further information on IrDA interfaces and IDAPSY, if required.
21479544.indd/200110
38
21479544.indd/200110
Notes
39
The current addresses of the sales offices in Germany and the subsidiaries and agen-
cies worldwide can be found on the Demag Cranes & Components GmbH homepage at
Printed in Germany
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter (Germany) Subject to change. Not liable for errors or omissions.
MGS-DR load detector
Description and notes
050109 enEN 211 038 44 720 IS 819

Manufacturer: Demag Cranes & Components GmbH
P.O. Box 67 · D-58286 Wetter, Germany
Telephone +49 (0) 2335 92-0 · Telefax +49 (0) 2335 927676
www.demagcranes.com
Contents 1 MGS-DR load detector 3

1.1 Use 3
1.2 Operating principle 3
1.3 MGS limit switch 3
1.4 MGS mounting 3
2 Overload cut-off and overload protection function with

Dematik® MGS-DR 4
2.1 General 4
2.2 Overload signal/protection by MGS-DR 4
2.3 Partial load switching point 5
2.4 Inspection 5
2.5 Function check 5
2.5.1 With DR control 5
2.5.2 Without DR control, with MKA-2 contact evaluator 6
2.6 Overload signal 6
3 Safety features 6
4 Notes for the acceptance test of hoist units with overload protection 7
4.1 125 % overload for the crane acceptance test 7
5 Fitting and application instructions 8

5.1 General 8
5.2 Measurements 8
5.3 EMC construction guidelines 8
5.4 Connection of the electrical equipment 8
5 Technical data and order numbers 9
7 Tables 10
7.1 MGS overload protective device 10
7.2 Crossbars for MGS 12
8 MGS limit switch installation instructions 14

9 Replacing SGS units with MGS 16
10 Instructions for finding faults 18
11 MGS dimensions/connection dimensions 19
21103844.indd/050109
2
1 MGS-DR load detector
1.1 Use DR hoists and supporting structures can be protected by means of the MGS-DR
load detector.
The units can be used on all DR hoists when certain features are taken into con-
sideration. They are intrinsically safe, i.e. if there is a broken wire, no operating
voltage or if an input signal is missing, the load can no longer be lifted.
1.2 Operating principle The load detector consists of the MGS-DR geared limit switch and the DR control
system.
The spring element of the MGS unit consists of an oval steel ring which is de-
formed by approx. 0,8 mm at rated load. A microswitch arranged between the long
sides of the spring element is actuated by the spring motion.
The DR control system evaluates the microswitch signal in order to act on the hoist
controls accordingly.
The MGS unit is generally installed at the rope anchorage point (crosshead, retain-
ing plate) or at the upper return or compensating sheave.
The MGS unit must be suspended in such a way that only tensile forces are trans-
mitted.
1.3 MGS limit switch Since hoist units can be subjected to different loads in accordance with their FEM
group, the MGS load cut-off point is adjusted to the relevant rated load before the
unit leaves the factory. Refer to the table on page 9 for hoist unit to MGS order
number assignments.
Hoist units which have load capacities that do not match the FEM classification
have to be fitted with an MGS unit adjusted to the special load capacity before
leaving the factory.
Avoid hard blows against the MGS-DR unit as they might modify the switch-
ing point setting.
Protective measures must be taken against radiant heat for operation in hot
atmospheres. MGS-DR units are not suitable for operation in acid-laden atmos-
pheres. A strain gauge carrier link with additional surface protection must be used
in such cases.
MGS-DR units are supplied with a permanently connected measuring cable as
standard. This must be connected direct.
MGS-DR limit switches may only be used in connection with a MKA-2 contact
evaluator or a DR control system.
Important
The partial load switching point cannot be evaluated when a MKA-2 contact evalu-
ator is used in connection with a MGS-DR unit.
1.4 MGS mounting MGS-DR units are attached between the rope/return sheave and the connect-
ing structure by means of two pins. The rope-side pin has a minimum play of
Zmin=1,3 mm in the retaining hole of the connecting structure to enable the MGS
spring element to expand in length.
21103844.indd/050109
3
2 Overload cut-off and overload protection function with
Dematik® MGS-DR
2.1 General When a load is lifted, vibrations occur in the rope which are measured as short-
term load peaks. These vibrations depend on the load, the lifting speed and the
rope length, they should, however, not result in a cut-out at rated load.
When an unknown load is lifted at great speed, the measuring system will switch
off in the event of an overload, however, an overload of the hoist unit cannot be
prevented with certainty due to run-on of the hoist motor. This type of load limita-
tion is referred to as overload cut-off.
If, on the other hand, a load is lifted at a relatively small speed, hardly any vibra-
tions occur in the rope. If during the lifting process an overload occurs, the measur-
ing system will detect any load exceeding the rated load very accurately and the
hoist unit will be immediately switched off. Owing to the low speed, there is hardly
any run-on of the motor so that overloading of the hoist unit is prevented. This type
of load limitation is called overload protection. Overload protection is therefore only
possible in connection with a creep lifting speed.
2.2 Overload signal/ The rope force caused by the load is transformed into the actuating path of a cam
by means of the spring element (oval ring), which actuates a normally closed
protection by MGS-DR switch (MGS). This interrupts a frequency signal, which is fed to two controllers via
a digital input arrangement. Both controllers evaluate the signal. In the event of an
overload, both controllers terminate the lifting motion independently of each other.
The lowering motion is always possible regardless of the load.
The controllers permanently exchange the results of their evaluations via the serial
interface. If one of the controllers determines that cut-off of the MGS unit was not
detected by the other controller, the first controller creates an error message and
prevents the lifting motion.
Rope tensile force

Limit load% Rope tensile force Limit load %
Load > 100 %
110 110
Rated load Rated load
100 100
Manual
switch-off/switch-on
Time Time
Hoist speed Hoist speed
Main lifting Main lifting

motion motion
0 Time 0 Time
Fig. 1 40992244.eps
21103844.indd/050109
4
2.3 Partial load switching The partial load switching point (creep lifting time) is not controlled by the MGS-DR
unit, but by the slip measurement of the hoist unit motor.
point
2.4 Inspection Functioning of the load detection devices must be checked during the prescribed
annual inspection of the installation.
We recommend that the annual inspection be carried out by an experienced De-
mag technician.
2.5 Function check a) with test load

2.5.1 With DR control The creep and main lifting motions must be switched off by lifting a load > the limit
load. The overload symbol must appear on the display.
b) without test load

The creep and main lifting motions must be interrupted by removing the MGS plug-
in connector (X53). The overload symbol must appear on the display.
21103844.indd/050109
5
2.5.2 Without DR control, with a) with test load
MKA-2 contact evaluator “CLK”, “o.k.”, “ ” and “ ” on the front panel indicate that the unit is ready for
operation and the ready status.
The „CLK“ diode blinks in the rhythm of the measuring intervals during opera-
tion. The “ ” light-emitting diode lights up to indicate that the creep lifting
speed has been enabled by closed contact 13-14 and “ ” light-emitting diode
lights up to indicate that the main lifting speed has been enabled by closed
contact 23-24. However, contacts 13-14 and 23-24 are only closed when the
“o.k.” light-emitting diode lights up at the same time.
a1) By lifting a load > the partial load and < the limit load, nothing will happen
when the MKA-2 unit is used as an overload cut-off; the creep lifting time has
to be initiated when it is used as overload protection (main hoist contacts
23-24 are open, “ ” light-emitting diode is off). The main lifting motion is
released again after the fixed creep lifting time, which is set to 5 seconds, has
elapsed.
a2) By lifting a load > the limit load, the creep lifting and main lifting contact must
open after a maximum of 529 milliseconds when the limit load is exceeded.
b) no load
Without a test load, only the function of the MKA-2 contact evaluator can be
tested.
To do this, the wire must be disconnected from terminal 2 of the MKA-2 unit.
The unit must then respond as described in a2).
2.6. Overload signal a) Depending on the DSE control pendant type, an overload signal is indicated by
means of an overload symbol on the control pendant display for DR hoist units
fitted with a DR control system.
b) In the case of DR hoist units that are not fitted with a DR control system, but
which have a MKA-2 contact evaluator, an overload signal is only indicated
when the creep and main lifting light-emitting diodes and the OK diode of the
MKA-2 contact evaluator are extinguished
3 Safety features
The cable to the contact of the external load detector, the digital input and the sig-
nal paths of both controllers are monitored by the use of a dynamic control signal.
The lifting motion is immediately disabled if a short circuit with the control voltage
or a defective imput is detected. Lowering is still possible (emergency operation).
21103844.indd/050109
6
4 Notes for the acceptance test of hoist
units with overload protection
4.1 125 % overload for the To enable the test weight of 125 % of the rated load to be lifted during the ac-
ceptance test of hoist units/crane installations with DR control system, DIP switch
crane acceptance test Code 301 switch 6 must be moved to the “On” position while the control system is
switched on.
The acceptance-test function remains active for approx. 15 min. when the DIP
switch is switched on, after which it is de-activated. It can only be activated again
by switching the DIP switch off and on again.
To enable the test weight of 125 % of the rated load to be lifted during the ac-
ceptance test of hoist units/crane installations that are not fitted with a DR control
system, but which have a MKA-2 contact evaluator, contact input 2-3 of the MKA-2
unit must be bridged.
Important
This jumper must be removed following the acceptance test.
Switch off the installation before carrying out any cabling and wiring and
maintenance work.
789
456
AB
Code304 No function when MGS fitted

CDE
23
F0 1
789
456
AB

CDE
23
F0 1
789
456
AB

CDE
23
F0 1
CAN / parallel control

8
Control on load test bench

7
Overload test ON
6
Trolley / crane due to CAN ID

5
Code301
Trolley fast/slow/programmable brake application
4
CAN Baud rate

3
2
ON
CAN ID
1
Note:
42662044.eps
21103844.indd/050109
7
5 Fitting and application instructions
5.1 General MGS-DR protection switches are built and tested to DIN 57411 Part 1/VDE 0411
Part 1 and DIN ISO 9001 and leave the factory in perfectly safe condition. To main-
tain this condition and ensure safe operation, the operator must comply with the
instructions and warnings contained in this document.
5.2 Measurements Measurements on the devices or on cables connected to them may only be carried
out with high-resistance voltmeters or similar measuring devices. Measurements
with simple voltage and continuity testers (buzzers) may destroy the equipment.
5.3 EMC construction All units have been tested in accordance with the EMC directives and comply with
the relevant standards regarding interference emission and resistance to interfer-
guidelines ence for application in industrial environments.
To comply with the EMC requirements, the following points must be considered for
integration into overall systems:
• Integration of electronic components to meet EMC requirements
• Use of prescribed and approved cables, particularly screened cables as re-
quired by the operating instructions, if required.
• Connection of the cable shields according to the operating instructions
• Adherence to minimum distances for the application of cables and wiring with
different voltages.
5.4 Connection of the MGS-DR overload switches are electrically connected direct to the crane circuit
board. Plug connector X53 is coded to prevent reverse polarity and can only be
electrical equipment connected in one plug position. The same plug position is used when an SGS unit
is replaced by an MGS unit.
21103844.indd/050109
8
6 Technical data and order numbers
Technical data MGS-DR Limit switch

Part no.: see table below
Switching capacity: 10 mA/24 V =
Ambient temperature: -20°C to +70°C
Type of enclosure: IP 67
Mounting position: any
DR 3 – 10 measuring cable: LIYY 4 x 0,25

Part no.: 466 933 44
DR 20 measuring cable: LIYCY 4 x 0,25 screened

Part no.: 466 420 44
MGS part nos.: DR 3 Part no.

Overload cut-off 2m 719 327 33
DR 5
DR 10
DR 20 single groove
Overload cut-off 1Am 730 582 33
DR 20 multi-groove
Overload cut-off 1Am 730 586 33
Note:
The part numbers contain the following parts:
– MGS complete with cable and plug connector
– 2 off head pins
– 2 off retaining rings
– corresponding number of spacer rings and shims
21103844.indd/050109
9
7 Tables
7.1 MGS overload protective device

Table 1: MGS overload protective device for DR 3 - 10
Hoist unit Reeving SWL FEM Force on MGS Lever arm Rope force MGS switching MGS
[kg] [kg] [kg] point [kg] part no.:
1600 2m 400,00 800 440,00 719 327 33
2/1 1250 3m 312,50 625 350,00 719 328 33
1000 4m 250,00 500 280,00 719 329 33
DR 3 1/2
3200 2m 400,00 800 440,00 719 327 33
4/1 2500 3m 312,50 625 350,00 719 328 33
2000 4m 250,00 500 280,00 719 329 33
3200 1Am 1024,46 1600 1100,00 719 530 33
2500 2m 800,36 1250 880,00 719 527 33
2/1
2000 3m 640,29 1000 700,00 719 528 33
1600 4m 512,23 800 550,00 719 529 33
DR 5 1/1,5618
6300 1Am 1008,45 1575 1100,00 719 530 33
5000 2m 800,36 1250 880,00 719 527 33
4/1
4000 3m 640,29 1000 700,00 719 528 33
3200 4m 512,23 800 550,00 719 529 33
6300 1Am 1575,00 3150 1760,00 719 130 33
5000 2m 1250,00 2500 1380,00 719 127 33
2/1
4000 3m 1000,00 2000 1100,00 719 128 33
3200 4m 800,00 1600 880,00 719 129 33
12500 1Am 1562,50 3125 1760,00 719 130 33
DR 10 10000 2m 1250,00 1/2 2500 1380,00 719 127 33
4/1
8000 3m 1000,00 2000 1100,00 719 128 33
6300 4m 787,50 1575 880,00 719 129 33
16000 2m 1333,33 2667 1380,00 719 127 33
6/1 12500 3m 1041,67 2083 1100,00 719 128 33
10000 4m 833,33 1667 880,00 719 129 33
21103844.indd/050109
10
Table 2: MGS overload protective device for DR 20
Hoist unit SWL [kg] FEM Force on MGS [kg] MGS switching point [kg] MGS part no.:
12500 1Am 6250,0 6880,00 730 582 33
10000 2m 5000,0 5500,00 730 583 33
2/1
8000 3m 4000,0 4400,00 730 584 33
6300 4m 3150,0 3470,00 730 585 33
25000 1Am 6250,0 6880,00 730 528 33
20000 2m 5000,0 5500,00 730 583 33
4/1
16000 3m 4000,0 4400,00 730 584 33
12500 4m 3125,0 3470,00 730 585 33
40000 1Am 6666,7 6880,00 730 582 33
32000 2m 5333,3 5500,00 730 583 33
6/1
25000 3m 4166,7 4400,00 730 584 33
20000 4m 3333,3 3470,00 730 585 33
50000 1Am 6250,0 6880,00 730 582 33
40000 2m 5000,0 5500,00 730 583 33
8/1
32000 3m 4000,0 4400,00 730 584 33
25000 4m 3125,0 3470,00 730 585 33
12500 1Am
10000 2m
4/2
8000 3m
6300 4m
Double rope lead-offs only with ZMS
25000 1Am
20000 2m
8/2
16000 3m
12500 4m
21103844.indd/050109
11
7.2 Crossbars for MGS
Designation Drum Reevig FEM DR 3 DR 5 DR 10
length
Type Part no. Type Part no. Type Part no.
FDR
2/1
1Am FDR 5 479 704 33 FDR 10 on request
4/1
2/1
2m FDR 3 479 839 33 FDR 5 479 866 33 FDR 10 479 890 33
MGS overload 4/1
H12
protection 2/1
3m FDR 3 479 840 33 FDR 5 479 867 33 FDR 10 479 891 33
4/1
2/1
4m FDR 3 479 841 33 FDR 5 479 868 33 FDR 10 479 892 33
4/1
2/1
1Am FDR 5 479 705 33 FDR 10 on request
4/1
2/1
2m FDR 3 479 842 33 FDR 5 479 869 33 FDR 10 479 893 33
MGS overload 4/1
H20
protection 2/1
3m FDR 3 479 843 33 FDR 5 479 870 33 FDR 10 479 894 33
4/1
2/1
4m FDR 3 479 844 33 FDR 5 479 871 33 FDR 10 479 895 33
4/1
2/1 479 711 33 479 800 33
1Am FDR 5 FDR 10
4/1 479 710 33 on request
2/1 479 993 33 479 801 33
2m FDR 5 FDR 10
MGS overload 4/1 479 866 33 479 890 33
H30
protection 2/1 479 994 33 479 802 33
3m FDR 5 FDR 10
4/1 479 867 33 479 891 33
2/1 479 995 33 479 803 33
4m FDR 5 FDR 10
4/1 479 868 33 479 892 33
2/1 479 804 33
1Am FDR 10
4/1 on request
2/1 479 805 33
2m FDR 10
MGS overload 4/1 479 890 33
H40
protection 2/1 479 806 33
3m FDR 10
4/1 479 891 33
2/1 479 807 33
4m FDR 10
4/1 479 892 33
21103844.indd/050109
12
Designation Drum Reeving FEM DR 3 DR 5 DR 10
length
Type Part no. Type Part no. Type Part no.
EKDR
2/1 479 701 33
1Am EKDR 5 EKDR 10 on request
4/1 479 704 33
2/1 479 845 33 479 872 33 479 896 33
2m EKDR 3 EKDR 5 EKDR 10
MGS overload 4/1 479 839 33 479 866 33 479 890 33
H12
protection 2/1 479 846 33 479 873 33 479 897 33
4/1 479 840 33 479 867 33 479 891 33
2/1 479 847 33 479 874 33 479 898 33
4/1 479 841 33 479 868 33 479 892 33
2/1 479 702 33
4/1 479 705 33
2/1 479 848 33 479 875 33 479 839 33
MGS overload 4/1 479 842 33 479 869 33 479 893 33
H20
protection 2/1 479 849 33 479 876 33 479 900 33
4/1 479 843 33 479 870 33 479 894 33
2/1 479 850 33 479 877 33 479 901 33
4/1 479 844 33 479 871 33 479 895 33
2/1 479 703 33
4/1 479 706 33
2/1 on request
2m EKDR 5 EKDR 10 on request
MGS overload 4/1 479 707 33
H30
protection 2/1 on request
4/1 479 708 33
2/1 on request
4/1 479 709 33
EZDR
2/1 479 851 33 479 854 33
2m EZDR 5 EZDR 10
4/1 479 866 33 479 890 33
MGS overload 2/1 479 852 33 479 955 33

H12 3m EZDR 5 EZDR 10
protection 4/1 479 867 33 479 891 33
2/1 479 853 33 479 956 33
4m EZDR 5 EZDR 10
4/1 479 868 33 479 892 33
2/1 479 851 33 479 854 33
2m EZDR 5 EZDR 10
4/1 479 869 33 479 893 33
MGS overload 2/1 479 852 33 479 955 33

H20 3m EZDR 5 EZDR 10
protection 4/1 479 870 33 479 894 33
2/1 479 853 33 479 956 33
4m EZDR 5 EZDR 10
4/1 479 871 33 479 895 33
2m 479 902 33
MGS overload
H20, H40 6/1 3m EZDR 10 479 903 33
protection
4m 479 904 33
2m 479 878 33
MGS overload
H40 4/1 3m EZDR 10 479 879 33
protection
4m 479 880 33
21103844.indd/050109
13
8 MGS limit switch installation instructions
EZDR 20, 4/1 reeving
42371044.eps
3 4
1. Fit retaining plate (3).

2 2. Insert rope end with rope wedge into rope socket (9) and first sus-
pend it from the retaining plate with 1 head pin (1) without MGS unit
5
(8), briefly apply load to the bottom block so that the rope and rope
wedge are pulled into the rope socket. Then remove the load and
6 remove the head pin from the retaining plate.
3. Grease head pin (2) and insert it into the upper bore hole of the re-
taining plate, then push the MGS unit onto the head pin (the recess
1 in the MGS housing must face towards the upper bore hole), then
7 insert the head pin all the way in.
4. Push rope socket (9) between the retaining plate sides from below,
8 ensure that the lower half of the MGS unit is within the rope socket,
an insert 2nd greased head pin (1) all the way through.
5. Check that lower head pin (1) can move freely in the retaining plate
9 bore hole with the attached rope socket and MGS unit (play be-
tween bore hole circumference and head pin must be ≥ 1,3 mm).
6. Secure both head pins (1/2) with thrust washers (4/7) and secure
them with double spring clips (5/6).
7. Refer to the next page for arrangement of the cable. Complete the
electrical connections according to the circuit diagram.
42710744.eps
21103844.indd/050109
Fig. 2
14
DR 3 - 10 cable arrangement
2/1 reeving 2 1
• Lead connecting cable (1) out of the top of the

crossbar.
• Secure the connecting cable to the cross mem-
ber of the DR rope hoist using cable ties (2).
42381044.eps
3 • Attach the connecting cable to the travel roller

5
housing using cable clips (3).
4 Note:
The cable clips must be glued to the housing;
before fitting them, clean the areas where they
are attached to the housing using cleaning
solvent (free of grease).
• Secure the connecting cable to the connecting
rod of the DR rope hoist using cable guides (4).
• Lead the connecting cable into housing (5) us-
1 ing cable clips.
42381144.eps
3
4/1; 6/1 rope reeving
6 • Connecting cable (1) can be led direct into

housing (6) when the switch is installed, cable
clips then do not need to be used from the
outside. Secure any excess connecting cable
inside the housing as shown in the diagram.
1
42382444.eps
Terminal box, all variants (2/1; 4/1; 6/1)

7
• Introduce a suitable length of the connecting
cable into the electrical housing.
• Secure any excess connecting cable in the
housing using cable clips (7).
21103844.indd/050109
42381244.eps
Fig. 3 15
9 Replacing SGS units with MGS
Replacement for 2/1 reeving
SGS removal MGS-DR installation
Note:
The inner bore hole of the lever must be used
when fitting the MGS unit.
42382944.eps
Fig. 4
21103844.indd/050109
16
Replacement for 4/1; 6/1 reeving
SGS removal MGS-DR installation
Note:
The inner bore hole of the lever must be used
when fitting the MGS unit.
Fig. 5 42382844.eps
21103844.indd/050109
17
10 Instructions for finding faults
Dematik® MGS load limit switch
Fault/measurement Cause Remedy
a) MGS incorrectly connected Wiring error The plug connector is coded before leaving the fac-
tory, it can only be connected to the circuit board
in one plug position. Replace the plug or MGS, if
necessary
b) Switch-off characteristics Micro-switch defective 1 Check the micro-switch:
No load
Limit load => no continuity
c) Visual check Measuring cable torn off or damaged
Replace the MGS unit
a) MGS incorrectly installed MGS is mechanically destroyed (Pay attention to part no./load capacity)
e) Switches off when load < rated load Incorrect MGS unit Rope force at 110 % rated load must match
the switching point printed on the MGS unit
Replace the MGS unit
f) Does not switch off when load > 115 % rated load 1 Incorrect MGS unit see e)
2 MGS out of adjustment Replace the MGS unit
3 Force incorrectly transmitted Check rope suspension and fitting
4 MGS unit defective Check the MGS unit
5 MKA-2 or DR control system defective Replace the MKA-2 unit or DR control system
21103844.indd/050109
18
11 MGS dimensions/connection dimensions
Important:
Check distance z between the lower pin and
the connecting structure when installing the
MGS unit (zmin = 1,3 mm).
The contact surfaces between the MGS
unit and the pin must be lubricated using a
suitable agent (e.g. Molykote Longtherm 2,
part no. 972 399 44).
See page 9 for Hoist unit - MGS assignment.
Zmin
Fig. 6 41909545.eps
Rated load L A C E B+0,2 P Dh11

Type
MGS [T] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
DR 3 0,5 91 61 19 11,0 76,2 1,7 16
DR 5 1,0 103 67 20 12,5 85,2 2,2 20
DR 10 1,6 107 68 21 13,0 85,2 2,2 20
DR 20 4/2 8/2 3,15 130 81 23 15,0 100,6 4,7 25
DR 20
5,0 174 108 28 26,0 135,8 2,3/5,8 40
2/1; 4/1; 6/1; 8/1
Connection dimensions
T ± 0,2 MD11 FH13 K Smin Rmax
Type
[mm] [mm] [mm] [mm] [mm] [mm]
DR 3 60,8 16 18,0 21 11 28
DR 5 65,8 20 22,0 25 13 30
DR 10 65,8 20 22,0 28 14 30
DR 20 4/2 8/2 76,0 25 27,5 32 16 35
DR 20
96,0 40 43,0 50 27 60
2/1; 4/1; 6/1; 8/1
21103844.indd/050109
19
The current addresses of the sales offices in Germany and the subsidiaries and agen-
cies worldwide can be found on the Demag Cranes & Components homepage at
www.demagcranes.com ► Contact and Demag worldwide

P.O. Box 67 · D-58286 Wetter, Germany
Printed in Germany
Telephone +49 (0) 2335) 92-0 · 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.
Section III - Component Parts List
DEMAG
RECOMMENDED SPARE PARTS LIST
CUSTOMER: AGGREKO INTERNATIONAL PROJECTS

ORDER NO: 502262 CRANE TYPE: ZKKE CAP. : 15 TONS
P.O. NO: NHB-00052 SPAN: 41’ –11.5”
SERIAL NO: 13057 & 13058 HOIST TYPE: EZ DR10-16 6/1-13.3 Z-0.7-6
VOLTAGE: 460/3/60
COMPONENT DESCRIPTION Part No. Qty
BRAKE LININGS
Hoist Motor – Brake size B140 Brake overhaul set 260 981 33 1
Hoist Motor – Brake size B140 Brake wear and tear set 260 984 33 1
Trolley Motor – Brake size B007 Brake overhaul set 260 967 33 1
Trolley Motor – Brake size B007 Brake wear and tear set 260 970 33 1
Bridge Motor – Brake size B020 Brake overhaul set 260 972 33 2
Bridge Motor – Brake size B020 Brake wear and tear set 260 975 33 2
HOIST REEVING
Wire Rope Set, DR10 H20 4/1 13mm Dia. 705 962 33 1
Rope Guide 704 850 33 1
Grease DG 67 for Rope Guide 001 058 44 2
FUSES
Main Fuse –F011 70 A TYPE J 002 036 49 3
Control Transformer – primary –F017.1 2 A TYPE CC 719 800 45 2
Control Transformer – sec. -F017.2 3 A TYPE CC 719 979 45 2
CAN Bus Protection – F1 & F2 0.25 A TYPE GMA 132 477 49 2
Bridge Inverter –F016 30 A TYPE CC 132 304 49 3
Hoist Inverter –F041 50 A TYPE J 002 034 49 3

Hoist Brake Control Circuit Brkr –Q011 10 A TYPE GV2 LE14 Non-stock -
Hoist Resistor Overload Relay –F047 3RU1136-4EB1, 22-32A 537 252 84 3
CONTACTORS
Main Contactor – K022 TeSys LC1-D80E7 719 615 45 1
Control Relay for Main Contactor –K021 CA2-SK20E7 792 829 44 1
MISC. ELECTRICAL
Transformer - T017 STR130, 130VA 460/48V 719 924 33 1
Hoist Inverter – G041 DeDrive DIC-4-040, 18.5kw 537 911 84 1
Hst Inverter CAN Com Module –D045 CM-CAN 537 726 84 1
Hoist Inverter Sub-assy./Inverter -A011 DR10 basic board, DR10 set 711 986 33 1
Controller Inverter Module – A011.1 HUB, Inverter FI card 719 470 33 1
Hoist Braking Resistor – R047, R047.1 RHK8 44R 101872, 44 ohm, 730 890 33 2
9.6KW
Trolley Inverter – G014 DeDrive DIC-4-007,.3.0 kw 719 804 33 1
Trolley Braking Resistor – R017 PWR R 400, 120 ohm, 719 971 33 1
Bridge Inverter – G024 DeDrive DIC-4-025,.11 kw 719 966 33 1
Bridge Sub-assy. Board – A031 DR bridge board 719 482 33 1
Bridge Braking Resistor – R027 PWR R 600, 68 ohm 537 734 84 8
Geared Limit Switch – S021 SGG 719 099 45 1
Hoist Motor Pulse-Generator – B055 AG3 204 443 84 1
Pendant Controller – S012 DSE10-R-VVV-2TY (10m cable) 773 625 44 1
MGS Overload – S023 DR10 6/1 SET (16.0t) 719 127 33 1
Filter Fan, Hoist Encl –E013 (lower) Pfannenberg 11622804050 008 774 49 1
Filter Fan, Hoist Encl –E014 (upper) Pfannenberg 11622804053 008 775 49 1
Filter Thermostat – B013 KTS 011, 10A, 1NO 730 524 33 1
MOTORS *
Hoist Motor DR10 V3 Set _ M041 ZBR 132 C4 B140 705 907 33 1
Trolley Motor Set _ M016 ZBA 80A4 I See Demag 1
Bridge Motor _ M024, M026 ZBA 90B4 I See Demag 1
* Motors are not considered typical recommended spare parts. However, down time for critical equipment may warrant their purchase.
Ersatzteilliste
Spare parts list
Liste de pièces de rechange
Lista de repuestos
Demag-Seilzug EZDR-Pro 10
Demag rope hoist EZDR-Pro 10
Demag palan à câble EZDR-Pro 10
Demag polipasto de cable EZDR-Pro 10
080805 XC 217 119 44 721 IS 813

# Hubantrieb EZDR-Pro 10
1
DE
70010133.jpg
2 3
70190133.jpg 70190033.jpg
4 5
70190433.jpg 70190533.jpg
217119k1.p65/080805
# Änderungen gegenüber vorheriger Ausgabe

Beispiel
2 # 1 70410133 1 Hubantrieb DR10-V1
# Hubantrieb EZDR-Pro 10
Teil-Nr Bestell-Nr Stück Bezeichnung Werkstoff Norm
# 1 70410133 1 Hubantrieb DR10-V1 2/1, 4/1, 4/2

# 1 70410233 1 Hubantrieb DR10-V2 2/1, 4/1, 4/2, 6/1
# 1 70410333 1 Hubantrieb DR10-V3 2/1, 4/1, 4/2
# 1 70410533 1 Hubantrieb DR10-V1 6/1
2 70590133 1 Hubgetriebe DR10 V1 Set 2/1, 4/1, 4/2 1)
2 70590233 1 Hubgetriebe DR10 V2 Set 2/1, 4/1, 4/2, 6/1 1)
2 70590333 1 Hubgetriebe DR10 V3 Set 2/1, 4/1, 4/2 1)
# 2 70580133 1 Hubgetriebe DR10 V1 Set 6/1
3 70590033 1 Dichtung DR10 Set 1)
4 70590433 1 Getriebegehäuse DR10 Set 1)
5 70590533 1 Hubmotor DR10 V1 Set 2/1, 4/1, 4/2
DE
5 70590633 1 Hubmotor DR10 V2 Set 2/1, 4/1, 4/2, 6/1
5 70590733 1 Hubmotor DR10 V3 Set 2/1, 4/1, 4/2
# 5 70580233 1 Hubmotor DR10 V1 Set 6/1
21711901.tbl
217119k1.p65/080805
1) Füllmenge 7,2 Liter, Bestell-Nr. 472 902 44 (1,0 kg). 3

# Hubeinheit EZDR-Pro 10 - H12 - H20
Einscherung 2/1 - SGS - ZMS
DE
42648644.jpg
1 3 4 6
SGS
70393633.jpg
ZMS
70190833.jpg 70591033.jpg 70394533.jpg 70191733.jpg
7 8 2m, 3m, 4m 9
SGS
70191933.jpg
ZMS
70191433.jpg 70395833.jpg 70196733.jpg
10 13 14 15
70080033.jpg 70197733.jpg 71913933.jpg 70588033.jpg
16 17 18 19
70588133.jpg 70588533.jpg 70588633.jpg 75221044.jpg
20 22 23 24
217119k1.p65/080805
70589033.jpg
21
4 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

1 70590833 1 Bolzen DR10 H12 Set

1 70590933 1 Bolzen DR10 H20 Set
3 70591033 1 Radsatz EZDR Set
4 70593633 1 Seilkeiltraverse EZDR 10 2m SGS
4 70593333 1 Seilkeiltraverse EZDR 10 ZMS
6 70591733 1 Seiltasche DR10 Set
7 70591933 1 Überlastabschaltung DR10 2m SGS
DE
7 70591833 1 Zugmessstab ZMS DR10 2/1Set
8 70595833 1 Drahtseil DR10 H12 2/1 Set 2m
8 70599633 1 Drahtseil DR10 H12 2/1 Set 3m, 4m
9 70596733 1 Seiltrommel DR10 H12 1r
# 10 70480033 1 Seilführung DR 10/13 Li Set
13 70597733 1 Verkleidungsblech DR10 H12 V1
14 71913933 1 Gehäuse kompl. DR10 FU
15 70588033 1 Radblock 125 A Set
16 70588133 1 Radblock 125 NA Set
17 70588533 1 Fahrmotor EZDR Set
18 70588633 1 Getriebe Set
19 75221044 1 Rollenführungsset DRS125
20 70589033 1 Laufrolle B62 DRS Set
21 70591133 1 Puffer 70x 70 Set
# 22 70506033 1 Andruckschwinge Set EZDR
23 70197633 1 Stützrolle DR 3 Set EZDR 10
# 24 70589533 1 Fahrantrieb EZDR Set
21711903.tbl
217119k1.p65/080805
5
DE
42648744.jpg
1 3 4 5 6
SGS
70193733.jpg
ZMS
70190833.jpg 70591033.jpg 70394833.jpg 70194633.jpg 70191733.jpg
7 8 2m, 3m, 4m 9
SGS
70191933.jpg
ZMS
70191433.jpg 70196133.jpg 70196733.jpg
10 12 13 14
2m, 3m 4m
15 16 17 18 19
20 22 23 24
217119k1.p65/080805
70589033.jpg
21
6 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

1 70590833 1 Bolzen DR10 H12 Set

1 70590933 1 Bolzen DR10 H20 Set
4 70594833 1 Oberflasche EZDR10 4/1 Set 2m, 3m
4 70595133 1 Oberflasche EZDR10 4/1 4m Set
5 70594633 1 Seilkeiltraverse H12 4/1 ZMS 2m, 3m
5 70594733 1 Seilkeiltraverse H20 4/1 ZMS 2m, 3m
5 70594433 1 Seilkeiltraverse H12 4/1 ZMS 4m
5 70594533 1 Seilkeiltraverse H20 4/1 ZMS 4m
5 70593733 1 Seilkeiltraverse H12 4/1 2m SGS
DE
7 70591433 1 Zugmessstab ZMS DR10 4/1Set ZMS
12 70595233 1 Seilrolle DR10 4/1 Set 2m, 3m
12 70595333 1 Seilrolle DR10 4/1 Set 4m
15 70588033 1 Radblock 125 A Set
16 70588133 1 Radblock 125 NA Set
21 70591133 1 Puffer 70x 70 Set
21711904.tbl
217119k1.p65/080805
7
# Hubeinheit EZDR-Pro 10 - H40
DE
42688844.jpg
1 3 4 5 6
SGS
70583733.jpg
ZMS
7 8 2m, 3m, 4m 9
SGS
70191933.jpg
ZMS
70191433.jpg 70196133.jpg 70196733.jpg
10 12 13 14
2m, 3m 4m
15 16 17 18 19
20 22 23 24
217119k1.p65/080805
70589033.jpg
21
8 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

# Hubeinheit EZDR-Pro 10 - H40
# 1 70594333 1 Bolzen DR10 H40 Set

4 70594833 1 Oberflasche EZDR10 4/1 Set 2m, 3m
4 70595133 1 Oberflasche EZDR10 4/1 4m Set
# 5 70584033 1 Seilkeiltraverse H40 ZMS 2m, 3m
# 5 70584133 1 Seilkeiltraverse H40 ZMS 4m
# 5 70583733 1 Seilkeiltraverse H40 4/1 2m SGS
DE
# 8 70596033 1 Drahtseil DR10 H40 4/1 Set 2m
# 8 70596333 1 Drahtseil DR10 H40 4/1 Set 3m, 4m
# 9 70596933 1 Seiltrommel DR10 H40 1r
12 70595233 1 Seilrolle DR10 4/1 Set 2m, 3m
# 13 70597933 1 Verkleidungsblech DR10 H40
15 70588033 1 Radblock 125 A Set
16 70588133 1 Radblock 125 NA Set
21 70591133 1 Puffer 70x 70 Set
21711905.tbl
217119k1.p65/080805
9
# Hubeinheit EZDR-Pro 10 - H12 - H20 - H40
Einscherung 4/2
DE
42590944.jpg
1 3 5
70190833.jpg 70591033.jpg 70595733.jpg

7 8 9 10
70191433.jpg 70596433.jpg 70197033.jpg 70080033.jpg
11 12 13 14 15
16 17 18 19
70588133.jpg 70588533.jpg 70588633.jpg 75221044.jpg
20 22 23 24
217119k1.p65/080805
70589033.jpg
21
10 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

# Hubeinheit EZDR-Pro 10 - H12 - H20 - H40
Einscherung 4/2
1 70590833 1 Bolzen DR10 H12 Set

1 70590933 1 Bolzen DR10 H20 Set
1 70594333 1 Bolzen DR10 H40 Set
5 70595733 1 Ausgleichsrolle EZDR10 Set
7 70591833 1 Zugmessstab ZMS DR10 2/1Set
8 70596433 1 Drahtseil DR10 H12 4/2 Set
DE
# 11 70481233 1 Seilführung DR 10/9 Re Set
12 70595433 1 Seilrolle DR10 4/2 Set
15 70588033 1 Radblock 125 A Set
16 70588133 1 Radblock 125 NA Set
21 70591133 1 Puffer 70x 70 Set
23 70597633 1 Stützrolle DR10 Set EZDR 10
21711906.tbl
217119k1.p65/080805
11
DE
42665744.jpg
1 3 4 6
SGS
70586333.eps
ZMS
70190833.eps 70591033.eps 70586033.eps 70191733.eps
7 8 9
SGS
70191933.jpg
ZMS
70191433.jpg 70195833.jpg 70196733.jpg
10 12 13 14 15
70080033.jpg 70585433.eps 70197733.jpg 71913933.jpg 70588033.jpg
16 17 18 19
70588133.jpg 70588533.jpg 70588733.jpg 75221044.jpg
20 22 23 24
217119k1.p65/080805
70589033.jpg
21
12 70591133.jpg 70506033.jpg 70197633.jpg 70589633.jpg

1 70590933 1 Bolzen DR10 H20 Set

1 70594333 1 Bolzen DR10 H40 Set
3 70581033 1 Radsatz 160 EZDR Set
4 70586033 1 Seilkeiltraverse 6/1 2m SGS
4 70586333 1 Seilkeiltraverse 6/1 ZMS 2m, 3m
4 70586433 1 Seilkeiltraverse 6/1 ZMS 4m
7 70584433 1 Überlastabschaltung DR10 6/1 SGS
DE
12 70585433 1 Oberflasche 6/1 Set
15 70588233 1 Radblock 160 A Set
16 70588333 1 Radblock 160 NA Set
17 70588433 1 Fahrmotor ZBA 90 Set
18 70588733 1 Getriebe EZDR A30 Set
21 70581133 1 Puffer 100 Set
# 23 70197633 1 Stützrolle DR 3 Set EZDR10
24 70589633 1 Fahrantrieb ZBA90 A30 Set
21711907.tbl
217119k1.p65/080805
13
# Unterflasche 2/1-2m, 3m, 4m
1 2 3 2m, 3m 4m
2m, 3m 4m
DE
70598033.jpg 70598233.jpg
6 7 8
2m, 3m 4m
2m, 3m
70585233.jpg
82921933.jpg
4
4m
71321033.jpg 34182633.jpg 71304033.jpg 71293033.jpg 82926133.jpg 82926933.jpg 70585333.jpg
# 1 71321033 1 Unterflasche 1-rollig 230/13 2m, 3m

# 2 82921933 1 Unterflasche 1-rollig 280/14 4m
3 70598033 1 Seilrollenhaube 2/1 Set 2m, 3m
# 3 70587933 1 Seilrollenhaube 2/1 Set 4m
# 4 34182633 1 Hakenmaulsicherung 2,5 DIN 15106
# 6 71304033 1 Lasthaken RSN 2,5 T Set 2m, 3m
# 6 71293033 1 Doppellasthaken RSN 2,5 T Set 2m, 3m
# 7 15084333 1 Einfachhaken mit Traverse ASN 2,5S 4m
# 7 15084533 1 Doppellasthaken BSN 2,5S+TRAV 4m
# 8 70585233 1 Seilrolle DR10 2/1 Set 2m, 3m
# 8 70585333 1 Seilrolle DR10 2/1 Set 4m
21701905.tbl
Unterflasche 4/1-2m, 3m, 6/1

1 4/1-2m, 3m 6/1 2 3
34182633.jpg
5 6
70198133.jpg
4

217119k1.p65/080805
# 1 71323033 1 Unterflasche 2-rollig 230/13 4/1

# 1 71324033 1 Unterflasche 3-rollig 280/13 5V 6/1
2 70598133 1 Seilrollenhaube 4/1 Set
# 3 34182733 1 Hakenmaulsicherung 4 4/1 DIN 15106
4 70595233 1 Seilrolle DR10 4/1 Set
5 70598433 1 Lasthaken RSN 4 Set 4/1
# 6 71295033 1 Doppellasthaken RSN 4 T Set 4/1
14 21711914.tbl
# Unterflasche 4/1-4m, 4/2
1 2 3
4/2
4/2
DE
70598233.jpg
4/1-4m
82926933.jpg
6
82926833.jpg
4
4/1-4m
70598333.jpg 34182633.jpg
7 8
4/1-4m 4/2
82926033.jpg 70595333.jpg 70595433.jpg 82926133.jpg
Unterflasche 4/1-4m
2 70598333 1 Seilrollenhaube 4/1 Set 4m

3 82926933 1 Doppellasthaken GSN 5-S +TRAV
4 82926033 1 Unterflasche 2-rollig 280/14
6 34182833 1 Hakenmaulsicherung 5 DIN 15106
8 82926144 1 Einfachhaken mit Traverse GSN 5-S
21701907.tbl
Unterflasche 4/2
# 1 82926833 1 Unterflasche 2-rollig 225/11

2 70598233 1 Seilrollenhaube 4/2 Set
# 3 15084533 1 Doppellasthaken BSN 2,5S+TRAV
# 6 34182633 1 Hakenmaulsicherung 2,5 DIN 15106
7 70595433 1 Seilrolle DR10 4/2 Set
# 8 15084333 1 Einfachhaken mit Traverse ASN 2,5S
217119k1.p65/080805
21701908.tbl
15
Reparaturset Hubmotor ZBR 132
1 2 3
DE
26098433.jpg 26098133.jpg 70598733.jpg
1 26098433 1 Verschleissset B140

2 26098133 1 Überholungsset B140/ZBA132
3 70598733 1 Hubmotor Z132 LH Set
21701912.tbl
Reparaturset Fahrmotor ZBA 71, ZBA 90

1 2 3
ZBA 71 ZBA 71
26096233.jpg 26096033.jpg
ZBA 90 ZBA 90
26098433.jpg 26096733.jpg 70598733.jpg
ZBA 71

2 26096033 1 Überholungsset B003
3 70599033 1 Fahrmotor Z 71 LH Set
21701911.tbl
ZBA 90
217119k1.p65/080805

2 26096733 1 Überholungsset B007/ZBA 80
3 70599133 1 Fahrmotor Z90 LH Set
21711911.tbl
16
# Elektrische Bauteile EZDR-Pro 10
1 2 3 4
DE
71998033.jpg 71988933.jpg 71989333.jpg 71999133.jpg
5 8 11
71999633.jpg
9 6/1
70199233.jpg 71999533.jpg 71997033.jpg
7 10 6/1
71989133.jpg 71999733.jpg 71997133.jpg 71999033.jpg
1 71998533 1 Baugruppe Deckel DR10T V1Set

1 71998633 1 Baugruppe Deckel/Umrichter DR10T Set
# 2 71988933 1 Katzfahrendschalter EZDR Set
3 71989433 1 Leistungsschalter 25A Set
4 71999333 1 Dichtungsprofil Set 1,5 M
5 70599233 1 Gehäuse Elektrik Set DR10 1)
7 71989233 1 Schütz DR5V2-DR10 Set
8 71999633 1 Getriebegrenzschalter SGG Set
9 71999533 1 Freq.Umrichter Dedriv DIC-4-002-C
# 9 71997033 1 Freq.Umrichter Dedriv DIC-4-007-C 6/1
10 71999733 1 Bremswiderstand 470R Set
# 10 71997133 1 Bremswiderstand 120R Set 6/1
# 11 71999833 1 Steckerleitung Set EZDR
21711915.tbl
217119k1.p65/080805
1) Die Verschraubungen nach DIN 912 sind mit Loctite 290 zu sichern. Bestell-Nr. 007 275 84. 17
# Hoist drive EZDR-Pro 10
1
EN
70010133.jpg
2 3
70190133.jpg 70190033.jpg
4 5
70190433.jpg 70190533.jpg
217119k2.p65/110705
# Alterations compared with previous issue

Example
18 # 1 70410133 1 Lifting drive DR10-V1
# Hoist drive EZDR-Pro 10
Item no. Part no. Quantity Designation Material Standard
# 1 70410133 1 Lifting drive DR10-V1 2/1, 4/1, 4/2

# 1 70410233 1 Lifting drive DR10-V2 2/1, 4/1, 4/2, 6/1
# 1 70410333 1 Lifting drive DR10-V3 2/1, 4/1, 4/2
# 1 70410533 1 Lifting drive DR10-V1 6/1
2 70590133 1 Lifting gearbox DR10 V1 Set 2/1, 4/1, 4/2 1)
2 70590233 1 Lifting gearbox DR10 V2 Set 2/1, 4/1, 4/2, 6/1 1)
2 70590333 1 Lifting gearbox DR10 V3 Set 2/1, 4/1, 4/2 1)
# 2 70580133 1 Lifting gearbox DR10 V1 Set 6/1
3 70590033 1 Seal DR10 Set 1)
4 70590433 1 Gearbox housing DR10 Set 1)
5 70590533 1 Lifting motor DR10 V1 Set 2/1, 4/1, 4/2
5 70590633 1 Lifting motor DR10 V2 Set 2/1, 4/1, 4/2, 6/1
5 70590733 1 Lifting motor DR10 V3 Set 2/1, 4/1, 4/2
# 5 70580233 1 Lifting motor DR10 V1 Set 6/1
21711901.tbl
EN
217119k2.p65/110705
1) Quantity 7,2 litre, part no. 472 902 44 (1,0 kg). 19

# Hoist unit EZDR-Pro 10 - H12 - H20
2/1 reeving - SGS - ZMS
EN
42648644.jpg
1 3 4 6
SGS
70393633.jpg
ZMS
70190833.jpg 70591033.jpg 70394533.jpg 70191733.jpg
7 8 2m, 3m, 4m 9
SGS
70191933.jpg
ZMS
70191433.jpg 70395833.jpg 70196733.jpg
10 13 14 15
70080033.jpg 70197733.jpg 71913933.jpg 70588033.jpg
16 17 18 19
70588133.jpg 70588533.jpg 70588633.jpg 75221044.jpg
20 22 23 24
217119k2.p65/110705
70589033.jpg
21
20 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

1 70590833 1 Pin DR10 H12 Set

1 70590933 1 Pin DR10 H20 Set
3 70591033 1 Wheel set EZDR Set
4 70593633 1 Rope wedge crosshead EZDR 10 2m SGS
4 70593333 1 Rope wedge crosshead EZDR 10 ZMS
6 70591733 1 Rope anchorage DR10 Set
7 70591933 1 Overload cut-off DR10 2m SGS
7 70591833 1 Strain gauge carr. link ZMS DR10 2/1Set
8 70595833 1 Wire rope DR10 H12 2/1 Set 2m
8 70599633 1 Wire rope DR10 H12 2/1 Set 3m, 4m
9 70596733 1 Rope drum DR10 H12 1r
9 70596833 1 Rope drum DR10 H20 1r
# 10 70480033 1 Rope guide DR 10/13 Li Set
13 70597733 1 Cladding plate DR10 H12 V1
14 71913933 1 Housing kompl. DR10 FU
EN
15 70588033 1 Wheel block 125 A Set
16 70588133 1 Wheel block 125 NA Set
17 70588533 1 Travel motor EZDR Set
18 70588633 1 Gearbox Set
19 75221044 1 Roller guide set DRS125
20 70589033 1 Travel roller B62 DRS Set
21 70591133 1 Buffer 70x 70 Set
# 22 70506033 1 Thrust rocker Set EZDR
23 70197633 1 Supporting roller DR 3 Set EZDR 10
# 24 70589533 1 Travel drive EZDR Set
21711903.tbl
217119k2.p65/110705
21
EN
42648744.jpg
1 3 4 5 6
SGS
70193733.jpg
ZMS
7 8 2m, 3m, 4m 9
SGS
70191933.jpg
ZMS
70191433.jpg 70196133.jpg 70196733.jpg
10 12 13 14
2m, 3m 4m
15 16 17 18 19
20 22 23 24
217119k2.p65/110705
70589033.jpg
21
22 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

1 70590833 1 Pin DR10 H12 Set

1 70590933 1 Pin DR10 H20 Set
4 70594833 1 Top block EZDR10 4/1 Set 2m, 3m
4 70595133 1 Top block EZDR10 4/1 4m Set
5 70594633 1 Rope wedge crosshead H12 4/1 ZMS 2m, 3m
5 70594733 1 Rope wedge crosshead H20 4/1 ZMS 2m, 3m
5 70594433 1 Rope wedge crosshead H12 4/1 ZMS 4m
5 70594533 1 Rope wedge crosshead H20 4/1 ZMS 4m
5 70593733 1 Rope wedge crosshead H12 4/1 2m SGS
7 70591433 1 Strain gauge carr. link ZMS DR10 4/1Set ZMS
EN
9 70596733 1 Rope drum DR10 H12 1r
9 70596833 1 Rope drum DR10 H20 1r
12 70595233 1 Rope sheave DR10 4/1 Set 2m, 3m
12 70595333 1 Rope sheave DR10 4/1 Set 4m
21 70591133 1 Buffer 70x 70 Set
21711904.tbl
217119k2.p65/110705
23
# Hoist unit EZDR-Pro 10 - H40
EN
42688844.jpg
1 3 4 5 6
SGS
70583733.jpg
ZMS
7 8 2m, 3m, 4m 9
SGS
70191933.jpg
ZMS
70191433.jpg 70196133.jpg 70196733.jpg
10 12 13 14
2m, 3m 4m
15 16 17 18 19
20 22 23 24
217119k2.p65/110705
70589033.jpg
21
24 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

# Hoist unit EZDR-Pro 10 - H40
# 1 70594333 1 Pin DR10 H40 Set

4 70594833 1 Top block EZDR10 4/1 Set 2m, 3m
4 70595133 1 Top block EZDR10 4/1 4m Set
# 5 70584033 1 Rope wedge crosshead H40 ZMS 2m, 3m
# 5 70584133 1 Rope wedge crosshead H40 ZMS 4m
# 5 70583733 1 Rope wedge crosshead H40 4/1 2m SGS
# 8 70596033 1 Wire rope DR10 H40 4/1 Set 2m
# 8 70596333 1 Wire rope DR10 H40 4/1 Set 3m, 4m
# 9 70596933 1 Rope drum DR10 H40 1r
12 70595233 1 Rope sheave DR10 4/1 Set 2m, 3m
# 13 70597933 1 Cladding plate DR10 H40
EN
21 70591133 1 Buffer 70x 70 Set
21711905.tbl
217119k2.p65/110705
25
# Hoist unit EZDR-Pro 10 - H12 - H20 - H40
4/2 reeving
EN
42590944.jpg
1 3 5
70190833.jpg 70591033.jpg 70595733.jpg

7 8 9 10
70191433.jpg 70596433.jpg 70197033.jpg 70080033.jpg
11 12 13 14 15
16 17 18 19
70588133.jpg 70588533.jpg 70588633.jpg 75221044.jpg
20 22 23 24
217119k2.p65/110705
70589033.jpg
21
26 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

# Hoist unit EZDR-Pro 10 - H12 - H20 - H40
4/2 reeving
1 70590833 1 Pin DR10 H12 Set

1 70590933 1 Pin DR10 H20 Set
1 70594333 1 Pin DR10 H40 Set
5 70595733 1 Compensating sheave EZDR10 Set
7 70591833 1 Strain gauge carr. link ZMS DR10 2/1Set
8 70596433 1 Wire rope DR10 H12 4/2 Set
8 70596533 1 Wire rope DR10 H20 4/2 Set
8 70596633 1 Wire rope DR10 H40 4/2 Set
9 70597033 1 Rope drum DR10 H12 2r
9 70597133 1 Rope drum DR10 H20 2r
9 70597233 1 Rope drum DR10 H40 2r
# 11 70481233 1 Rope guide DR 10/9 Re Set
12 70595433 1 Rope sheave DR10 4/2 Set
EN
21 70591133 1 Buffer 70x 70 Set
23 70597633 1 Supporting roller DR10 Set EZDR 10
21711906.tbl
217119k2.p65/110705
27
EN
42665744.jpg
1 3 4 6
SGS
70586333.eps
ZMS
70190833.eps 70591033.eps 70586033.eps 70191733.eps
7 8 9
SGS
70191933.jpg
ZMS
70191433.jpg 70195833.jpg 70196733.jpg
10 12 13 14 15
16 17 18 19
70588133.jpg 70588533.jpg 70588733.jpg 75221044.jpg
20 22 23 24
217119k2.p65/110705
70589033.jpg
21
28 70591133.jpg 70506033.jpg 70197633.jpg 70589633.jpg

1 70590933 1 Pin DR10 H20 Set

1 70594333 1 Pin DR10 H40 Set
3 70581033 1 Wheel set 160 EZDR Set
4 70586033 1 Rope wedge crosshead 6/1 2m SGS
4 70586333 1 Rope wedge crosshead 6/1 ZMS 2m, 3m
4 70586433 1 Rope wedge crosshead 6/1 ZMS 4m
7 70584433 1 Overload cut-off DR10 6/1 SGS
9 70596833 1 Rope drum DR10 H20 1r
9 70596933 1 Rope drum DR10 H40 1r
12 70585433 1 Top block 6/1 Set
EN
17 70588433 1 Travel motor ZBA 90 Set
18 70588733 1 Gearbox EZDR A30 Set
21 70581133 1 Buffer 100 Set
# 23 70197633 1 Supporting roller DR 3 Set EZDR10
24 70589633 1 Travel drive ZBA90 A30 Set
21711907.tbl
217119k2.p65/110705
29
# Bottom block 2/1-2m, 3m, 4m
1 2 3 2m, 3m 4m
2m, 3m 4m
70598033.jpg 70598233.jpg
6 7 8
2m, 3m 4m
2m, 3m
70585233.jpg
82921933.jpg
EN
4
4m
# 1 71321033 1 Single-sheave bott.block 230/13 2m, 3m

# 2 82921933 1 Single-sheave bott.block 280/14 4m
3 70598033 1 Rope sheave hood 2/1 Set 2m, 3m
# 3 70587933 1 Rope sheave hood 2/1 Set 4m
# 4 34182633 1 Hook safety catch 2,5 DIN 15106
# 6 71304033 1 Load hook RSN 2,5 T Set 2m, 3m
# 6 71293033 1 Double load hook RSN 2,5 T Set 2m, 3m
# 7 15084333 1 Simple hook with cross beam ASN 2,5S 4m
# 7 15084533 1 Double load hook BSN 2,5S+TRAV 4m
# 8 70585233 1 Rope sheave DR10 2/1 Set 2m, 3m
# 8 70585333 1 Rope sheave DR10 2/1 Set 4m
21701905.tbl
Bottom block 4/1-2m, 3m, 6/1
1 4/1-2m, 3m 6/1 2 3
34182633.jpg
5 6
70198133.jpg
4

217119k2.p65/110705
# 1 71323033 1 2-sheave bottom block 230/13 4/1

# 1 71324033 1 Bottom block 3-sheave 280/13 5V 6/1
2 70598133 1 Rope sheave hood 4/1 Set
# 3 34182733 1 Hook safety catch 4 Set 4/1 DIN 15106
5 70598433 1 Load hook RSN 4 Set 4/1
# 6 71295033 1 Double load hook RSN 4 T Set 4/1
30 21711914.tbl
# Bottom block 4/1-4m, 4/2
1 2 3
4/2
4/2
70598233.jpg
4/1-4m
82926933.jpg
6
EN
82926833.jpg
4
4/1-4m
70598333.jpg 34182633.jpg
7 8
4/1-4m 4/2
82926033.jpg 70595333.jpg 70595433.jpg 82926133.jpg
Bottom block 4/1-4m

2 70598333 1 Rope sheave hood 4/1 Set 4m

3 82926933 1 Double load hook GSN 5-S +TRAV
4 82926033 1 2-sheave bottom block 280/14
6 34182833 1 Hook safety catch 5 Set DIN 15106
8 82926133 1 Simple hook with cross beam GSN 5-S
21701907.tbl
Bottom block 4/2

# 1 82926833 1 2-sheave bottom block 225/11

2 70598233 1 Rope sheave hood 4/2 Set
# 3 15084533 1 Double load hook BSN 2,5S+TRAV
# 6 34182633 1 Hook safety catch 2,5 DIN 15106
# 8 15084333 1 Simple hook with cross beam ASN 2,5S
217119k2.p65/110705
21701908.tbl
31
Lifting motor repair set ZBR 132
1 2 3
26098433.jpg 26098133.jpg 70598733.jpg

EN
1 26098433 1 Wear and tear set B140

2 26098133 1 Overhauling set B140/ZBA132
3 70598733 1 Lifting motor Z132 LH Set
21701912.tbl
Travel motor repair set ZBA 71, ZBA 90

1 2 3
ZBA 71 ZBA 71
26096233.jpg 26096033.jpg
ZBA 90 ZBA 90
26098433.jpg 26096733.jpg 70598733.jpg
ZBA 71

2 26096033 1 Overhauling set B003
3 70599033 1 Travel motor Z 71 LH Set
21701911.tbl
ZBA 90
217119k2.p65/110705

2 26096733 1 Overhauling set B007/ZBA 80
3 70599133 1 Travel motor Z 90 LH Set
21711911.tbl
32
# Electrical components EZDR-Pro 10
1 2 3 4
71998033.jpg 71988933.jpg 71989333.jpg 71999133.jpg

5 8 11
EN
71999633.jpg
9 6/1
70199233.jpg 71999533.jpg 71997033.jpg
7 10 6/1
71989133.jpg 71999733.jpg 71997133.jpg 71999033.jpg
1 71998533 1 Cover sub-assemmbly DR10T V1Set

1 71998633 1 Cover sub-assemmbly/inverter DR10T Set
# 2 71988933 1 Cross-travel limit switch EZDR Set
3 71989433 1 Power circuit breaker 25A Set
4 71999333 1 Profiled joint Set 1,5 M
5 70599233 1 Housing el.equipm. Set DR10 1)
7 71989233 1 Contactor DR5V2-DR10 Set
8 71999633 1 Geared limit switch SGG Set
9 71999533 1 Freq.inverter Dedriv DIC-4-002-C
# 9 71997033 1 Freq.inverter Dedriv DIC-4-007-C 6/1
10 71999733 1 Braking resistance 470R Set
# 10 71997133 1 Braking resistance 120R Set 6/1
# 11 71999833 1 Patch cord Set EZDR
21711915.tbl
217119k2.p65/110705
1) The bolted connections to DIN 912 must be secured with Loctite 290. Order no. 007 275 84. 33
# Mécanisme de levage EZDR-Pro 10
70010133.jpg
2 3
FR
70190133.jpg 70190033.jpg
4 5
70190433.jpg 70190533.jpg
217119k3.p65/080805
# Modifications par rapport à l’édition précédente

Exemple
34 # 1 70410133 1 Mécanisme de levage DR10-V1
# Mécanisme de levage EZDR-Pro 10
Rep. No réf. Qté. Désignation Matériaux Norme
# 1 70410133 1 Mécanisme de levage DR10-V1 2/1, 4/1, 4/2

# 1 70410233 1 Mécanisme de levage DR10-V2 2/1, 4/1, 4/2, 6/1
# 1 70410333 1 Mécanisme de levage DR10-V3 2/1, 4/1, 4/2
# 1 70410533 1 Mécanisme de levage DR10-V1 6/1
2 70590133 1 Réducteur de levage DR10 V1 Set 2/1, 4/1, 4/2 1)
2 70590233 1 Réducteur de levage DR10 V2 Set 2/1, 4/1, 4/2, 6/1 1)
2 70590333 1 Réducteur de levage DR10 V3 Set 2/1, 4/1, 4/2 1)
# 2 70580133 1 Réducteur de levage DR10 V1 Set 6/1
3 70590033 1 Joint d’étanchéité DR10 Set 1)
4 70590433 1 Carter réducteur DR10 Set 1)
5 70590533 1 Moteur de levage DR10 V1 Set 2/1, 4/1, 4/2
5 70590633 1 Moteur de levage DR10 V2 Set 2/1, 4/1, 4/2, 6/1
5 70590733 1 Moteur de levage DR10 V3 Set 2/1, 4/1, 4/2
# 5 70580233 1 Moteur de levage DR10 V1 Set 6/1
21711901.tbl
FR
217119k3.p65/080805
1) Quantité de remplissage 7,2 litre, no de réf. 472 902 44 (1,0 kg). 35

# Unité de levage EZDR-Pro 10 - H12 - H20
Mouflage 2/1 - SGS - ZMS
42648644.jpg
1 3 4 6
SGS
70393633.jpg
FR
ZMS
70190833.jpg 70591033.jpg 70394533.jpg 70191733.jpg
7 8 2m, 3m, 4m 9
SGS
70191933.jpg
ZMS
70191433.jpg 70395833.jpg 70196733.jpg
10 13 14 15
70080033.jpg 70197733.jpg 71913933.jpg 70588033.jpg
16 17 18 19
70588133.jpg 70588533.jpg 70588633.jpg 75221044.jpg
20 22 23 24
217119k3.p65/080805
70589033.jpg
21
36 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

1 70590833 1 Axe DR10 H12 Set

1 70590933 1 Axe DR10 H20 Set
3 70591033 1 Galet équipé EZDR Set
4 70593633 1 Traverse attache-câble EZDR 10 2m SGS
4 70593333 1 Traverse attache-câble EZDR 10 ZMS
6 70591733 1 Poche à câble DR10 Set
7 70591933 1 Interrupteur-limiteur charge DR10 2m SGS
7 70591833 1 Capteur de mesure ZMS DR10 2/1Set
8 70595833 1 Câble métallique DR10 H12 2/1 Set 2m
8 70599633 1 Câble métallique DR10 H12 2/1 Set 3m, 4m
9 70596733 1 Tambour à câble DR10 H12 1r
# 10 70480033 1 Guide-câble DR 10/13 Li Set
13 70597733 1 Tôle de coffrage DR10 H12 V1
14 71913933 1 Boîtier kompl. DR10 FU
15 70588033 1 Bloc-galet 125 A Set
16 70588133 1 Bloc-galet 125 NA Set
17 70588533 1 Moteur de translation EZDR Set
18 70588633 1 Réducteur Set
19 75221044 1 Kit guidage par galets DRS125
20 70589033 1 Galet B62 DRS Set
21 70591133 1 Tampon élastique 70x 70 Set
# 22 70506033 1 Balancier presseur Set EZDR
23 70197633 1 Galet d’appui DR 3 Set EZDR 10
# 24 70589533 1 Mécan. translation EZDR Set
FR
21711903.tbl
217119k3.p65/080805
37
42648744.jpg
1 3 4 5 6
SGS
70193733.jpg
ZMS
FR
7 8 2m, 3m, 4m 9
SGS
70191933.jpg
ZMS
70191433.jpg 70196133.jpg 70196733.jpg
10 12 13 14
2m, 3m 4m
15 16 17 18 19
20 22 23 24
217119k3.p65/080805
70589033.jpg
21
38 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

1 70590833 1 Axe DR10 H12 Set

1 70590933 1 Axe DR10 H20 Set
4 70594833 1 Moufle supérieure EZDR10 4/1 Set 2m, 3m
4 70595133 1 Moufle supérieure EZDR10 4/1 4m Set
5 70594633 1 Traverse attache-câble H12 4/1 ZMS 2m, 3m
5 70594733 1 Traverse attache-câble H20 4/1 ZMS 2m, 3m
5 70594433 1 Traverse attache-câble H12 4/1 ZMS 4m
5 70594533 1 Traverse attache-câble H20 4/1 ZMS 4m
5 70593733 1 Traverse attache-câble H12 4/1 2m SGS
7 70591433 1 Capteur de mesure ZMS DR10 4/1Set ZMS
12 70595233 1 Poulie à câble DR10 4/1 Set 2m, 3m
12 70595333 1 Poulie à câble DR10 4/1 Set 4m
FR
15 70588033 1 Bloc-galet 125 A Set
20 70589033 1 Galet B62 DRS Set
21711904.tbl
217119k3.p65/080805
39
# Unité de levage EZDR-Pro 10 - H40
42688844.jpg
1 3 4 5 6
SGS
70583733.jpg
ZMS
FR
7 8 2m, 3m, 4m 9
SGS
70191933.jpg
ZMS
70191433.jpg 70196133.jpg 70196733.jpg
10 12 13 14
2m, 3m 4m
15 16 17 18 19
20 22 23 24
217119k3.p65/080805
70589033.jpg
21
40 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

# Unité de levage EZDR-Pro 10 - H40
# 1 70594333 1 Axe DR10 H40 Set

4 70594833 1 Moufle supérieure EZDR10 4/1 Set 2m, 3m
4 70595133 1 Moufle supérieure EZDR10 4/1 4m Set
# 5 70584033 1 Traverse attache-câble H40 ZMS 2m, 3m
# 5 70584133 1 Traverse attache-câble H40 ZMS 4m
# 5 70583733 1 Traverse attache-câble H40 4/1 2m SGS
# 8 70596033 1 Câble métallique DR10 H40 4/1 Set 2m
# 8 70596333 1 Câble métallique DR10 H40 4/1 Set 3m, 4m
# 9 70596933 1 Tambour à câble DR10 H40 1r
12 70595233 1 Poulie à câble DR10 4/1 Set 2m, 3m
# 13 70597933 1 Tôle de coffrage DR10 H40
15 70588033 1 Bloc-galet 125 A Set
20 70589033 1 Galet B62 DRS Set
FR
21711905.tbl
217119k3.p65/080805
41
# Unité de levage EZDR-Pro 10 - H12 - H20 - H40
Mouflage 4/2
42590944.jpg
1 3 5
FR
70190833.jpg 70591033.jpg 70595733.jpg

7 8 9 10
70191433.jpg 70596433.jpg 70197033.jpg 70080033.jpg
11 12 13 14 15
16 17 18 19
70588133.jpg 70588533.jpg 70588633.jpg 75221044.jpg
20 22 23 24
217119k3.p65/080805
70589033.jpg
21
42 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

# Unité de levage EZDR-Pro 10 - H12 - H20 - H40
Mouflage 4/2
1 70590833 1 Axe DR10 H12 Set

1 70590933 1 Axe DR10 H20 Set
1 70594333 1 Axe DR10 H40 Set
5 70595733 1 Poulie d’équilibrage EZDR10 Set
7 70591833 1 Capteur de mesure ZMS DR10 2/1Set
8 70596433 1 Câble métallique DR10 H12 4/2 Set
# 11 70481233 1 Guide-câble DR 10/9 Re Set
12 70595433 1 Poulie à câble DR10 4/2 Set
15 70588033 1 Bloc-galet 125 A Set
20 70589033 1 Galet B62 DRS Set
23 70597633 1 Galet d’appui DR10 Set EZDR 10
21711906.tbl
FR
217119k3.p65/080805
43
42665744.jpg
1 3 4 6
SGS
70586333.eps
FR
ZMS
70190833.eps 70591033.eps 70586033.eps 70191733.eps
7 8 9
SGS
70191933.jpg
ZMS
70191433.jpg 70195833.jpg 70196733.jpg
10 12 13 14 15
16 17 18 19
70588133.jpg 70588533.jpg 70588733.jpg 75221044.jpg
20 22 23 24
217119k3.p65/080805
70589033.jpg
21
44 70591133.jpg 70506033.jpg 70197633.jpg 70589633.jpg

1 70590933 1 Axe DR10 H20 Set

1 70594333 1 Axe DR10 H40 Set
3 70581033 1 Galet équipé 160 EZDR Set
4 70586033 1 Traverse attache-câble 6/1 2m SGS
4 70586333 1 Traverse attache-câble 6/1 ZMS 2m, 3m
4 70586433 1 Traverse attache-câble 6/1 ZMS 4m
7 70584433 1 Interrupteur-limiteur charge DR10 6/1 SGS
12 70585433 1 Moufle supérieure 6/1 Set
15 70588233 1 Bloc-galet 160 A Set
17 70588433 1 Moteur de translation ZBA 90 Set
18 70588733 1 Réducteur EZDR A30 Set
20 70589133 1 Galet B72 DRS Set
21 70581133 1 Tampon élastique 100 Set
FR
# 23 70197633 1 Galet d’appui DR 3 Set EZDR10
24 70589633 1 Mécan. translation ZBA90 A30 Set
21711907.tbl
217119k3.p65/080805
45
# Moufle inférieure 2/1-2m, 3m, 4m
1 2 3 2m, 3m 4m
2m, 3m 4m
70598033.jpg 70598233.jpg
6 7 8
2m, 3m 4m
2m, 3m
70585233.jpg
82921933.jpg
4
4m
# 1 71321033 1 Moufle infér.1 poulie 230/13 2m, 3m

FR
# 2 82921933 1 Moufle infér.1 poulie 280/14 4m

3 70598033 1 Capot poulie à cable 2/1 Set 2m, 3m
# 3 70587933 1 Capot poulie à cable 2/1 Set 4m
# 4 34182633 1 Linguet de sécurité 2,5 DIN 15106
# 6 71304033 1 Crochet porte-charge RSN 2,5 T Set 2m, 3m
# 6 71293033 1 Crochet charge double RSN 2,5 T Set 2m, 3m
# 7 15084333 1 Crochet simple avec palonnier ASN 2,5S 4m
# 7 15084533 1 Crochet charge double BSN 2,5S+TRAV 4m
# 8 70585233 1 Poulie à câble DR10 2/1 Set 2m, 3m
# 8 70585333 1 Poulie à câble DR10 2/1 Set 4m
21701905.tbl
Moufle inférieure 4/1-2m, 3m, 6/1
1 4/1-2m, 3m 6/1 2 3
34182633.jpg
5 6
70198133.jpg
4

217119k3.p65/080805
# 1 71323033 1 Moufle infér.2 poulies 230/13 4/1

# 1 71324033 1 Moufle infér.3 poulies 280/13 5V 6/1
2 70598133 1 Capot poulie à cable 4/1 Set
# 3 34182733 1 Linguet de sécurité 4 Set 4/1 DIN 15106
5 70598433 1 Crochet porte-charge RSN 4 Set 4/1
# 6 71295033 1 Crochet charge double RSN 4 T Set 4/1
46 21711914.tbl
# Moufle inférieure 4/1-4m, 4/2
1 2 3
4/2
4/2
70598233.jpg
4/1-4m
82926933.jpg
6
82926833.jpg
4
4/1-4m
70598333.jpg 34182633.jpg
8
FR
7
4/1-4m 4/2
82926033.jpg 70595333.jpg 70595433.jpg 82926133.jpg
Moufle inférieure 4/1-4m

2 70598333 1 Capot poulie à cable 4/1 Set 4m

3 82926933 1 Crochet charge double GSN 5-S +TRAV
4 82926033 1 Moufle infér.2 poulies 280/14
6 34182833 1 Linguet de sécurité 5 Set DIN 15106
8 82926133 1 Crochet simple avec palonnier GSN 5-S
21701907.tbl
Moufle inférieure 4/2

# 1 82926833 1 Moufle infér.2 poulies 225/11

2 70598233 1 Capot poulie à cable 4/2 Set
# 3 15084533 1 Crochet charge double BSN 2,5S+TRAV
# 6 34182633 1 Linguet de sécurité 2,5 DIN 15106
# 8 15084333 1 Crochet simple avec palonnier ASN 2,5S
217119k3.p65/080805
21701908.tbl
47
Kit de réparation moteur de levage ZBR 132
1 2 3
26098433.jpg 26098133.jpg 70598733.jpg
1 26098433 1 Kit pièces d’usure B140

2 26098133 1 Kit de révision B140/ZBA132
3 70598733 1 Moteur de levage Z132 LH Set
21701912.tbl
Kit de réparation moteur de translation ZBA 71, ZBA 90

1 2 3
FR
ZBA 71 ZBA 71
26096233.jpg 26096033.jpg
ZBA 90 ZBA 90
26098433.jpg 26096733.jpg 70598733.jpg
ZBA 71

2 26096033 1 Kit de révision B003
3 70599033 1 Moteur de translation Z 71 LH Set
21701911.tbl
ZBA 90
217119k3.p65/080805

2 26096733 1 Kit de révision B007/ZBA 80
3 70599133 1 Moteur de translation Z 90 LH Set
21711911.tbl
48
# Eléments électriques EZDR-Pro 10
1 2 3 4
71998033.jpg 71988933.jpg 71989333.jpg 71999133.jpg

5 8 11
71999633.jpg
9 6/1
70199233.jpg 71999533.jpg 71997033.jpg
FR
7 10 6/1
71989133.jpg 71999733.jpg 71997133.jpg 71999033.jpg
1 71998533 1 Module couvercle DR10T V1Set

1 71998633 1 Module couvercle/convertis. DR10T Set
# 2 71988933 1 Fin de course direct.chariot EZDR Set
3 71989433 1 Disjoncteur 25A Set
4 71999333 1 Profilé d’étanchéité Set 1,5 M
5 70599233 1 Boîtier électrique Set DR10 1)
7 71989233 1 Contacteur DR5V2-DR10 Set
8 71999633 1 Sélecteur à vis de préc. SGG Set
9 71999533 1 Convertisseur Dedriv DIC-4-002-C
# 9 71997033 1 Convertisseur Dedriv DIC-4-007-C 6/1
10 71999733 1 Résistance de freinage 470R Set
# 10 71997133 1 Résistance de freinage 120R Set 6/1
# 11 71999833 1 Fiche de connexion Set EZDR
21711915.tbl
217119k3.p65/080805
1) Les éléments de vissage selon DIN 912 doivent être sécurisés avec du produit liquide Loctite 290. No de réf. 007 275 84. 49
# Mecanismo de elevación EZDR-Pro 10
70010133.jpg
2 3
ES
70190133.jpg 70190033.jpg
4 5
70190433.jpg 70190533.jpg
217119k4.p65/080805
Modificaciones con respecto a la edición anterior

Ejemplo
50 # 1 70410133 1 Accionam.elevación DR10-V1

# Mecanismo de elevación EZDR-Pro 10
N° pieza N° ref. Cdad. Denominación Material Norma
# 1 70410133 1 Accionam.elevación DR10-V1 2/1, 4/1, 4/2

# 1 70410233 1 Accionam.elevación DR10-V2 2/1, 4/1, 4/2, 6/1
# 1 70410333 1 Accionam.elevación DR10-V3 2/1, 4/1, 4/2
# 1 70410533 1 Accionam.elevación DR10-V1 6/1
2 70590133 1 Reductor de elevación DR10 V1 Set 2/1, 4/1, 4/2 1)
2 70590233 1 Reductor de elevación DR10 V2 Set 2/1, 4/1, 4/2, 6/1 1)
2 70590333 1 Reductor de elevación DR10 V3 Set 2/1, 4/1, 4/2 1)
# 2 70580133 1 Reductor de elevación DR10 V1 Set 6/1
3 70590033 1 Junta DR10 Set 1)
4 70590433 1 Carcasa de reductor DR10 Set 1)
5 70590533 1 Motor de elevación DR10 V1 Set 2/1, 4/1, 4/2
5 70590633 1 Motor de elevación DR10 V2 Set 2/1, 4/1, 4/2, 6/1
5 70590733 1 Motor de elevación DR10 V3 Set 2/1, 4/1, 4/2
# 5 70580233 1 Motor de elevación DR10 V1 Set 6/1
21711901.tbl
ES
217119k4.p65/080805
1) Cantidad necesaria 7,2 litro, nº de ref. 472 902 44 (1,0 kg). 51

# Unidad de elevación EZDR-Pro 10 - H12 - H20
Disposición 2/1 - SGS - ZMS
42648644.jpg
1 3 4 6
SGS
70393633.jpg
ZMS
70190833.jpg 70591033.jpg 70394533.jpg 70191733.jpg
7 8 2m, 3m, 4m 9
SGS
70191933.jpg
ES
ZMS
70191433.jpg 70395833.jpg 70196733.jpg
10 13 14 15
70080033.jpg 70197733.jpg 71913933.jpg 70588033.jpg
16 17 18 19
70588133.jpg 70588533.jpg 70588633.jpg 75221044.jpg
20 22 23 24
217119k4.p65/080805
70589033.jpg
21
52 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

1 70590833 1 Perno DR10 H12 Set

1 70590933 1 Perno DR10 H20 Set
3 70591033 1 Juego de rueda EZDR Set
4 70593633 1 Travesaño cuña de cable EZDR 10 2m SGS
4 70593333 1 Travesaño cuña de cable EZDR 10 ZMS
6 70591733 1 Guardacable DR10 Set
7 70591933 1 Limitación de carga DR10 2m SGS
7 70591833 1 Captador dinamométrico ZMS DR10 2/1Set
8 70595833 1 Cable metálico DR10 H12 2/1 Set 2m
8 70599633 1 Cable metálico DR10 H12 2/1 Set 3m, 4m
9 70596733 1 Tambor de cable DR10 H12 1r
# 10 70480033 1 Guía de cable DR 10/13 Li Set
13 70597733 1 Chapa protectora DR10 H12 V1
14 71913945 1 Carcasa kompl. DR10 FU
15 70588033 1 Conjunto de rueda 125 A Set
16 70588133 1 Conjunto de rueda 125 NA Set
17 70588533 1 Motor de traslación EZDR Set
18 70588633 1 Reductor Set
19 75221044 1 Juego guía de rodillos DRS125
20 70589033 1 Rodillo B62 DRS Set
21 70591133 1 Tope 70x 70 Set
# 22 70506033 1 Balancin de presión Set EZDR
23 70197633 1 Rodillo soporte DR 3 Set EZDR 10
# 24 70589533 1 Accionam.traslación EZDR Set
21711903.tbl
ES
217119k4.p65/080805
53
42648744.jpg
1 3 4 5 6
SGS
70193733.jpg
ZMS
7 8 2m, 3m, 4m 9
SGS
70191933.jpg
ES
ZMS
70191433.jpg 70196133.jpg 70196733.jpg
10 12 13 14
2m, 3m 4m
15 16 17 18 19
20 22 23 24
217119k4.p65/080805
70589033.jpg
21
54 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

1 70590833 1 Perno DR10 H12 Set

1 70590933 1 Perno DR10 H20 Set
4 70594833 1 Motón superior EZDR10 4/1 Set 2m, 3m
4 70595133 1 Motón superior EZDR10 4/1 4m Set
5 70594633 1 Travesaño cuña de cable H12 4/1 ZMS 2m, 3m
5 70594733 1 Travesaño cuña de cable H20 4/1 ZMS 2m, 3m
5 70594433 1 Travesaño cuña de cable H12 4/1 ZMS 4m
5 70594533 1 Travesaño cuña de cable H20 4/1 ZMS 4m
5 70593733 1 Travesaño cuña de cable H12 4/1 2m SGS
7 70591433 1 Captador dinamométrico ZMS DR10 4/1Set ZMS
12 70595233 1 Polea de cable DR10 4/1 Set 2m, 3m
12 70595333 1 Polea de cable DR10 4/1 Set 4m
21 70591133 1 Tope 70x 70 Set
ES
21711904.tbl
217119k4.p65/080805
55
# Unidad de elevación EZDR-Pro 10 - H40
42688844.jpg
1 3 4 5 6
SGS
70583733.jpg
ZMS
7 8 2m, 3m, 4m 9
SGS
ES
70191933.jpg
ZMS
70191433.jpg 70196133.jpg 70196733.jpg
10 12 13 14
2m, 3m 4m
15 16 17 18 19
20 22 23 24
217119k4.p65/080805
70589033.jpg
21
56 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

# Unidad de elevación EZDR-Pro 10 - H40
# 1 70594333 1 Perno DR10 H40 Set

4 70594833 1 Motón superior EZDR10 4/1 Set 2m, 3m
4 70595133 1 Motón superior EZDR10 4/1 4m Set
# 5 70584033 1 Travesaño cuña de cable H40 ZMS 2m, 3m
# 5 70584133 1 Travesaño cuña de cable H40 ZMS 4m
# 5 70583733 1 Travesaño cuña de cable H40 4/1 2m SGS
# 8 70596033 1 Cable metálico DR10 H40 4/1 Set 2m
# 8 70596333 1 Cable metálico DR10 H40 4/1 Set 3m, 4m
# 9 70596933 1 Tambor de cable DR10 H40 1r
12 70595233 1 Polea de cable DR10 4/1 Set 2m, 3m
# 13 70597933 1 Chapa protectora DR10 H40
21 70591133 1 Tope 70x 70 Set
21711905.tbl
ES
217119k4.p65/080805
57
# Unidad de elevación EZDR-Pro 10 - H12 - H20 - H40
Disposición 4/2
42590944.jpg
1 3 5
70190833.jpg 70591033.jpg 70595733.jpg

7 8 9 10
ES
70191433.jpg 70596433.jpg 70197033.jpg 70080033.jpg
11 12 13 14 15
16 17 18 19
70588133.jpg 70588533.jpg 70588633.jpg 75221044.jpg
20 22 23 24
217119k4.p65/080805
70589033.jpg
21
58 70591133.jpg 70506033.jpg 70197633.jpg 70589533.jpg

# Unidad de elevación EZDR-Pro 10 - H12 - H20 - H40
Disposición 4/2
1 70590833 1 Perno DR10 H12 Set

1 70590933 1 Perno DR10 H20 Set
1 70594333 1 Perno DR10 H40 Set
5 70595733 1 Polea de compensación EZDR10 Set
7 70591833 1 Captador dinamométrico ZMS DR10 2/1Set
8 70596433 1 Cable metálico DR10 H12 4/2 Set
# 11 70481233 1 Guía de cable DR 10/9 Re Set
12 70595433 1 Polea de cable DR10 4/2 Set
21 70591133 1 Tope 70x 70 Set
23 70597633 1 Rodillo soporte DR10 Set EZDR 10
21711906.tbl
ES
217119k4.p65/080805
59
42665744.jpg
1 3 4 6
SGS
70586333.eps
ZMS
70190833.eps 70591033.eps 70586033.eps 70191733.eps
7 8 9
SGS
70191933.jpg
ES
ZMS
70191433.jpg 70195833.jpg 70196733.jpg
10 12 13 14 15
16 17 18 19
70588133.jpg 70588533.jpg 70588733.jpg 75221044.jpg
20 22 23 24
217119k4.p65/080805
70589033.jpg
21
60 70591133.jpg 70506033.jpg 70197633.jpg 70589633.jpg

1 70590933 1 Perno DR10 H20 Set

1 70594333 1 Perno DR10 H40 Set
3 70581033 1 Juego de rueda 160 EZDR Set
4 70586033 1 Travesaño cuña de cable 6/1 2m SGS
4 70586333 1 Travesaño cuña de cable 6/1 ZMS 2m, 3m
4 70586433 1 Travesaño cuña de cable 6/1 ZMS 4m
7 70584433 1 Limitación de carga DR10 6/1 SGS
12 70585433 1 Motón superior 6/1 Set
17 70588433 1 Motor de traslación ZBA 90 Set
18 70588733 1 Reductor EZDR A30 Set
21 70581133 1 Tope 100 Set
# 23 70197633 1 Rodillo soporte DR 3 Set EZDR10
24 70589633 1 Accionam.traslación ZBA90 A30 Set
21711907.tbl
ES
217119k4.p65/080805
61
# Motón inferior 2/1-2m, 3m, 4m
1 2 3 2m, 3m 4m
2m, 3m 4m
70598033.jpg 70598233.jpg
6 7 8
2m, 3m 4m
2m, 3m
70585233.jpg
82921933.jpg
4
4m
# 1 71321033 1 Motón inferior 1 polea 230/13 2m, 3m

# 2 82921933 1 Motón inferior 1 polea 280/14 4m
3 70598033 1 Caperuza polea de cable 2/1 Set 2m, 3m
# 3 70587933 1 Caperuza polea de cable 2/1 Set 4m
# 4 34182633 1 Pestillo de seguridad 2,5 DIN 15106
# 6 71304033 1 Gancho de carga RSN 2,5 T Set 2m, 3m
# 6 71293033 1 Gancho de carga doble RSN 2,5 T Set 2m, 3m
# 7 15084333 1 Gancho simple con travesaño ASN 2,5S 4m
# 7 15084533 1 Gancho de carga doble BSN 2,5S+TRAV 4m
# 8 70585233 1 Polea de cable DR10 2/1 Set 2m, 3m
# 8 70585333 1 Polea de cable DR10 2/1 Set 4m
ES
21701905.tbl
Motón inferior 4/1-2m, 3m, 6/1

1 4/1-2m, 3m 6/1 2 3
34182633.jpg
5 6
70198133.jpg
4

217119k4.p65/080805
# 1 71323033 1 Motón inferior 2 poleas 230/13 4/1

# 1 71324033 1 Motón inferior, 3 poleas 280/13 5V 6/1
2 70598133 1 Caperuza polea de cable 4/1 Set
# 3 34182733 1 Pestillo de seguridad 4 Set 4/1 DIN 15106
5 70598433 1 Gancho de carga RSN 4 Set 4/1
# 6 71295033 1 Gancho de carga doble RSN 4 T Set 4/1
62 21711914.tbl
# Motón inferior 4/1-4m, 4/2
1 2 3
4/2
4/2
70598233.jpg
4/1-4m
82926933.jpg
6
82926833.jpg
4
4/1-4m
70598333.jpg 34182633.jpg
7 8
4/1-4m 4/2
ES
82926033.jpg 70595333.jpg 70595433.jpg 82926133.jpg
Motón inferior 4/1-4m

2 70598333 1 Caperuza polea de cable 4/1 Set 4m

3 82926933 1 Gancho de carga doble GSN 5-S +TRAV
4 82926033 1 Motón inferior 2 poleas 280/14
6 34182833 1 Pestillo de seguridad 5 Set DIN 15106
8 82926133 1 Gancho simple con travesaño GSN 5-S
21701907.tbl
Motón inferior 4/2

# 1 82926833 1 Motón inferior 2 poleas 225/11

2 70598233 1 Caperuza polea de cable 4/2 Set
# 3 15084533 1 Gancho de carga doble BSN 2,5S+TRAV
# 6 34182633 1 Pestillo de seguridad 2,5 DIN 15106
# 8 15084333 1 Gancho simple con travesaño ASN 2,5S
217119k4.p65/080805
21701908.tbl
63
Juego de reparación motor de elevación ZBR 132
1 2 3
26098433.jpg 26098133.jpg 70598733.jpg
1 26098433 1 Juego piezas de desgaste B140

2 26098133 1 Juego para revisión B140/ZBA132
3 70598733 1 Motor de elevación Z132 LH Set
21701912.tbl
Juego de reparación motor de traslación ZBA 71, ZBA 90

1 2 3
ZBA 71 ZBA 71
ES
26096233.jpg 26096033.jpg
ZBA 90 ZBA 90
26098433.jpg 26096733.jpg 70598733.jpg
ZBA 71

2 26096033 1 Juego para revisión B003
3 70599033 1 Motor de traslación Z 71 LH Set
217019
ZBA 90
217119k4.p65/080805

2 26096733 1 Juego para revisión B007/ZBA 80
3 70599133 1 Motor de traslación Z 90 LH Set
21711911.tbl
64
# Piezas eléctricas EZDR-Pro 10
1 2 3 4
71998033.jpg 71988933.jpg 71989333.jpg 71999133.jpg

5 8 11
71999633.jpg
9 6/1
70199233.jpg 71999533.jpg 71997033.jpg
7 10 6/1
71989133.jpg 71999733.jpg 71997133.jpg 71999033.jpg
1 71998533 1 Conjunto tapa DR10T V1Set
ES
1 71998633 1 Conjunto tapa/convertidor DR10T Set
# 2 71988933 1 Final de carrera trasl.carro EZDR Set
3 71989433 1 Interruptor potencia 25A Set
4 71999333 1 Perfil de obturación Set 1,5 M
5 70599233 1 Carcasa eqpo.eléct. Set DR10 1)
7 71989233 1 Contactor DR5V2-DR10 Set
8 71999633 1 FDC de engranajes SGG Set
9 71999533 1 Conv. frec. Dedriv DIC-4-002-C
# 9 71997033 1 Conv. frec. Dedriv DIC-4-007-C 6/1
10 71999733 1 Resistencia de frenado 470R Set
# 10 71997133 1 Resistencia de frenado 120R Set 6/1
# 11 71999833 1 Cable interconexión Set EZDR
21711915.tbl
217119k4.p65/080805
1) Las uniones atornilladas según DIN @1 se tienen que asegurar con Loctite 290. Nº de ref. 007 275 84. 65
66
217119k5.p65/080805
217119k5.p65/080805
67
Printed in Germany Basse/080805/1T

Postfach 67 · D-58286 Wetter
Telefon (0 23 35) 92-0 · Telefax (0 23 35) 92 76 76
www.demagcranes.com
Nachdruck, auch auszugsweise, nur mit Genehmigung der Demag Cranes & Components GmbH, D-58286 Wetter Druckfehler, Irrtümer und Änderungen vorbehalten
Component parts
ZBA 80 - ZBF 80 - ZBS 80 - ZNA 80 - ZNS 80 motors
ZBA 90A - ZNA 90A motors
0702 EN/US 229 242 49 721 IS 919

Contents
Page
Direct input
ZBA 80/90A, ZBF 80, ZBS 80 motor with B007 or B020 brake, 4
ZNA 80/90A motor without brake , direct input 8
ZBA 80/90A, ZBF 80 motor with B007 or B020 brake
Coupling connection
ZNA 80/90A motor without brake, coupling connection 14
Manual brake release, brake function and wear monitoring,

ZBA 80/90A, ZBF 80 - for B007 or B020 brake 16

Example
#8 342 528 99 1 Retaining ring 28X1.5 DIN 471
2
Component parts list
Helical
D 10 D 20 D 30 D 40 D 50 D 60 D 70 D 80 D 90
gearboxes
Part number 229 220 49 229 221 49 229 222 49 229 223 49 229 224 49 229 225 49 229 226 49 229 227 49 229 228 49
Angular
W 10 W 20 W 30 W 40 W 50 W 60 W 70 W 80 W 90 W 100
gearboxes
Part number 229 230 49 229 231 49 229 232 49 229 233 49 229 234 49 229 235 49 229 236 49 229 237 49 229 238 49 229 239 49
Offset
A 10 A 20 A 30 A 40 A 50 A 60 A 70 A 80 A 90
gearboxes
Part number 229 210 49 229 211 49 229 212 49 229 213 49 229 214 49 229 215 49 229 216 49 229 217 49 229 218 49
22285707.tbl
3
ZBA 80/90A, ZBF 80, ZBS 80 motor with B007 or B020 brake
Direct input
42519644.eps
4
Direct input
# 1 Pinion for parts see page 3 3)

# 2 34306344 1 Cover plate 25X40X4 RB25 3)
# 3 36646499 1 Oil seal A 25X 42X 7 3) NBR DIN 3760
# 4 34250399 1 Retaining ring 25X2 3) DIN 471
# 10 31339499 1 Locking screw M10X1 for Pos. 10 5.8 DIN 908
# 11 36710199 1 O-ring 8 X2 B for Pos. 10 NB 70 DIN 3770
# 12 21861584 1 End cap D 10D W10 D
# 12 21861884 1 End cap D 20D D20 T, W20 D, W20 T
# 12 21862184 1 End cap D 30D D30 T, W30 D, W30 T
# 12 21862484 1 End cap D 40D D40 T, D60 T, W40 D, W40 T, W60 Q
# 12 21862784 1 End cap D 50D D50 T, D70 T, W50 D, W50 T, W70 Q, W80 Q
# 13 21863084 1 End cap D 60D D80 T, W60 T, W90 Q, A70 D, A70 T
# 13 21863384 1 End cap D 70D D90 T, W70 T,W80 T, W100 Q, A80 D, A80 T
# 14 21860984 1 End cap A 10D A20D, A20 T
# 14 21861284 1 End cap A 30D A30 T, A40 D, A40 T
# 14 21863684 1 End cap A 50D A50 T, A60 D, A60 T
# 15 33988899 2 Sealing ring A16 X20 X1.5 for Pos. 13 CU DIN 7603
# 16 31340399 2 Locking screw M16X1.5 for Pos. 13 4.6 DIN 908
# 17 15073599 1 Grooved ball bearing 6205 2Z 3) DIN 625
# 20 Rotor ZBA 3)
# 21 Rotor ZBF 3)
# 21 Rotor ZBS 3)
26 Stator 1)
# 27 79499144 4 Locking screw M25X1.5
# 28 00465498 1 Lock washer S 5
29 34050599 1 Washer A 5.3X 10 X1 140HV A2F DIN 125
30 31921499 1 Hex.socket cylind.screw M 5 X 12 10.9 A2F DIN 912
31 26089084 1 Brake control GE 3 A B007, B020
31 26089184 1 Brake control GP 3 A B007, B020
31 26089284 1 Brake control GE 1.5A B007, B020
31 26089384 1 Brake control GP 1.5A B007, B020
31 26089484 1 Brake control GS 1 AC B007, B020
# 31 26094384 1 Brake control GF 0.8A B007
32 26087084 1 Current relay SE I<= 16A
32 26089784 1 Voltage relay VE 1 AC
32 26089884 1 VDR resistor
# 33 31892399 2 Hex.socket cylind.screw M 4 X 16 10.9 A2F DIN 912
35 05492284 1 Terminal board KB 71- 90 c/w items 36 - 38, Z80
36 00465498 1 Lock washer S 5
38 20892084 1 Stator connection accessories Z 63 Z80/90A
39 21880284 1 Seal Z 63-80
42 21880084 1 Terminal box cover Z 63- 80 c/w item 39
44 15073499 1 Grooved ball bearing 6204 2Z DIN 625
45 34273544 1 Bearing sealing ring 6204ZIV
46 34273244 1 Corrugated ring 40X 46.5X0.5
48 00465598 1 Lock washer S 6
50 00465498 4 Lock washer S 5
51 21866284 1 End cap BS ZB 80 B007 ZB90A 2)
51 21866384 1 End cap BS ZB 80 B020 ZB90A 2)
54 26010784 1 Friction plate B007 ZBA
55 26010984 3 Collar pin B007
55 26020984 3 Collar pin B020
56 35424299 1 Key A 5X 5X 18 C 45 K DIN 6885
57 34251799 1 Retaining ring 17X1 DIN 471
58 26011684 1 Engaging element B007-ZB 80
58 26021584 1 Engaging element B020-ZB080
59 26097084 1 Wear and tear set B007 c/w items 63, 65, 68
60 26010684 1 Anchor plate B007 ZBA
60 26022984 1 Anchor plate B020 ZBF
63 26010584 1 Stop disk B007
63 26020584 1 Stop disk B020
64 26011284 3 Spring spacing B007
22286401.tbl
1) Specify size, performance, mode of operation, voltage, frequency and model.

2) State option “integrated pulse generator“ when ordering, if required.
3) When ordering these components, please indicate the complete model code with serial number of gearbox and motor. This data ise specified on the rating
plates. If required, the components will be supplemented and joined by Demag Cranes & Components.
5
Direct input
65 26011084 Spring brake B007 WHITE ZBA 4)

65 26011184 Spring brake B007 RED ZBA 4)
65 26021184 Spring brake B020 RED ZBA, ZBF 4)
65 26022784 Spring brake B020 BLUE ZBF 4)
66 26019584 1 Magnet body B004/B007 240V
66 26019684 1 Magnet body B004/B007 480V
66 26019784 1 Magnet body B004/B007 575V
66 26029584 1 Magnet body B020 240V
66 26029684 1 Magnet body B020 480V
66 26029784 1 Magnet body B020 575V
68 15056399 3 Hexagonal nut M 5 B007 8 A2F DIN 985
76 15088499 1 Oil seal AS 16X 22X 7 B007-Z80 NBR DIN 3760
77 21871584 1 Fan impeller light Z 80 Z90A
81 21871084 1 Fan cover long ZB 80 ZB90A
82 21871484 1 Hood extension ZB 80-EF
83 21873084 1 Fan cover EF Z 80 additional integrated fan
85 26096784 1 Overhauling set B007/ZBA 80 c/w items 54, 55, 57, 58, 61, 62, 64, 76
85 26097384 1 Overhauling set B020/ZBF 80 c/w items 55, 57, 58, 60, 64, 76
87 15126399 4 Hex.socket cylind.screw M 5 X130 10.9 DAC DIN 912
22286401.tbl
Option
53 26013084 1 Cover strip BOO7 Type of enclosure IP55
53 26023084 1 Cover strip B020 Type of enclosure IP55
54 26013384 1 Holder covering tape B007 Type of enclosure IP55, only ZBF
61 26011884 1 Anchor plate G-HBL/B007 ZBA, For reduced sound design
62 26011484 1 Damping plate B007 ZBA, For reduced sound design
67 15152099 3 Washer A 5.3X 10.0X1.0 B007, Type of enclosure IP55 PP DIN 125
# 75 34150099 1 Shim 16X 22X0.5 B007, Type of enclosure IP55 ST2K50 DIN 988
# 75 15163999 1 Supporting plate 16X 30X0.5 B020, Type of enclosure IP55 DIN 988
76 15143099 1 Oil seal AS 16X 22X 7 B007, Type of enclosure IP55 NBR DIN 3760
78 21871784 1 Fan impeller heavy Z 80 Z90A
79 35409899 1 Key A 5X 5X 22 C 45 K DIN 6885
22286408.tbl
4) Quantity required depends on braking torque, see operating instructions 229 203 49.
6
Direct input
42519644.eps
7
ZNA 80/90A motor without brake
Direct input
42519744.eps
8
Direct input
# 1 Pinion for parts see page 3 3)

# 2 34306344 1 Cover plate 25X40X4 RB25 3)
# 3 36646499 1 Oil seal A 25X 42X 7 3) NBR DIN 3760
# 10 21861584 1 End cap D 10D W10 D
# 10 21861884 1 End cap D 20D D20 T, W20 D, W20 T
# 10 21862184 1 End cap D 30D D30 T, W30 D, W30 T
# 10 21862484 1 End cap D 40D D40 T, D60 T, W40 D, W40 T, W60 Q
# 10 21862784 1 End cap D 50D D50 T, D70 T, W50 D, W50 T, W70 Q, W80 Q
# 11 36710199 1 O-ring 8 X2 B for Pos. 10 NB 70 DIN 3770
# 12 31339499 1 Locking screw M10X1 for Pos. 10 5.8 DIN 908
# 13 21863084 1 End cap D 60D D80 T, W60 T, W90 Q, A70 D, A70 T
# 13 21863384 1 End cap D 70D D90 T, W70 T,W80 T, W100 Q, A80 D, A80 T
# 14 21860984 1 End cap A 10D A20D, A20 T
# 14 21861284 1 End cap A 30D A30 T, A40 D, A40 T
# 14 21863684 1 End cap A 50D A50 T, A60 D, A60 T
# 15 33988899 2 Sealing ring A16 X20 X1.5 for Pos. 13 CU DIN 7603
# 16 31340399 2 Locking screw M16X1.5 for Pos. 13 4.6 DIN 908
17 15073599 1 Grooved ball bearing 6205 2Z 3) DIN 625
18 34265199 1 Retaining ring 52X2 3) DIN 472
# 20 Rotor ZNA 3)
26 Stator 1)
# 27 79499144 4 Locking screw M25X1.5
28 00465498 1 Lock washer S 5
35 05492284 1 Terminal board KB 71- 90 c/w item 36 - 38, Z 80/90 A
36 00465498 1 Lock washer S 5
39 21880284 1 Seal Z 63-80
48 00465598 1 Lock washer S 6
50 00465498 4 Lock washer S 5
51 21866684 1 End cap BS ZNA 80 ZN90A
81 21870584 1 Fan cover short ZN 80 ZN90A
22286402.tblG
Option
76 36696299 1 Oil seal A 18X 32X 7 Type of enclosure IP55 NBR-CFW DIN 3760
79 35409899 1 Key A 5X 5X 22 heavy fan C 45 K DIN 6885
22286409.tbl
1) Specify type designation, performance, mode of operation, voltage, frequency and model.
3) When ordering these components, please indicate the complete model code with serial number of gearbox and motor.
This data is specified on the rating plates. If required, the components will be supplemented and joined by Demag Cranes & Components.
9
Coupling connection
42519944.eps
10
Coupling connection

# 13 21865184 1 End cap B14
19 35425799 1 Key B 6X 6X 20 C 45 K DIN 6885
20 21837084 1 Rotor ZBA 80A 2 COUPLING
20 21837184 1 Rotor ZBA 80B 2 COUPLING ZBA 90A 2
20 21837284 1 Rotor ZBA 80A 4 COUPLING ZBA 80A 8/4, B 4
20 21837384 1 Rotor ZBA 80B 4 COUPLING ZBA 80B 8/4, 90A 4, 8/4
20 21837484 1 Rotor ZBA 80A 6 COUPLING ZBA 80A 8, 4/2, 8/2, 12/2, 12/4, B 12/2
20 21837584 1 Rotor ZBA 80B 6 COUPLING ZBA 80B 8, 4/2, 8/2, 12/4, 90A 6, 8, 4/2, 8/2, 12/2, 12/4
21 21834384 1 Rotor ZBF 80A COUPLING ZBF 80A 2, 4, 4/2, 8/2
26 Stator 1)
# 27 79499144 4 Locking screw M25X1.5
# 28 00465498 1 Lock washer S 5
31 26094384 1 Brake control GF 0.8A B007
32 26089884 1 VDR resistor
36 00465498 1 Lock washer S 5
39 21880284 1 Seal Z 63-80
48 00465598 1 Lock washer S 6
50 00465498 4 Lock washer S 5
51 21866284 1 End cap BS ZB 80 B007 ZB90A 2)
51 21866384 1 End cap BS ZB 80 B020 ZB90A 2)
55 26010984 3 Collar pin B007
55 26020984 3 Collar pin B020
56 35424299 1 Key A 5X 5X 18 C 45 K DIN 6885
22286403.tbl
2) State option "integrated pulse generator" when ordering, if required.
11
Coupling connection
58 26011684 1 Engaging element B007-ZB 80

63 26010584 1 Stop disk B007
63 26020584 1 Stop disk B020
66 26019584 1 Magnet body B004/B007 240V
66 26019684 1 Magnet body B004/B007 480V
66 26019784 1 Magnet body B004/B007 575V
66 26029584 1 Magnet body B020 240V
66 26029684 1 Magnet body B020 480V
66 26029784 1 Magnet body B020 575V
81 21871084 1 Fan cover long ZB 80 ZB90A
82 21871484 1 Hood extension ZB 80-EF
85 26097384 1 Overhauling set B020/ZBF 80 c/w items 55, 57, 58, 60, 64, 76
22286403.tbl
Option
53 26013084 1 Cover strip BOO7 Type of enclosure IP55
53 26023084 1 Cover strip B020 Type of enclosure IP55
# 75 34150099 1 Shim 16X 22X0.5 B007, Type of enclosure IP55 ST2K50 DIN 988
# 75 15163999 1 Supporting plate 16X 30X0.5 B020, Type of enclosure IP55 DIN 988
79 35409899 1 Key A 5X 5X 22 C 45 K DIN 6885
22286408.tbl
12
Coupling connection
42519944.eps
13
Coupling connection
42520044.eps
14
Coupling connection

# 13 21865184 1 End cap B14
19 35425799 1 Key B 6X 6X 20 C 45 K DIN 6885
20 21837684 1 Rotor ZNA 80A2 COUPLING
20 21837784 1 Rotor ZNA 80B2 COUPLING ZNA 90A 2
20 21837884 1 Rotor ZNA 80A4 COUPLING ZNA 80A 8/4, B 4
20 21837984 1 Rotor ZNA 80B4 COUPLING ZNA 80B 8/4, 90A 4, 8/4
20 21838084 1 Rotor ZNA 80A6 COUPLING ZNA 80A 4/2, 8, 8/2, 12/2, 12/4, B 12/2
20 21838184 1 Rotor ZNA 80B6 COUPLING ZNA 80B 8, 4/2, 8/2, 12/4, 90A 6, 8, 4/2, 8/2, 12/2, 12/4
26 Stator 1)
# 27 79499144 4 Locking screw M25X1.5
# 29 00465498 1 Lock washer S 5
36 00465498 1 Lock washer S 5
39 21880284 1 Seal Z 63-80
48 00465598 1 Lock washer S 6
50 00465498 4 Lock washer S 5
51 21866684 1 End cap BS ZNA 80 ZNA90A
81 21870584 1 Fan cover short ZN 80 ZN90
22286404.tbl
Option
76 36696299 1 Oil seal A 18X 32X 7 Type of enclosure IP55 NBR-CFW DIN 3760
22286409.tbl
15
ZBA 80/90A, ZBF 80 - for B007 or B020 brake
Manual brake release for B007 or B020 brake
Brake function and wear monitoring for B007 oder B020 brake
41759244.eps
16
ZBA 80/90A, ZBF 80 - for B007 or B020 brake
1 Armature disc for ZBA, B007
1 26070084 1 Armature plate reworked B007 2) or 3)
1 26070184 1 Armature plate reworked B007 2) and 3)
Armature disc for ZBA, B007, for reduced sound design
1 26011884 1 Anchor plate G-HBL/B007 1)
1 26070784 1 Armature plate reworked B007 2) or 3) or 1) and 2) or 1) and 3)
1 26070884 1 Armature plate reworked B007 2) and 3) or 1) and 2) and 3)
Armature disc reworked for ZBA, B020
Armature disc for ZBF, B020
1 26071384 1 Armature plate reworked B020 1)
1 26071584 1 Armature plate reworked B020 1) and 2) or 1) and 3)
1 26071784 1 Armature plate reworked B020 1) and 2) and 3)
Armature disc for ZBA, B020, for reduced sound design
2 Damping disc for ZBA, B007, for reduced sound design
2 26011484 1 Damping plate B007 1)
2 26070984 1 Damping plate reworked B007 2) or 3) or 1) and 2) or 1) and 3)
2 26071084 1 Damping plate reworked B007 2) and 3) or 1) and 2) and 3)
Damping disc for ZBA, B020, for reduced sound design
2 26021484 1 Damping plate B020 1)
3 26010584 1 Stop disk B007
3 26020584 1 Stop disk B020
4 33249799 2 Hexagonal nut M 4 8 A2F ISO 4032
5 15134599 2 Stud M 4 X 55 B007 8.8 A2F DIN 835
5 15134699 2 Stud M 5 X 60 B020 8.8 A2F DIN 835
Magnet body B007
6 26018184 1 Magnet body B007 180V HBL 1), 4)
6 26018284 1 Magnet body reworked B007 180V 2) or 3)
6 26018384 1 Magnet body reworked B007 180V 1) and 2) or 1) and 3), 4)
6 26018484 1 Magnet body reworked B007 180V 2) and 3), 4)
6 26018584 1 Magnet body reworked B007 180V 1) and 2) and 3), 4)
Magnet body B020
7 26013184 2 Holding bolt seal B007
8 15099699 2 Grooved pin 4X16 B007 ST A2F ISO 8741
8 15099799 2 Grooved pin 5X26 B020 ST A2F ISO 8741
# 9 26093284 1 Brake release lever FL-HBLA B007, Z80 kpl. (Teil-Nr. 25)
# 9 26093184 1 Brake release lever FL-HBLA B020, Z80 kpl. (Teil-Nr. 25)
# 10 26094284 1 Brake release lever HBLN B007, B020 kpl. (Teil-Nr. 25)
13 26013684 1 Lifting stirrup B007
14 26013784 2 Spring -VOR 0.6 X6.5 X 11.3
14 26023484 2 Spring -VOR 0.8 X 8.4X 13.8
15 35046499 2 Washer 4.3X 12 X1 B007 ST140HVA2F DIN 9021
15 35046699 2 Washer 5.3X 15 X1.2 B020 ST140HVA2F DIN 9021
18 31953499 1 Hex.socket cylind.screw M 4 X 10 10.9 DIN 912
20 26017084 1 Stud bolt micro-switch FK/NUE for Mikros. V4LS B020, V4NSE B007
20 26037184 1 Stud bolt micro-switch FK/NUE for Mikros. V4NSE B020
21 34065199 1 Washer B 4.3X 9 X0.8 140HV A2F DIN 125
22 26017384 1 Microswitch V4NSE preassem., 2) or 3) (ZBA); 3) (ZBF)
22 26017484 1 Microswitch V4LS preassem., 2) (ZBF)
23 34276844 1 Entry bush 10 - 6 RD
24 21871884 1 Fan cover HBL ZB 80
# 25 33320699 1 Hexagonal nut BM12 X1.5 B007, B020 04 A2F DIN 439
26 26019884 1 Adapter FL ZB 63- 80 B020
26 26019984 1 Adapter FL ZB 80-B007
27 26017884 1 Cover plate ZB 63/ 80 ZB90A
28 22872384 1 EXT.COVER ZB100 EF+MBR
29 21872984 1 Fan cover EF+HBL additional integrated fan 22286407.tbl
1) Manual brake release 2) Adjustment monitoring

3) Function monitoring 4) Other voltages upon request.
17
California Ohio
Connecticut Ontario
Illinois Quebec
Michigan Texas
Missouri
529 E. 5th Street • Washington, Missouri 63090 2700 E. 11th, Suite 200B • DFW Airport, Texas 75261
Washington
16771 N.E. 80th Street, Suite 205 • Redmond, Washington 98052
Telephone: (425) 883-4668 • Fax: (425) 883-4828
Demag Cranes and Components

29201 Aurora Road
Telephone: (440) 248-2400
Fax: (440) 248-3086
Component parts
ZBA 90B - ZBF 90B - ZNA 90B motors
ZBA 100 - ZBF 100 - ZNA 100 motors
0702 EN/US 229 244 49 721 IS 919

Contents
Page
Direct input
Motor ZBA 90B/100, ZBF 90B/100 with B020 or B050 brake 4
Motor ZBF 90B 4
Motor ZNA 90B/100 without brake 8
Coupling connection
Motor ZBA 90B/100, ZBF 100 with B020 or B050 brake 10
Motor ZBF 90B with B020 brake 10
Motor ZNA 90B/100 without brake 14
Motor ZBA 90B/100, ZBF 90B/100, manual brake release,

brake function, wear monitoring for B020 or B050 brake 16
# = Alterations compared with previous issue

Example

2
Component parts list
Helical
D 10 D 20 D 30 D 40 D 50 D 60 D 70 D 80 D 90
gearboxes
Part number 229 220 49 229 221 49 229 222 49 229 223 49 229 224 49 229 225 49 229 226 49 229 227 49 229 228 49
Angular
W 10 W 20 W 30 W 40 W 50 W 60 W 70 W 80 W 90 W 100
gearboxes
Part number 229 230 49 229 231 49 229 232 49 229 233 49 229 234 49 229 235 49 229 236 49 229 237 49 229 238 49 229 239 49
Offset
A 10 A 20 A 30 A 40 A 50 A 60 A 70 A 80 A 90
gearboxes
Part number 229 210 49 229 211 49 229 212 49 229 213 49 229 214 49 229 215 49 229 216 49 229 217 49 229 218 49
22285707.tbl
3
ZBA 90B/100, ZBF 100 motors with B020 or B050 brake
ZBF 90B with B020
Direct input
42519644.eps
4
ZBF 90B with B020
Direct input
1 Pinion For component parts see page 3

2 34306444 1 Cover plate 35X52X4.5RB35 3)
3 36706599 1 Oil seal A 35X 52X 7 3) NBR DIN 3760
4 34243599 1 Retaining ring 35X2.5 3) DIN 471
10 31339499 1 Locking screw M10X1 for Pos. 12 5.8 DIN 908
11 36710199 1 O-ring 8 X2 B for Pos. 12 NB 70 DIN 3770
12 22861584 1 End cap D 20D Z90 B, D20 D/T, W20 D/T
12 22862184 1 End cap D 40D Z90 B, D40 D/T, D60 T, W40 D/T, W60 Q
12 22862484 1 End cap D 50D Z90 B, D50 D/T, D70 T, W50 D/T, W70 Q, W80 Q
13 22862784 1 End cap D 60D Z90 B, A70 D/T, D60 D, D80 T, W60 T, W90 Q
13 22863084 1 End cap D 70D Z90 B, A80 D/T, D70 D, D90 T, W70 T, W80 T, W100 Q
13 22863384 1 End cap D 80D Z90 B, A90 D/T, D80 D, W90 T
14 22860984 1 End cap A 10D Z90 B, A10 D, A20 D/T
14 22861284 1 End cap A 30D Z90 B, A30 D/T, A40 D/T
15 33988899 2 Sealing ring A16 X20 X1.5 for Pos. 13 CU DIN 7603
16 31340399 2 Locking screw M16X1.5 for Pos. 13 4.6 DIN 908
20 Rotor ZBA 3)
21 Rotor ZBF 3)
26 Stator 1)
27 79499044 4 Locking screw M32X1.5
29 00465498 1 Lock washer S 5
31 26094384 1 Brake control GF 0.8A B020, B050
32 26089884 1 VDR resistor B020, B050
35 06992284 1 Terminal board KB100-125 c/w items 36 - 38
36 00465498 1 Lock washer S 5
38 22892084 1 Stator connection accessories Z100
39 22880284 1 Seal Z100
42 22880084 1 Terminal box cover Z100 c/w item 39
46 30000444 1 Corrugated ring 51X 61 X0.5
48 00465698 4 Lock washer S 8
50 00465598 4 Lock washer S 6
51 22866284 1 End cap BS ZB100 B020 B020 2)
51 22866384 1 End cap BS ZB100 B050 B050 2)
55 26020984 3 Collar pin B020 MK
55 26030984 3 Collar pin B050 MK
56 35425999 1 Key A 6X 6X 25 C 45 K DIN 6885
57 34252299 1 Retaining ring 22X1.2 DIN 471
22287601.tbl
5
ZBF 90B with B020
Direct input
61 26031884 1 Anchor plate G/B050
62 26031484 1 Damping plate B050 ZBA
63 26020584 1 Stop disk B020
63 26030584 1 Stop disk B050
64 26031284 3 Spring spacing
66 26029584 1 Magnet body B020 240V
66 26029684 1 Magnet body B020 480V
66 26029784 1 Magnet body B020 575V
66 26039584 1 Magnet body B050 240V
66 26039684 1 Magnet body B050 480V
66 26039784 1 Magnet body B050 575V
76 15088699 1 Oil seal AS 20X 30X 7 B020 NBR DIN 3760
77 22871584 1 Fan impeller light Z 100
81 22871084 1 Fan cover long ZB100
# 82 22871484 1 Hood extension ZB100-EF
# 83 22873084 1 Fan cover EF Z100 additional integrated fan
85 26097284 1 Overhauling set B020/ZBA100 c/w items 54 - 58, 60 - 62, 64, 76
85 26097484 1 Overhauling set B020/ZBF100 c/w items 54 - 58, 60 - 62, 64, 76
22287601.tbl
Option
53 26023084 1 Cover strip B020 ZBA, ZBF, IP55 enclosure
54 26023384 1 Holder covering tape B020 ZBF, IP55 enclosure
61 26021884 1 Anchor plate G-HBL/B020 ZBA, reduced noise level design
61 26031884 1 Anchor plate G/B050 ZBA, reduced noise level design
62 26021484 1 Damping plate B020 ZBA, reduced noise level design
62 26031484 1 Damping plate B050 ZBA, ZBF, reduced noise level design
67 15152199 3 Washer A 6.4X 12.0X1.6 B020, IP55 PP DIN 125
75 15164099 1 Supporting plate 20X 30X0.5 B020, IP55 DIN 988
76 15143299 1 Oil seal AS 20X 30X 7 B020, IP55 NBR DIN 3760
78 22871784 1 Fan impeller heavy Z 100 Z90B/Z100
22287606.tbl
6
ZBF 90B with B020
Direct input
42519644.eps
7
ZNA 90B/100 motor without brake
Direct input
42519744.eps
8
Direct input
1 Pinion For component parts see page 3

2 34306444 1 Cover plate 35X52X4.5RB35 3)
3 36706599 1 Oil seal A 35X 52X 7 3) NBR DIN 3760
10 31339499 1 Locking screw M10X1 for Pos. 12 5.8 DIN 908
11 36710199 1 O-ring 8 X2 B for Pos. 12 NB 70 DIN 3770
12 22862184 1 End cap D 40D Z90 B, D40 D/T, D60 T, W40 D/T, W60 Q
12 22862484 1 End cap D 50D Z90 B, D50 D/T, D70 T, W50 D/T, W70 Q, W80 Q
13 22862784 1 End cap D 60D Z90 B, A70 D/T, D60 D, D80 T, W60 T, W90 Q
13 22863084 1 End cap D 70D Z90 B, A80 D/T, D70 D, D90 T, W70 T, W80 T, W100 Q
13 22863384 1 End cap D 80D Z90 B, A90 D/T, D80 D, W90 T
14 22860984 1 End cap A 10D Z90 B, A10 D, A20 D/T
15 33988899 2 Sealing ring A16 X20 X1.5 for Pos. 13 CU DIN 7603
16 31340399 2 Locking screw M16X1.5 for Pos. 13 4.6 DIN 908
20 Rotor ZNA 3)
26 Stator 1)
28 00465498 1 Lock washer S 5
36 00465498 1 Lock washer S 5
39 22880284 1 Seal Z100
48 00465698 4 Lock washer S 8
50 00465598 4 Lock washer S 6
51 22866684 1 End cap ZNA100 2)
78 22871684 1 Fan impeller heavy Z 100
81 22870584 1 Fan cover short ZN100
84 00465498 4 Lock washer S 5
22287602.tbl
Option
76 36639199 1 Oil seal A 22X 40X 7 Z90B/Z100, IP55 enclosure NBR DIN 3760
22287607.tbl
9
ZBF 90B motors with B020 brake
Coupling connection
42519944.eps
10
Coupling connection

13 22865184 1 End cap B14
19 35457199 1 Key B 8X 7X 20 C 45 K DIN 6885
20 22832784 1 Rotor ZBA100A COUPLING Z90 B 2, 4, 6, 8, 4/2, 8/2, 12/2, 12/4
Z100 A-4, 4/2, 8/4, 12/2, 12/4
20 22832884 1 Rotor ZBA100B COUPLING Z90 B-8/4
Z100 A-2, 8, AL-4, B-2, 4, 6, 8, 4/2, 8/2, 8/4, 12/2, 12/4
21 22833384 1 Rotor ZBF100A COUPLING Z90 B 2, 4, 8/2, 12/2
21 22833484 1 Rotor ZBF100B COUPLING Z100 A-2, 4, 4/2, 8/2
26 Stator 1)
28 00465498 1 Lock washer S 5
31 26094384 1 Brake control GF 0.8A B020, B050
32 26089884 1 VDR resistor B020, B050
36 00465498 1 Lock washer S 5
39 22880284 1 Seal Z100
48 00465698 4 Lock washer S 8
50 00465598 4 Lock washer S 6
51 22866284 1 End cap BS ZB100 B020 B020 2)
51 22866384 1 End cap BS ZB100 B050 B050 2)
55 26020984 3 Collar pin B020
55 26030984 3 Collar pin B050
56 35425999 1 Key A 6X 6X 25 C 45 K DIN 6885
61 26031884 1 Anchor plate G/B050 ZBA
62 26031484 1 Damping plate B050 ZBA
63 26020584 1 Stop disk B020
63 26030584 1 Stop disk B050
22287603.tbl
11
Coupling connection

64 26031284 3 Spring spacing
66 26029584 1 Magnet body B020 240V
66 26029684 1 Magnet body B020 480V
66 26029784 1 Magnet body B020 575V
66 26039584 1 Magnet body B050 240V
66 26039684 1 Magnet body B050 480V
66 26039784 1 Magnet body B050 575V
81 22871084 1 Fan cover long ZB100
# 82 22871484 1 Hood extension ZB100-EF
22287603.tbl
Option
61 26021884 1 Anchor plate G-HBL/B020 ZBA, reduced noise level design
61 26031884 1 Anchor plate G/B050 ZBA, reduced noise level design
62 26021484 1 Damping plate B020 ZBA, reduced noise level design
62 26031484 1 Damping plate B050 ZBA, ZBF, reduced noise level design
22287606.tbl
12
Coupling connection
42519944.eps
13
Coupling connection
42520044.eps
14
Coupling connection
12 34243599 2 Retaining ring 35X2,5 DIN 471

13 22865184 1 End cap B14
19 35457199 1 Key B 8X 7X 20 C 45 K DIN 6885
20 22833184 1 Rotor ZNA100A COUPLING Z90 B-2, 4, 6, 8, 4/2, 8/2, 12/2, 12/4
Z100 A-4, 4/2, 8/4, 12/2, 12/4
20 22833284 1 Rotor ZNA100B COUPLING Z90 B-8/4
Z100 A-2, 8, AL-4, B-2, 4, 6, 8, 4/2, 8/2, 8/4, 12/2, 12/4
26 Stator 1)
28 00465498 1 Lock washer S 5
36 00465498 1 Lock washer S 5
39 22880284 1 Seal Z100
48 00465698 4 Lock washer S 8
50 00465598 4 Lock washer S 6
51 22866684 1 End cap ZNA100 2)
80 34251799 1 Retaining ring 17X1 FEDST DIN 471
81 22870584 1 Fan cover short ZN100
22287604.tbl
Option
76 36639199 1 Oil seal A 22X 40X 7 Type of enclosure IP55 NBR DIN 3760
78 22871784 1 Fan impeller heavy Z 100 heavy fan
22287608.tbl
15
brake function, wear monitoring for B020 or B050 brake
Manual brake release for B020 or B050 brake
Brake function and wear monitoring for B020 or B050 brake
41759244.eps
16
brake function, wear monitoring for B020 or B050 brake
1 Pressure plate for ZBA B020

Pressure plate for ZBF B050
1 26072284 1 Armature plate reworked B050 1)
Pressure plate for ZBA, Reduced noise level design, B020
1 26071884 1 Armature plate reworked B020 2) or 3) or 1) and 2) or 1) and 3)
Pressure plate for ZBA, Reduced noise level design B050
1 26031884 1 Anchor plate G/B050 1)
2 Damping plate for ZBA, Reduced noise level design, B020
2 26021484 1 Damping plate B020 1)
Damping plate for ZBA, Reduced noise level design, B050
2 26031484 1 Damping plate B050 1)
2 26073384 1 Damping plate reworked B050 1) and 2) or 1) and 3) or 2) or 3)
2 26073584 1 Damping plate reworked B050 1) and 2) and 3)
3 26020584 1 Stop disk B020
3 26030584 1 Stop disk B050
4 15069099 2 Hexagonal nut M 5 B020, B050 8 A2F ISO 4032
5 15134699 2 Stud M 5 X 60 B020 8.8 A2F DIN 835
5 15134799 2 Stud M 5 X 65 B050 8.8 A2F DIN 835
6 Magnet body B020
Magnet body B050
7 26023184 2 Holding bolt seal B020 B020, B050
8 15099799 2 Grooved pin 5X26 B020, B050 ST A2F ISO 8741
9 26093384 1 Brake release lever FL-HBLA B020, ZB100
9 26093484 1 Brake release lever FL-HBLA B050, Z90B, ZB100
10 26094284 1 Brake release lever HBLN B020, ZB100
10 26094584 1 Brake release lever HBLN B050, Z90B, ZB100
14 26023484 2 Spring -VOR 0.8 X 8.4X 13.8
14 26023784 2 Spring -VOR 0.9 X 8.3X 12.9 B050
15 35046699 2 Washer 5.3X 15 X1.2 B020, B050 ST140HVA2F DIN 9021
16 15056399 2 Hexagonal nut M 5 B020, B050 8 A2F DIN 985
17 26013184 1 Holding bolt seal B007 B020, B050
20 26037084 1 Stud bolt micro-switch FK Microswitch, V4NSE B050
20 26037184 1 Stud bolt micro-switch FK/NUE Microswitch, V4NSE B020,V4LS B050
20 26017084 1 Stud bolt micro-switch FK/NUE Microswitch, V4LS B020
21 34065199 1 Washer B 4.3X 9 X0.8 140HV A2F DIN 125
22 26017384 1 Microswitch V4NSE 2) for ZBA, 3) for ZBA and ZBF
22 26017484 1 Microswitch V4LS 2) for ZBF
23 34276844 1 Entry bush 10 - 6 RD
24 22871884 1 Fan cover HBL ZB100
# 25 33320699 1 Hexagonal nut BM12 X1.5 B020, B050 04 A2F DIN 439
26 26029984 1 Adapter FL ZB100-B020
26 26039884 1 Adapter FL ZB100-B050 B020, B050
27 26027884 1 Cover plate ZB100/132 B020, B050
28 22872384 1 EXT.COVER ZB100 EF+MBR
29 22872984 1 COVER,HAN EF+MBR additional integrated fan
22287605.tbl
1) Manual release
2) Adjustment monitoring
3) Function monitoring
4) Other voltages upon request.
17
California Ohio
Connecticut Ontario
Illinois Quebec
Michigan Texas
Missouri
Washington
Telephone: (425) 883-4668 • Fax: (425) 883-4828

29201 Aurora Road
Telephone: (440) 248-2400
Fax: (440) 248-3086
Component parts
Offset gearboxes A20
0702 EN/US 229 211 49 721 IS 913.70

Contents
Page
Gearbox type designation (example) 3

Torque bracket 4
Torque arm MA 112-1 5
AM 20 DD, 2-stage direct input 8
AM 20 TD, 3-stage direct input 10
AM 20 DL/DS, 2-stage coupling connection 12
AM 20 TL/TS, 3-stage coupling connection 14
AF 20 DD, 2-stage direct input 16
AF 20 TD, 3-stage direct input 18
AF 20 DL/DS, 2-stage coupling connection 20
AF 20 TL/TS, 3-stage coupling connection 22
Coupling and motor connection A20 - DL/DS - TL/TS 24
Coupling and motor connection A20 - DL/TL 25

Example
#8 342 530 99 1 Retaining ring 30X1.5 FEDST DIN 471

2
# Gearbox type designation (example)
Type designation Mounting code

Transmission ratio
Terminall box position
Output shaft code
Model code
A U V 20 D D - B14.0 - 25 - 0 - 25.3
Input type
D Direct input
L Light coupling
S Heavy coupling
R Slipping clutch
Number of stages
D 2-stage
T 3-stage
Sizes
10, 20, 30, 40, 50, 60, 70, 80, 90
Output shaft design

V Solid shaft with key V 25
E Splined solid shaft E 35
H Hollow shaft with key H 24
K Splined hollow shaft K 30
B Hollow shaft with shrink disc (motor side) B 28
Housing design
U Universal (AU20-AU90)
G Foot mounting (AG30-AG90)

F Flange mounting (AF20-AF90)
M Torque bracket arrangement (integrated torque bracket; AM10 - AM40)
D Torque bracket arrangement (centering for flange-fitted torque bracket; AD40-AD80)
Gearbox type
A offset gearbox
# Gearbox rating plate:
Demag Cranes & Components

Type: AMH20 DD Oil = 0.5 l
Model : B14.0 - 25 - 1/25.3

Seria.l number: 300 919 45
Order Number : 84295400
ASN: 00501
30091945 Assembled in USA
3
Torque arm
70 71 73 74 75
76 77 78
41080944.eps
Item # Part # Quantity Designation Material Standard

70 81195044 1 Torque arm set (item # 71, 73-78) AF-AFL04
71 30803399 1 Socket hd. screw M12 X 85 8.8 A2F
73 81195444 2 Spring element
74 34069699 1 Washer 13 X 30 X 6 ST A2F DIN 7349
75 33461244 1 Safety nut V M12 8 A2F DIN 980
76 00460998 2 Set nut M12 A2F
77 31621799 2 Washer 13 X 24 X3 C 45A2E HV DIN 6916
78 30760099 2 Socket hd. screw M12 X 40 10.9 A2F DIN 933
22282409.tbl
4
Torque arm MA 112-1
41890144.eps

1 75379044 1 Torque arm set cpl. (item # 2 - 4) M112-1
2 30044144 4 Safety nut M 8 10 A2F
3 15106999 4 Socket hd. screw M 6 X 35 8.8MK A2F DIN 912
4 34045599 4 Washer 6.4X 11 X1.6 140HV A2F DIN 433
41890144.tbl
5
Torque arm MA 125-1
41890244.eps

1 75239044 1 Torque arm set M125-1 cpl. (item # 2 - 4) M125-1
2 30044144 4 Safety nut M 8 10 A2F
41890244.tbl
6
Torque arm MA 160-1
41890444.eps

1 75268844 1 Torque arm-M160-1 cpl. (item # 2-4) PA6 GF30 75268844
2 30044244 4 Safety nut M10 10 A2F N01189299
41890444.tbl
7
AM20 DD, 2-stage direct input
71
100 101
100 101
42071946.eps
8
41890744
4 00508798 1 Oil seal AS 40X 52X 7 NBR DIN 3760

6 34040499 6 Washer 5.3X 9.0X1 140HV A2F DIN 433
9 34301544 4 Threaded insert M 8X12M12 C
11 36710199 3 O-ring 8 X2 B NB 70 DIN 3770
12 31339499 3 Locking screw M10X1 5.8 DIN 908
14 78711444 1 Cover gearbox AM20
15 78711544 1 Gearbox seal A20 from 01.01.1999
35 36060199 1 Grooved ball bearing 6301 DIN 625
36 34348999 1 Supporting plate 12X 18X1.2 DIN 988
37 84139946 1 Double wheel Z16M1.50Z 41M1.25 i = 6.21
40 84142046 1 Output shaft hollow splined Z63 K 30 1)
40 84140046 1 Output shaft hollow splined Z61 K 30 2)
42 84142146 1 Output shaft hollow w/key Z63 H 24 1)
42 84140146 1 Output shaft hollow w/key Z61 H 24 2)
42 84143246 1 Output shaft hollow inch z63 H 1)
42 84141246 1 Output shaft hollow inch z61 H 2)
# 54 84143046 1 Output shaft with gear Z63 E 35 1)
56 84142846 1 Output shaft with gear Z63 E 11 1)
56 84140846 1 Output shaft with gear Z61 E 11 2)
61 34279744 1 Plug 52 X 6.5
65 30022144 2 Lock screw M 8X35
66 15055399 2 Cylinder pin 10 M 6X 12 ST50 K ISO 2338
67 78710444 1 Gearbox housing A20
68 78701644 1 Gearbox seal A10/A20 from 01.01.1999
69 00508798 1 Oil seal AS 40X 52X 7 DIN 3760
70 71609844 1 Cap AF04/AFM04
# Pinion for DD mot. Z63/71/80/90A 3)
# 71 78602144 1 Pinion Z 12 M0.93B 24 i = 25.3-28.0 3)
# 71 78602644 1 Pinion Z 11 M1.25B 24 i = 20.1-22.2 3)
# 71 78603144 1 Pinion Z 13 M1.25B 24 i = 16.4-18.1 3)
# 71 78603644 1 Pinion Z 16 M1.25B 24 i = 12.6-13.9 3)
# 71 78604144 1 Pinion Z 19 M1.25B 24 i = 9.95-11.0 3)
# 71 78604644 1 Pinion Z 22 M1.25B 24 i = 8.05-8.91 3)
# 71 78605144 1 Pinion Z 26 M1.25B 24 i = 6.21-6.87 3)
# Pinion for DD mot 5.3-28.0 3)
# 71 78602744 1 Pinion Z 11 M1.25B 24 i = 20.1-22.2 3)
# 71 78603244 1 Pinion Z 13 M1.25B 24 i = 16.4-18.1 3)
# 71 78603744 1 Pinion Z 16 M1.25B 24 i = 12.6-13.9 3)
# 71 78604244 1 Pinion Z 19 M1.25B 24 i = 9.95-11.0 3)
# 71 78604744 1 Pinion Z 22 M1.25B 24 i = 8.05-8.91 3)
# 71 78605244 1 Pinion Z 26 M1.25B 24 i = 6.21-6.87 3)
72 15064299 2 Stud M 8 X 22 10.9 B2=14 DIN 940
100 30028244 4 Lock nut M 8
# 101 22924049 1 Spare parts list motor Z63/Z71
# 101 22924249 1 Spare parts list motor Z80/Z90A
# 101 22924449 1 Spare parts list motor Z90B/Z100
22282402.tbl
# 1) i = 6.21-8.05-9.95-12.6-16.4-20.1-25.3
# 2) i = 6.87-8.91-11.0-13.9-18.1-22.2-28.0
# 3) The pinion gear is installed onto the motor shaft by Demag Cranes and Components.
9
100 101
100 101
42072044.eps
10

11 36710199 3 O-ring 8 X2 B NB 70 DIN 3770
12 31339499 3 Screw plug M10X1 5.8 DIN 908
32 84137946 1 Cluster gear Z11M0.93Z 30M1.25 i = 31.7-35.0
32 84136846 1 Cluster gear Z12M0.93Z 33M1.25 i = 52.1
# 32 84137546 1 Cluster gear Z11M1.25Z 53M0.93 i = 88.6-98.0
# 32 84136546 1 Cluster gear Z12M0.93Z 53M0.93 i = 112-124
37 84139446 1 Cluster gear Z16M1.50Z 56M1.25 i = 31.7-55.5-88.6
37 84139346 1 Cluster gear Z16M1.50Z 77M0.93 i = 39.9-52.1-70.0-112
37 84138346 1 Cluster gear Z14M1.60Z 77M0.93 i = 44.2-77.4-124
# 40 84142046 1 Output shaft hollow splined Z63 K 30 1)
# 42 84142146 1 Output shaft hollow w/key Z63 H 24 1)
# 42 84143246 1 Output shaft hollow inch z63 H 1)
61 34279744 1 Plug 52 X 6.5
65 30022144 2 Lock screw M 8X35 VB.RIPP
70 71609844 1 Cap AF04/AFM04
# Pinion for TD mot. Z63/71/80/90A 3)
# 71 78602144 1 Pinion Z 12 M0.93B 24 i = 88.6-98-112-124 3)
# 71 78603144 1 Pinion Z 13 M1.25B 24 i = 55.5-61.4-70-77.4 3)
# 71 78603644 1 Pinion Z 16 M1.25B 24 i = 55.5-61.4-70.0-77.4 3)
# 71 78604144 1 Pinion Z 19 M1.25B 24 i = 31.7-35-39.9-44.2 3)
72 15064299 2 Stud M 8 X 22 10.9 B2=14 DIN- 940
100 30028244 4 Lock nut M 8 VB.RIPP
# 101 22924449 1 Spare parts list motor Z90B/Z100
22282403.tbl
# 1) i = 31.7-39.9-52.1-55.5-70.0-88.6-112
# 2) i = 35.0-44.2-61.4-77.4-98.0-124
# 3) The pinion gear is installed onto the motor shaft by Demag Cranes and Components. When ordering replacement motor, specify gearbox ratio as shown
on data shield.
11
AM20 DL/DS, 2-stage coupling connection
Coupling and motor connection A20 - DL/DS - TL/TS,

see page 24 - 25.
42072144.eps
12
AM20 DL/DS, 2-stage coupling connection

11 36710199 3 O-ring 8 X2 B NB 70 DIN 3770
26 78642844 1 Pinion shaft Z 26 M1.25B 25 i = 6.21-6.87
26 78641144 1 Pinion shaft Z 11 M1.25B i = 20.1-22.2
27 35487399 1 Key B 5X 5X 21 C 45 K DIN 6885
# 42 84143246 1 Output shaft hollow inch Z63 H 1)
61 34279744 1 Plug 52 X 6.5
70 71609844 1 Cap AF04/AFM04
75 36716899 1 Oil seal A 17X 28X 7 NBR DIN 3760
22282406.tbl
# 1) i = 6.21-8.05-9.95-12.6-16.4-20.1-25.3
# 2) i = 6.87-8.91-11.0-13.9-18.1-22.2-28.0
13
AM20 TL/TS, 3-stage coupling connection
Coupling and motor connection A . . 20 - DL/DS - TL/TS,

see page 24 - 25.
42072244.eps
14
AM20 TL/TS, 3-stage coupling connection

11 36710199 3 O-ring 8 X2 B NB 70 DIN 3770
26 78642044 1 Pinion shaft Z 19 M1.25B 25 i = 31.7-35.0-39.9-44.1
26 78641744 1 Pinion shaft Z 16 M1,25B 25 i = 52.1
26 78641444 1 Pinion shaft Z 13 M1,25B 25 i = 55.5-61.4-70.0-77.4
26 78640544 1 Pinion shaft Z 12 M0,93B 25 i = 88.5-98.0-112-123
27 35487399 1 Key B 5X 5X 21 C 45 K DIN 6885
61 34279744 1 Plug 52 X 6.5
70 71609844 1 Cap AF04/AFM04
22282407.tbl
# 1) i = 31.7-39.9-52.1-55.5-70.0-88.6-112
# 2) i = 35.0-44.2-61.4-77.4-98.0-124
15
AF20 DD, 2-stage direct input
100 101
100 101
42072345.eps
16
AF20 DD, 2-stage direct input

3 78712644 1 Flange B5 160/ 85
11 36710199 3 O-ring 8 X2 B NB 70 DIN 3770
# 14 78711844 1 Cover gearbox AF/AU20
36 34348999 1 Supporting plate 12X 18X1,2 DIN 988
43 71111844 1 Compensating ring AFM04
# 51 84142546 1 Output shaft with gear Z63 V 25, AU 1)
# 52 84142746 1 Output shaft with gear Z63 V 25, AF 1)
# 52 84143446 1 Output shaft with gear inch Z63 V 1)
# 53 84142346 1 Output shaft with gear Z63 B 28 1)
58 35427899 1 Key A 8X 7X 45 C 45 K DIN 6885
58 00754449 1 Key 0.25 X 0.25 X 1.75 inch lg.
61 34279744 1 Plug 52 X 6.5
62 78719244 1 Shrink-fitting ring HSD 36-22
70 71609844 1 Cap AF04/AFM04
# Pinion for DD mot. Z63/71/80/90A 3)
# 71 78602144 1 Pinion Z 12 M0.93B 24 i = 25.3-28.0 3)
# 71 78602644 1 Pinion Z 11 M1.25B 24 i = 20.1-22.0 3)
# 71 78603144 1 Pinion Z 13 M1.25B 24 i = 16.4-18.1 3)
# 71 78603644 1 Pinion Z 16 M1.25B 24 i = 12.6-13.9 3)
# 71 78604144 1 Pinion Z 19 M1.25B 24 i = 9.95-11.0 3)
# 71 78604644 1 Pinion Z 22 M1.25B 24 i = 8.05-8.91 3)
# 71 78605144 1 Pinion Z 26 M1.25B 24 i = 6.21-6.87 3)
# Pinion for DD mot. Z90B/100 3)
# 71 78602244 1 Pinion Z 12 M0.93B 24 i = 25.3-28.0 3)
# 71 78602744 1 Pinion Z 11 M1.25B 24 i = 20.1-22.0 3)
# 71 78603244 1 Pinion Z 13 M1.25B 24 i = 16.4-18.1 3)
# 71 78603744 1 Pinion Z 16 M1.25B 24 i = 12.6-13.9 3)
# 71 78604244 1 Pinion Z 19 M1.25B 24 i = 9.95-11.0 3)
# 71 78604744 1 Pinion Z 22 M1.25B 24 i = 8.05-8.91 3)
# 71 78605244 1 Pinion Z 26 M1.25B 24 i = 6.21-6.87 3)
72 15064299 2 Stud M 8 X 22 10.9 B2=14 DIN 940
100 30028244 4 Lock nut M 8 VB.RIPP
# 101 22924449 1 Spare parts list motor Z90B/Z100 22282404.tbl
# 1) i = 6.21-8.05-9.95-12.6-16.4-20.1-25.3
# 2) i = 6.87-8.91-11.0-13.9-18.1-22.2-28.0
on data shield.
17
AF20 TD, 3-stage direct input
100 101
100 101
42072445.eps
18
AF20 TD, 3-stage direct input

3 78712644 1 Flange B5 160/ 85
11 36710199 3 O-ring 8 X2 B NB 70 DIN 3770
58 35427899 1 Key A 8X 7X 45 C 45 K DIN 6885
52 00754449 1 Key 0.25 X 0.25 X 1.75 inch lg.
61 34279744 1 Plug 52 X 6.5
70 71609844 1 Cap AF04/AFM04
Pinion for TD mot. Z63/71/80/90A 3)
# 71 78602144 1 Pinion Z 12 M0.93B 24 i = 88.6-98-112-124 3)
# 71 78603144 1 Pinion Z 13 M1.25B 24 i = 55.5-64.4-70-77.4 3)
# 71 78603644 1 Pinionv Z 16 M1.25B 24 i = 55.5-61.4-70.0-77.4 3)
# 71 78604144 1 Pinion Z 19 M1.25B 24 i = 31.7-35-39.9-44.2 3)
72 15064299 2 Stud M 8 X 22 10.9 B2=14 DIN 940
100 30028244 4 Lock nut M 8
# 101 22924249 1 Spare parts list motor Z80-Z90A
22282405.tbl
# 1) i = 31.7-39.9-52.1-55.5-70.0-88.6-112
# 2) i = 35.0-44.2-61.4-77.4-98.0-124
on data shield.
19
AF20 DL/DS, 2-stage coupling connection

see page 24 - 25.
42072544.eps
20
AF20 DL/DS, 2-stage coupling connection

3 78712644 1 Flange B5 160/ 85
11 36710199 3 O-ring 8 X2 B NB 70 DIN 3770
26 78641144 1 Pinion shaft Z 11 M1.25B i = 20.1-22.2
27 35487399 1 Key B 5X 5X 21 C 45 K DIN- 6885
36 34348999 1 Supporting plate 12X 18X1,2 DIN 988
# 52 84143446 1 Output shaft with gear inch z63 V 1)
58 35427899 1 Key A 8X 7X 45 C 45 K DIN 6885
58 00754449 1 Key 0.25 x 0.25 x 1.75 inch lg.
61 34279744 1 Plug 52 X 6.5
70 71609844 1 Cap AF04/AFM04
22282408.tbl
# 1) i = 6.21-8.05-9.95-12.6-16.4-20.1-25.3
# 2) i = 6.87-8.91-11.0-13.9-18.1-22.2-28.0
21
AF20 TL/TS, 3-stage coupling connection

see page 24 - 25.
42072644.eps
22
AF20 TL/TS, 3-stage coupling connection

3 78712644 1 Flange B5 160/ 85
11 36710199 3 O-ring 8 X2 B NB 70 DIN 3770
26 78641744 1 Pinion shaft Z 16 M1.25B 25 i = 52.1
26 78640544 1 Pinion shaft Z 12 M0.93B 25 i = 88.5-98.0-112-123
27 35487399 1 Key B 5X 5X 21 C 45 K DIN- 6885
32 84136546 1 Cluster gear Z12M0.93Z 53M0.93 i = 112-124
# 52 84143346 1 Ouput shaft with gear inch z63 V 1)
58 35427899 1 Key A 8X 7X 45 C 45 K DIN 6885
58 00754449 1 Key 0.25 x 0.25 x 1.75 inch lg.
61 34279744 1 Plug 52 X 6.5
70 71609844 1 Cap AF04/AFM04
22282409.tbl
# 1) i = 31.7-39.9-52.1-55.5-70.0-88.6-112
# 2) i = 35.0-44.2-61.4-77.4-98.0-124
23
Coupling and motor connection A20 - DL/DS - TL/TS
Mot. KB 71 - KB 90
42073644.eps
Mot. KB 71
90 71820544 1 Coupling half H 1N-16
92 71822144 1 Roller star coupling H1
95 71822344 1 Coupling half HT1N-16
97 71502044 1 Intermediate flange D04 71 125.1
99 35457799 1 Key B 5X 5X 20 C 45 K DIN 6885
102 20007084 1 Spare parts list motor KB 71-140
22282004.tbl
Mot. KB 80
99 35425799 1 Key B 6X 6X 20 C 45 K DIN 6885
22282005.tbl
Mot. KB 90
99 35457199 1 Key B 8X 7X 20 C 45 K DIN 6885
22282410.tbl
24
Coupling and motor connection A20 - DL/TL
Mot. Z 63 - Z 80
42073544.eps
Mot. Z 63/71
99 35457799 1 Key B 5X 5X 20 C 45 K DIN 6885
101 22924049 1 Spare parts list motor Z63/Z71
22282006.tbl
Mot. Z 80/90A
99 35425799 1 Key B 6X 6X 20 C 45 K DIN 6885
101 22924249 1 Spare parts list motor Z80/Z90a
22282007.tbl
25
California Ohio
Connecticut Ontario
Illinois Quebec
Michigan Texas
Missouri
Washington
Telephone: (425) 883-4668 • Fax: (425) 883-4828

29201 Aurora Road
Telephone: (440) 248-2400
Fax: (440) 248-3086
Component parts
Offset gearboxes A40
0702 EN/US 229 213 49 721 IS 983.1

Contents
Gearbox type designation (example) 3
MA 160-2 torque arm 4
MA 200-1 torque arm 5
AMK 40 - AMH 40 - AME 40 DD 2-stage direct input 6
ADK 40 - ADH 40 - ADE 40 DD 2-stage direct input 6
AMK 40 - AMH 40 - AME 40 TD 3-stage direct input 10
ADK 40 - ADH 40 - ADE 40 TD 3-stage direct input 10
AMK 40 - AMH 40 - AME 40 DL/S 2-stage coupling connection 12
ADK 40 - ADH 40 - ADE 40 DL/S 2-stage coupling connection 12
AMK 40 - AMH 40 - AME 40 TL/S 3-stage coupling connection 14
ADK 40 - ADH 40 - ADE 40 TL/S 3-stage coupling connection 14
AFK 40 - AFH 40 - AFV 40 - AFB 40 DD 2-stage direct input 16
AUK 40 - AUH 40 - AUV 40 - AUB 40 DD 2-stage direct input 16
AGK 40 - AGH 40 - AGV 40 - AGB 40 DD 2-stage direct input 16
AFK 40 - AFH 40 - AFV 40 - AFB 40 TD 3-stage direct input 20
AUK 40 - AUH 40 - AUV 40 - AUB 40 TD 3-stage direct input 20
AGK 40 - AGH 40 - AGV 40 - AGB 40 TD 3-stage direct input 20
AFK 40 - AFH 40 - AFV 40 - AFB 40 DL/S 2-stage coupling connection 22
AUK 40 - AUH 40 - AUV 40 - AUB 40 DL/S 2-stage coupling connection 22
AGK 40 - AGH 40 - AGV 40 - AGB 40 DL/S 2-stagecoupling connection 22
AFK 40 - AFH 40 - AFV 40 - AFB 40 TL/S 3-stage coupling connection 24
AUK 40 - AUH 40 - AUV 40 - AUB 40 TL/S 3-stage coupling connection 24
AGK 40 - AGH 40 - AGV 40 - AGB 40 TL/S 3-stagecoupling connection 24
Coupling and motor for DL/TL 26
Coupling and motor for DL/DS - TS/TS 28

Example

2
# Gearbox type designation (example)
Type designation Mounting code

Transmission ratio
Terminall box position
Output shaft code
Model code
A U V 40 D D - B14.0 - 30 - 0 - 22.7
Input type
D Direct input
L Light coupling
S Heavy coupling
R Slipping clutch
Number of stages
D 2-stage
T 3-stage
Sizes
10, 20, 30, 40, 50, 60, 70, 80, 90
Output shaft design

V Solid shaft with key V 30
# E Splined solid shaft E 11
# E Splined solid shaft E 46
H Hollow shaft with key H 35
K Splined hollow shaft K 35
B Hollow shaft with shrink disc (motor side) B 35
Housing design
U Universal (AU20-AU90)
G Foot mounting (AG30-AG90)

F Flange mounting (AF20-AF90)
M Torque bracket arrangement (integrated torque bracket; AM10 - AM40)
D Torque bracket arrangement (centering for flange-fitted torque bracket; AD40-AD80)
Gearbox type
A offset gearbox
# Gearbox rating plate:

Demag Cranes & Components
Type: AUV40DD Oil = 1.5 l
Model : B14.0 - 40 - 1/22.7

Seria.l number: 300 919 45
Order Number : 84295400
ASN: 00501
30091945 Assembled in USA
3
MA 160-2 torque arm
41890544.eps
Item no. Part number Quantity Designation Material Standard

1 75268944 1 Torque arm set M160-2 c/w items 2, 3
2 30044244 4 Safety nut M10 10 A2F
3 34277844 4 Safety screw M10X20
41890545.tbl
4
MA 200-1 torque arm
41890644.eps

1 75318844 1 Torque arm set M200-1 c/w items 2, 3
2 30044244 4 Safety nut M10 10 A2F
3 34277844 4 Safety screw M10X20
41890645.tbl
5
AMK 40 - AMH 40 - AME 40 DD 2-stage direct input
ADK 40 - ADH 40 - ADE 40 DD
42073744.eps
6
4 36688799 1 Seal ring AS 55X 72X 8 NBR DIN 3760
5 32154299 10 Hex. sock screw M6X45 10.9 A2F DIN 912
6 34065399 10 Washer A 6.4 140HV A2F DIN 125
9 33893244 4 Threaded bush M10X18X16
11 36710199 5 O-ring 8X2 B NB 70 DIN 3370
12 31339499 5 Screw plug M10X1 5.8 DIN 908
14 78731244 1 Gearbox cover AM40
15 78721644 1 Seal 2-GAF30/A40
16 78731044 1 Gearb.cover AF40/AG40 AD40
35 15055099 1 Grooved ball brg. 303 E DIN 5412
36 34349199 1 Support ring 17X 24X1.5 DIN 988
37 84154146 1 Cluster gear Z12M2.00Z107M0.93 i = 55.7
40 84157046 1 Output shaft w/gear Z75 K45 1)
42 84157146 1 Output shaft w/gear Z75 H40 1)
42 84158246 1 Output shaft w/gear Z75 inch H 1)
53 84157346 1 Output shaft w/gear Z75 B40 1)
54 84158046 1 Output shaft w/gear Z75 E50 1)
56 84157846 1 Output shaft w/gearR Z75 E11 1)
61 34289244 1 Plug 72 X 9 VK72X 9 NB
62 71628944 1 Shrink disk
65 30023244 2 Safety screw M10X40
66 15055399 2 Par. pin Z10 X 12 ST50 K ISO 2338
67 7873044 1 Gearb. housing A 40
68 78721644 1 Seal 2-GAF30/A40
69 36688799 1 Shaft seal ring NBR DIN 3760
70 81038644 1 Dust cap F.AF06
22283301.tbl
1) i = 8.78-11.7-14.9-19.0-22.7-28.1-36.1-44.3-55.7
2) i = 9.71-12.9-16.5-21.0-25.1-31.1-39.9-49.0-61.6
7
Pinion for mot. Z63/80

71 78605144 1 Pinion Z 26 M1.25B 24 i = 14.9-16.5
71 78604644 1 Pinion Z 22 M1.25B 24 i = 19.0-21.0
71 78604144 1 Pinion Z 19 M1.25B 24 i = 22.7-25.1
71 78603644 1 Pinion Z 16 M1.25B 24 i = 28.1-31.1
71 78603144 1 Pinion Z 13 M1.25B 24 i = 36.1-39.9
71 78602644 1 Pinion Z 11 M1.25B 24 i = 44.3-49.0
71 78602144 1 Pinion Z 12 M0.93B 26 i = 55.7-61.6
Pinion for mot. Z100
71 78606244 1 Pinion Z 37 M1.25B 24 i = 8.78-9.71
71 78605744 1 Pinion Z 31 M1.25B 24 i = 11.7-12.9
71 78605244 1 Pinion Z 26 M1.25B 24 i = 14.9-16.5
71 78604744 1 Pinion Z 22 M1.25B 24 i = 19.0-21.0
71 78604244 1 Pinion Z 19 M1.25B 24 i = 22.7-25.1
71 78603744 1 Pinion Z 16 M1.25B 24 i = 28.1-31.1
71 78603244 1 Pinion Z 13 M1.25B 24 i = 36.1-39.9
71 78602744 1 Pinion Z 11 M1.25B 24 i = 44.3-49.0
71 78602244 1 Pinion Z 12 M0.93B 26 i = 55.7-61.6
Pinion for mot. Z100
71 78606344 1 Pinion Z 37 M1.25B 24 i = 8.78-9.71
71 78605744 1 Pinion Z 31 M1.25B 24 i = 11.7-12.9
71 78605344 1 Pinion Z 26 M1.25B 24 i = 14.9-16.5
71 78604844 1 Pinion Z 22 M1.25B 24 i = 19.0-21.0
71 78604344 1 Pinion Z 19 M1.25B 24 i = 22.7-25.1
71 78603844 1 Pinion Z 16 M1.25B 24 i = 28.1-31.1
71 78603344 1 Pinion Z 13 M1.25B 24 i = 36.1-39.9
71 78602844 1 Pinion Z 11 M1.25B 24 i = 44.3-49.0
72 15059999 2 Threaded pin M10 X 25 10.9 DIN 835
100 30028344 4 Safety nut M10 10
101 22924049 1 Parts list Z63/Z71
101 22924249 1 Parts list Z80/Z90A
101 22924449 1 Parts list Z90B/Z100
101 22924649 1 Parts list Z112/Z132
8
42073744.eps
9
AMK 40 - AMH 40 - AME 40 TD 3-stage direct input
ADK 40 - ADH 40 - ADE 40 TD
42073844.eps

5 32154299 10 Hex.sock screw M6X45 10.9 A2F DIN 912
6 34065399 10 Washer 6.4 140HV A2F DIN 125
11 36710199 5 O ring 8 X 2 B NB 70 DIN 3770
12 31339499 5 Screw plug M10X1 5.8 DIN 908
14 78731244 1 Gearb.cover AM40
15 78721644 1 Seal 2-GAF30/A40
16 78731044 1 Gearb.cover AF40/AG40 AD40
32 84152746 1 Cluster gear Z13M1.25Z 48M1.25 i = 91.1-101
10
AMK 40 - AMH 40 - AME 40 TD 3-stage direct input
ADK 40 - ADH 40 - ADE 40 TD

35 15055099 1 Grooved ball bearing 303 E DIN 5412
37 84154346 1 Cluster gear Z12M2.00Z 75M1.25 i = 73.7-91.1-115-
150-184-231
37 84153346 1 Cluster gear Z11M2.00Z 75M1.25 i = 81.5-101-127-
166-203-256
61 34289244 1 Plug 72 X 9
65 30023244 2 Safety screw M10X40
66 15055399 2 Par. pin A10X12 ST50 K ISO 2338
67 7873044 1 Gearb.housing A 40
68 78721644 1 Seal 2-GAF30/A40
69 36688799 1 Seal ring NBR DIN 3760
70 81038644 1 Dust cap F.AF06
71 Pinion for motor Z63/80
71 78604644 1 Pinion Z 22 M1.25B 24 i = 73.7-81.5
71 78604144 1 Pinion Z 19 M1.25B 24 i = 91.1-101
71 78603644 1 Pinion Z 16 M1.25B 24 i = 115-127
71 78603144 1 Pinion Z 13 M1.25B 24 i = 150-166
71 78602644 1 Pinion Z 11 M1.25B 24 i = 184-203
71 78602144 1 Pinion Z 12 M0.93B 26 i = 231-256
71 Pinion for motor Z100
71 78604744 1 Pinion Z 22 M1.25B 24 i = 73.7-81.5
71 78604244 1 Pinion Z 19 M1.25B 24 i = 91.1-101
71 78603744 1 Pinion Z 16 M1.25B 24 i = 115-127
71 78603244 1 Pinion Z 13 M1.25B 24 i = 150-166
71 78602744 1 Pinion Z 11 M1.25B 24 i = 184-203
71 78602244 1 Pinion Z 12 M0.93B 26 i = 231-256
71 Pinion for motor Z132
71 78604844 1 Pinion Z 22 M1.25B 24 i = 73.7-81.5
71 78604344 1 Pinion Z 19 M1.25B 24 i = 91.1-101
71 78603844 1 Pinion Z 16 M1.25B 24 i = 115-127
71 78603344 1 Pinion Z 13 M1.25B 24 i = 150-166
71 78602844 1 Pinion Z 11 M1.25B 24 i = 184-203
72 15059999 2 Threaded pin M10 x 25 10.9 DIN 835
100 30028344 4 Safety nut M10
101 22924049 1 Motor parts list Z63/Z71
101 22924249 1 Motor parts list Z80/Z90A
101 22024649 1 Motor parts list Z90B/Z100
22283305.tbl
1) i = 73.8-91.1-115-150-184-231
2) i = 81.5-101-127-166-203-256
11
AMK 40 - AMH 40 - AME 40 DL/S 2-stage coupling connection
ADK 40 - ADH 40 - ADE 40 DL/S
Coupling and motor connection A40 - DL/S offset gearbox

see page 26 - 29. 42073944.eps

5 32154299 10 Hex. sock. screw M6 X 45 10.9 A2F DIN 912
6 34065399 10 Washer 6.4 140HV A2F DIN 125
11 36710199 5 O ring 8 X 2 B NB 70 DIN 3770
12 31339499 5 Screw plug M10X1 5.8 DIN 908
14 78731244 1 Gearb.cover AM40
15 78721644 1 Seal 2-GAF30/Z40
16 78731044 1 Gearb. cover AF40-AG40 AD40
22283302.tbl
12
AMK 40 - AMH 40 - AME 40 DL/S 2-stage coupling connection
ADK 40 - ADH 40 - ADE 40 DL/S
26 78643544 1 Pinion Z 37 M1.25B 27 i = 8.78-9.71

26 78643244 1 Pinion Z 31 M1.25B 27 i = 11.7-12.9
26 78642944 1 Pinion Z 26 M1.25B 27 i = 14.9-16.5
26 78642544 1 Pinion Z 22 M1.25B 27 i = 19.0-21.0
26 78642144 1 Pinion Z 19 M1.25B 27 i = 22.7-25.1
26 78641844 1 Pinion Z 16 M1.25B 27 i = 28.1-31.1
26 78641544 1 Pinion Z 13 M1.25B 27 i = 36.1-39.9
26 78671244 1 Pinion Z 11 M1.25B 27 i = 44.3-49.0
26 78640644 1 Pinion Z 12 M0.93B 27 i = 55.7-61.6
27 35487599 1 Key B 6X 6X 21 C 45 K DIN 6885
29 36055499 1 Grooved ball brg. 6204 DIN 625
36 34349199 1 Supporting ring 17X24X1.5 DIN 988
42 84155146 1 Output shaft w/gear Z/6 H40 2)
61 34289244 1 Plug 72 X 9
66 15055399 2 Par.pin A10 X 12 ST50 K ISO 2338
67 78730844 1 Gearb.housing A40-COUP
70 81038644 1 Dust cap F.AF06
75 37651599 1 Oil seal NBR DIN 3760
22283302.tbl
1) i = 8.78-11.7-14.9-19.0-22.7-28.1-36.1-44.3-55.7
2) i = 9.71-12.9-16.5-21.0-25.1-31.1-39.9-49.0-61.6
13
AMK 40 - AMH 40 - AME 40 TL/S 3-stage coupling connection
ADK 40 - ADH 40 - ADE 40 TL/S
Coupling and motor connection A 40 - TL/S offset gearbox

see page 26 - 29.
42074044.eps
14
AMK 40 - AMH 40 - AME 40 TL/S 3-stage coupling connection
ADK 40 - ADH 40 - ADE 40 TL/S
5 32154299 10 Hex. sock screw M6X45 10.9 A2F DIN 912
6 34065399 10 Washer 6.4 140HV A2F DIN 125
11 36710199 5 O-ring 8X2 B NB 70 DIN 3770
12 31339499 5 Screw plug M10X1 5.8 DIN 908
12 78731244 1 Gearb. cover AM40
15 78721644 1 Seal 2-GAF30/A40
16 78731044 1 Gearb.cover AF40/AG40 AD 40
26 78642544 1 Pinion Z 22 M1.25B 27 i = 73.7-81.5
26 78642144 1 Pinion Z 19 M1.25B 27 i = 91.1-101
26 78641844 1 Pinion Z 16 M1.25B 27 i = 115-127
26 78641544 1 Pinion Z 13 M1.25B 27 i = 150-166
26 78641244 1 Pinion Z 11 M1.25B 27 i = 184-203
26 78640644 1 Pinion Z 12 M0.93B 27 i = 231-256
27 35487599 1 Key B 6X 6X 21 C 45 K DIN 6885
34 36060199 1 Grooved ball brg 6301 DIN 625
35 15055099 1 Grooved ball brg 303E DIN 625
150-184-231
166-203-256
61 34289244 1 Plug 72 X 9
42 81038644 1 Dust cap
66 15055399 2 Par. pin A10 X 12 ST50 K ISO 2338
67 78730844 1 Gearb. housing-A40-coup
70 81038644 1 Dust cap F.AF06
75 37651599 1 Oil seal NBR DIN 3760
22283306.tbl
1) i =73.8-91.1-115-150-184-231
2) i = 81.5-101-127-166-203-256
15
AFK 40 - AFH 40 - AFV 40 - AFB 40 DD 2-stage direct input
AUK 40 - AUH 40 - AUV 40 - AUB 40 DD
AGK 40 - AGH 40 - AGV 40 - AGB 40 DD
42074144.eps
16
AUK 40 - AUH 40 - AUV 40 - AUB 40 DD
AGK 40 - AGH 40 - AGV 40 - AGB 40 DD
1 30024044 4 Lock screw M12X30 VB.RIPP
3 78732444 1 Flange B5 250/130
5 32154299 10 Hex.sock screw M6 X 45 10.9 A2F DIN 912
6 34065399 10 Washer 6.4 140HV A2F DIN 125
7 30024044 4 Lock scr. M12X30 VB.RIPP
8 78732044 1 Foot plate AG40
9 34355444 4 Threaded insert M12X17X16 C
11 36710199 5 O-ring 8X2 B NB 70 DIN 3770
12 31339499 5 Screw plug M10X1 5.8 DIN 908
14 78731044 1 Gearb.cover AF40/AG40
15 78721644 1 Seal 2-GAF30/A40
37 84153546 1 Cluster gear v Z11M2.00Z 69M1.25 i = 25.1
42 84157146 1 Output shaft w/gearv Z75 H40 1)
51 84157546 1 Output shaft w/gear Z75 V40 1)
51 84158446 1 Output shaft w/gear Z75 inch V 1)
57 00753298 1 Oil seal 48X 72X 7
58 35432399 1 Key Z12X 8X 70 C 45 K DIN 6885
61 34289244 1 Plug 72 X 9
65 30023244 2 Safety screw M10X40
66 15055399 2 Par. pin Z10 X 12 ST50 K ISO 2338
67 78730644 1 Gearb.housing AG40
68 78721644 1 Seal 2-GAF30/A40
70 81038644 1 Dust cap F.AF06
22283303.tbl
1) i =8.78-11.7-14.9-19.0-22.7-28.1-36.1-44.3-55.7
2) i = 9.71-12.9-16.5-21.0-25.1-31.1-39.9-49.0-61.6
17
AUK 40 - AUH 40 - AUV 40 - AUB 40 DD
AGK 40 - AGH 40 - AGV 40 - AGB 40 DD
Pinion for motor Z63/80
71 78605144 1 Pinion Z 26 M1.25B 24 i = 14.9-16.5
71 78604644 1 Pinion Z 22 M1.25B 24 i = 19.0-21.0
71 78604144 1 Pinion Z 19 M1.25B 24 i = 22.7-25.1
71 78603644 1 Pinion Z 16 M1.25B 24 i = 28.1-31.1
71 78603144 1 Pinion Z 13 M1.25B 24 i = 36.1-39.9
71 78602644 1 Pinion Z 11 M1.25B 24 i = 44.3-49.0
71 78602144 1 Pinion Z 12 M0.93B 26 i = 55.7-61.6
Pinion for motor Z100
71 78606344 1 Pinion Z 37 M1.25B 24 i = 8.78-9.71
71 78605744 1 Pinion Z 31 M1.25B 24 i = 11.7-12.9
71 78605244 1 Pinion Z 26 M1.25B 24 i = 14.9-16.5
71 78604744 1 Pinion Z 22 M1.25B 24 i = 19.0-21.0
71 78604244 1 Pinion Z 19 M1.25B 24 i = 22.7-25.1
71 78603744 1 Pinion Z 16 M1.25B 24 i = 28.1-31.1
71 78603244 1 Pinion Z 13 M1.25B 24 i = 36.1-39.9
71 78602744 1 Pinion Z 11 M1.25B 24 i = 44.3-49.0
71 78602244 1 Pinion Z 12 M0.93B 26 i = 55.7-61.6
71 78606344 1 Pinion Z 37 M1.25B 24 i = 8.78-9.71
71 78605844 1 Pinion Z 31 M1.25B 24 i = 11.7-12.9
71 78605344 1 Pinion Z 26 M1.25B 24 i = 14.9-16.5
71 78604844 1 Pinion Z 22 M1.25B 24 i = 19.0-21.0
71 78604344 1 Pinion Z 19 M1.25B 24 i = 22.7-25.1
71 78603844 1 Pinion Z 16 M1.25B 24 i = 28.1-31.1
71 78603344 1 Pinion Z 13 M1.25B 24 i = 36.1-39.9
71 78603344 1 Pinion Z 13 M1.25B 24 i = 36.1-39.9
71 78602844 1 Pinion Z 11 M1.25B 24 i = 44.3-49.0
72 15055399 2 Threaded pin M10X25 10.9 DIN 835
18
AUK 40 - AUH 40 - AUV 40 - AUB 40 DD
AGK 40 - AGH 40 - AGV 40 - AGB 40 DD
42074144.eps
19
AFK 40 - AFH 40 - AFV 40 - AFB 40 TD 3-stage direct input
AUK 40 - AUH 40 - AUV 40 - AUB 40 TD
AGK 40 - AGH 40 - AGV 40 - AGB 40 TD
42074244.eps

1 30024044 4 Lock.scr. M12X30 VB.RIPP
3 78732444 1 Flange B5 250/130
6 34065399 10 Washer 6.4 140HV A2F DIN 125
7 30024044 4 Lock scr. M12X30 VB.RIP
8 78732044 1 Foot plate AG40
11 36710199 5 O ring 8 X 2 B NB 70 DIN 3770
12 31339499 5 Screw plug M10X1 5.8 DIN 908
14 78731044 1 Gearb. cover AF40/AG40
15 78721644 1 Seal 2-GAF30/A40
2283307.tbl
20
AFK 40 - AFH 40 - AFV 40 - AFB 40 TD 3-stage direct input
AUK 40 - AUH 40 - AUV 40 - AUB 40 TD
AGK 40 - AGH 40 - AGV 40 - AGB 40 TD
35 15055099 1 Cyl. roller bearing 303 E DIN 5412
37 166-203-256
37 150-184-231
57 00753298 1 Oil seal 48X72X7
58 35432399 1 Key A12X 8X 70 C 45 K DIN 6885
59 36056099 1 Groovedball brg.6210 DIN 625
60 36056099 1 Groovedball brg.6210 DIN 625
61 34289244 1 Plug 72 X 9
65 30023244 2 Safety screw M10X40
66 15055399 2 Par. pin A10 X 12 ST50 K ISO 2338
67 78730644 1 Gearb.housing AG40
68 78721644 1 Seal 2-GAF30/A40
70 81038644 1 Dust cap F.AF06
Pinion for motor Z63/80
71 78604644 1 Pinion Z 22 M1.25B 24 i = 73.7-81.5
71 78604144 1 Pinion Z 19 M1.25B 24 i = 91.1-101
71 78603644 1 Pinion Z 16 M1.25B 24 i = 115-127
71 78603144 1 Pinion Z 13 M1.25B 24 i = 150-166
71 78602644 1 Pinion Z 11 M1.25B 24 i = 184-203
71 78602144 1 Pinion Z 12 M0.93B 26 i = 231-256
71 78604744 1 Pinion Z 22 M1.25B 24 i = 73.8-81.5
71 78604244 1 Pinion Z 19 M1.25B 24 i = 91.1-101
71 78603744 1 Pinion Z 16 M1.25B 24 i = 115-127
71 78603244 1 Pinion Z 13 M1.25B 24 i = 150-166
71 78602744 1 Pinion Z 11 M1.25B 24 i = 184-203
71 78602244 1 Pinion Z 12 M0.93B 26 i = 231-256
71 78604844 1 Pinion Z 22 M1.25B 24 i = 73.8-81.5
71 78604344 1 Pinion Z 19 M1.25B 24 i = 91.1-101
71 78603844 1 Pinion Z 16 M1.25B 24 i = 115-127
71 78603344 1 Pinion Z 13 M1.25B 24 i = 150-166
71 78602844 1 Pinion Z 11 M1.25B 24 i = 184-203
72 15059999 2 Threaded pin M10 X 25 10.9 DIN 835
100 30028344 4 Safety nut M10
101 22924849 1 Motor parts list Z112/A132
1) i =73.8-91.1-115-150-184-231
2) i = 81.5-101-127-166-203-256
21
AFK 40 - AFH 40 - AFV 40 - AFB 40 DL/S 2-stage coupling connection
AUK 40 - AUH 40 - AUV 40 - AUB 40 DL/S
AGK 40 - AGH 40 - AGV 40 - AGB 40 DL/S
Coupling and motor connection A40 - DL/S offset gearbox

see page 26 - 29.
42074344.eps

1 30024044 4 Lock scr. M12X30 VB.RIP
3 78732444 1 Flange B5 250/130
6 34065399 10 Washer 6.4 140HV A2F DIN 125
7 30024044 4 Lock.scr. M12X30 VB.RIP
8 78732044 1 Foot plate AG40
11 36710199 5 O ring 8 X 2 B NB 70 DIN 3770
12 31339499 5 Screw plug M10X1 5.8 DIN 908
14 78731044 1 Gearb.cover AF40/AG40
15 78721644 1 Seal 2-GAF30/A40
22283304.tbl
22
AFK 40 - AFH 40 - AFV 40 - AFB 40 DL/S 2-stage coupling connection
AUK 40 - AUH 40 - AUV 40 - AUB 40 DL/S
AGK 40 - AGH 40 - AGV 40 - AGB 40 DL/S
26 78643544 1 Pinion Z 37 M1.25B 27 i = 8.78-9.71
26 78643244 1 Pinion Z 31 M1.25B 27 i = 17.7-12.9
26 78642944 1 Pinion Z 26 M1.25B 27 i = 14.9-16.5
26 78642544 1 Pinion Z 22 M1.25B 27 i = 19.0-21.0
26 78642144 1 Pinion Z 19 M1.25B 27 i = 22.7-25.1
26 78641844 1 Pinion Z 16 M1.25B 27 i = 28.1-31.1
26 78641544 1 Pinion Z 13 M1.25B 27 i = 36.1-39.9
26 78641244 1 Pinion Z 11 M1.25B 27 i = 43.3-49.0
26 78640644 1 Pinion Z 12 M0.93B 27 i = 55.7-61.6
27 35487599 1 Key B 6X6X21 C 45 K DIN 6885
35 15055099 1 Grooved ball brg. 303E DIN 5412
36 34349199 1 Support.ring 17Z24Z1.5 DIN 988
57 00753298 1 Oil seal 48X 72X 7
58 35432399 1 Key A12X 8X 70 C 45 K DIN 6885
59 36056099 1 Groovedball bearing 6210 DIN 625
61 34289244 1 Plug 72 X 9
66 15055399 2 Par. pin A10 X 12 ST50 K ISO 2338
67 78730844 1 Gearb.housing-A40-coup
70 81038644 1 Dust cap F.AF06
75 37651599 1 Oil seal NBR DIN 3760
22283304.tbl
1) i =8.78-11.7-14.9-19.0-22.7-28.1-36.1-44.3-55.7
2) i = 9.71-12.9-16.5-21.0-25.1-31.1-39.9-49.0-61.6
23
AFK 40 - AFH 40 - AFV 40 - AFB 40 TL/S 3-stage coupling connection
AUK 40 - AUH 40 - AUV 40 - AUB 40 TL/S
AGK 40 - AGH 40 - AGV 40 - AGB 40 TL/S
Coupling and motor connection A40 - TL/S offset gearbox

see page 26 - 29.
42074444.eps
24
AFK 40 - AFH 40 - AFV 40 - AFB 40 TL/S 3-stage coupling connection
AUK 40 - AUH 40 - AUV 40 - AUB 40 TL/S
AGK 40 - AGH 40 - AGV 40 - AGB 40 TL/S
1 30024044 4 Lock scr. M12X30 VB.RIP
3 78732444 1 Flange B5 250/130
5 32154299 10 Hex.sock. screw M6 X 45 10.9 A2F DIN 912
6 34065399 10 Washer 6.4 140HV A2F DIN 125
7 30024044 4 Lock.scr. M12X30 VB.RIP
8 78732044 1 Foot plate AG40
11 36710199 5 O ring 8 X 2 B NB 70 DIN 3770
12 31339499 5 Screw plug M10X1 5.8 DIN 908
14 78731044 1 Gearb. cover AF40/AG40
15 78721644 1 Seal 2-GAF30/A40
26 78642544 1 Pinion Z 22 M1.25B 27 i = 73.7-81.5
26 78642144 1 Pinion Z 19 M1.25B 27 i = 91.1-101
26 78641844 1 Pinion Z 16 M1.25B 27 i = 115-127
26 78641544 1 Pinion Z 13 M1.25B 27 i = 150-166
26 78641244 1 Pinion Z 11 M1.25B 27 i = 184-203
26 78640644 1 Pinion Z 12 M0.93B 27 i = 231-256
27 35487599 1 Key B 6X6X21 C 45 K DIN 6885
32 84152546 1 Cluster gear Z13M1.25Z 54M1 i = 150-166
35 15055099 1 Grooved ball bearing 303 E DIN 5412
36 34349199 1 Support. ring 17X 24X1.5 DIN 988
150-184-231
166-203-256
57 00753298 1 Oil seal 48X 72X 7
58 35432399 1 Key A12X 8X 70 C 45 K DIN 6885
61 34289244 1 Plug 72 X 9
66 15055399 2 Par. pin A10 X 12 ST50 K ISO 2338
67 78730644 1 Gearb. housing-A40-coup
70 81038644 1 Dust cap F.AF06
75 37651599 1 Oil seal NBR DINC3760
22283308.tbl
1) i =73.8-91.1-115-150-184-231
2) i = 81.5-101-127-166-203-256
25
Coupling and motor connection A40 - DL/TL offset gearbox
Mot. Z63-Z100
42073544.eps
Coupling connection mot. Z63/Z71

93 34251699 1 Retaining ring DIN 471
96 30021044 4 Safety screw M 6X20
99 35457799 1 Key B 5X 5X 20 C 45 K DIN 6885
101 22924049 1 Parts list Z63/Z71
22282809.tbl
26
Coupling and motor connection A40 - DL/TL offset gearbox
Coupling connection mot. Z80/Z90A

97 71522244 1 Intermediate flange D06 160.2
99 35425799 1 Key B 6X 6X 20 C 45 K DIN 6885
101 22924249 1 Parts list Z80/Z90A
22282810.tbl
Coupling connection mot. Z90B/Z100

99 35457199 1 Key B 8X 7X 20 C 45 K DIN 6885
101 22924449 1 Parts list Z90B/Z100
22282812.tbl
27
Coupling and motor connection A40 - DL/S - TL/S offset gearbox
Mot. KB71 - KB100
94 98 99
96 97 102
90 91 92 93
95
42073644.eps
Coupling connection mot. KB 71

95 71822344 1 Coupling half ht1n-16
99 35457799 1 Key B 5X 5X 20 C 45 K DIN 6885
102 20007084 1 Parts list KB 71-140
22282813.tbl
28
Coupling and motor connection A40 - DL/S - TL/S offset gearbox

95 71822644 1 Coupling half Ht1N-19
96 30021944 4 Safety screw M 8X25 VB.RIPP
99 35425799 1 Key B 6X 6X 20 C 45 K DIN 6885
102 20007049 1 Parts list KB 71-140
22282814.tbl

95 71822844 1 Coupling half
96 30023044 4 Safety screw M10X30 VB.RIPP
99 35457199 1 Key B 8X 7X 20 C 45 K DIN 6885
102 20007049 1 Parts list KB 71-140
22282815.tbl

95 71822944 1 Coupling half
99 35457199 1 Key B 8X 7X 20 C 45 K DIN 6885
102 20007049 1 Parts list KB 71-140
22282815.tbl
29
California Ohio
Connecticut Ontario
Illinois Quebec
Michigan Texas
Missouri
Washington
Telephone: (425) 883-4668 • Fax: (425) 883-4828

29201 Aurora Road
Telephone: (440) 248-2400
Fax: (440) 248-3086
Component parts
DFW-L-E endtrucks with DRS 112 up to 200
300901 US / PDF 210503 229 248 49 721 IS 845.1

2
22924849.p65/210503
DFW-L-E / S side connection 71
1 84 85 83 82
Torque
bracket
11 2 81 83 10 4 5 3 7 2 11
(6) (8)
(9) 22273501.eps
1 DFW-L-E 112 / S endtruck complete 1)

1 DFW-L-E 112 / O endtruck complete 1)
2 Wheel block DRS 2)
3 75383044 4 Pin 18.5H8X 153 DRS 112
3 75232244 4 Pin 21 H 8X 161 DRS 125
3 75262244 4 Pin 30 H 8X 182 DRS 160
3 75323044 4 Pin 35 H 8X 214 DRS 200
4 34244699 8 Retaining ring 18X1.5 DRS 112 DIN 471
4 34248699 8 Retaining ring 30X2 DRS 160 DIN 471
5 34349299 8 Supporting plate 19X 26X1.5 DRS 112 DIN 988
5 34150699 8 Supporting plate 22X 30X2 DRS 125 DIN 988
6 34154399 16 Shim 19X 26X0.5 DRS 112 DIN 988
6 34154999 16 Shim 22X 32X0.5 DRS 125 DIN 988
6 34144599 16 Shim 30X 42X0.5 DRS 160 DIN 988
6 34143699 16 Shim 35X 45X0.5 DRS 200 DIN 988
7 65279344 Spacer plate 5 DFW112 DRS 112
10 65351744 1 Cover plate access hole for outdoor operation Ax <= 500 mm (19.69 in)
10 65351744 2 Cover plate access hole for outdoor operation Ax > 500 mm (19.69 in)
11 75201444 2 Bumper 100X100 M12
11 75201644 2 Bumper 130X130 M12
11 75201844 2 Bumper 160X160 M12
22924849.p65/210503
22273501.tbl

1) Order in accordance with type code in cataloge 203 320 44.
2) Order in accordance with type code in cataloge 203 350 44.
3
DFW-L-E / O top bolted connection
71
1
91
93
95
93
91
Torque
bracket
11 2 10 4 5 3 7 2 11
(6) (8)
(9)
22273518.eps
DFW-L-E / O top welded connection

71
1
Torque
bracket
11 2 10 4 5 3 7 2 11
(6) (8)
22924849.p65/210503
(9)
22273519.eps
4
End plate and bumper bracket, variant for USA
Travel wheel 112 Travel wheel 125
USA USA
A A-A
A A-A
43 43
46 47
45
44
41 41
48 48
22273510.eps 22273511.eps
A A
USA A USA A-A
A A-A
43
45
43
41
41
45
48
48
A 22273512.eps A 22273513.eps
41 32044599 2 Countersunk screw M12 X 25 DRS 112 8.8 A2F DIN 7991
41 15093299 2 Threaded pin M12 X 50 DRS 125, 160, 200 DIN 913
42 30044344 2 Lock nut M12 VB.RIPP DRS 125, 160, 200
43 65277044 2 End plate 112 USA DRS 112
43 65280044 2 End plate 125 USA DRS 125
43 65283344 2 End plate 160 USA DRS 160
43 65286644 2 End plate 200 USA DRS 200
44 65277244 2 Retainer end plate nut DRS 112
45 75200444 2 Spacer washer 12.5PU100 DRS 125, 160, 200
45 75200644 2 Spacer washer 16 PU130 DRS 160, 200
45 75200844 2 Spacer washer 15 PU160 DRS 200
46 34275644 4 Lock screw M12X20 VB.RIPP DRS 112
48 34275644 4 Lock screw M12X20 VB.RIPP DRS 112, 125
48 34276544 4 Lock screw M16X25 VB.RIPP DRS 160, 200
22273503.tbl
22924849.p65/210503
5
End plate and bumper bracket, variant with guide rollers

Guide rollers Guide rollers
A A-A A A-A
54 54
55
59 59
58 55
60 57
58
61
56
52
51 51 53 52
A
A
22273514.eps 22273515.eps

Guide rollers Guide rollers
A A-A
A A-A
54
54 55 59
55 59 58
58 57 57
52
53
51 51
53 52
A A
22273516.eps 22273517.eps

52 32509699 2 Threaded pin M12 X 40 DRS 112 10.9 DIN 913
52 15093299 2 Threaded pin M12 X 50 DRS 125, 160, 200 DIN 913
53 30044344 2 Lock nut M12 VB.RIPP DRS 125, 160, 200
54 65276944 2 End plate DFW112 HOR. DRS 112
54 65286844 2 End plate DFW200 DRS 200
55 65277244 2 Retainer end plate nut DRS 112, 125
56 65279544 2 Buffer adapter DFW112 DRS 112
57 75200444 2 Spacer washer 12.5PU100 DRS 125, 160, 200
57 75200644 2 Spacer washer 16 PU130 DRS 160, 200
57 75200844 2 Spacer washer 15 PU160 DRS 200
60 34544899 4 Split sleeve 8 X 20 DRS 112 ISO 13337
71 Comp. parts offset gearbox see page 8
71 Comp. parts wheel block/torque bracket see page 8
81 31616099 Hexagonal screw M20 X 85X46 HV; 2 x ny 10.9 HV DIN 6914
81 31618099 Hexagonal fitted screw M20X 80 HVP; 2 x ny 10.9 HVP DIN 7999
82 31620299 Hexagonal nut M20 HV; HVP; 2 x ny 10 HV DIN 6915
83 81016844 Washer 21 X 37 X 8 HV; HVP; 4 x ny C 45 V HV DIN 6916
84 81076244 Washer 22 X 50 X10 HV; HVP; 2 x ny
84 65026444 Washer 21 X 50 X10 HVP; 2 x ny
85 81070644 1 Mounting plate, non countersunk DRS 112/2000; ny = 2; Ax = 280
85 81070644 1 Mounting plate, non countersunk DRS 112/2500, 125/....; ny = 3; Ax = 280
85 81077844 1 Mounting plate, non countersunk DRS 160/2000 and 2500; ny = 4; Ax = 280
85 95982344 1 Mounting plate, non countersunk DRS 200/2000, 2500; ny = 4; Ax = 280
85 81026544 1 Mounting plate, countersunk DRS 112/2000; ny = 2; Ax = 280
85 81026544 1 Mounting plate, countersunk DRS 112/2500, 125/....; ny = 3; Ax = 280
85 95934744 1 Mounting plate, countersunk DRS 160/2000 and 2500; ny = 4; Ax = 280
85 95972244 1 Mounting plate, countersunk DRS 200/2000, 2500; ny = 4; Ax = 280
91 Hexagonal screw M16 x 70 HV; 4 x; for ekt = 2000 1)
91 Hexagonal screw M16 x 75 HV; 4 x; for ekt = 2500 1)
91 Hexagonal screw M20 x 80 HV; 4 x; for ekt = 2000 and 2500 1)
91 31618099 4 Hexagonal fitted screw M20X 80 HV; 4 x; for ekt = 3150 10.9 HVP DIN 7999
91 Hexagonal screw M20 x 80 HV; 4 x 1)
92 31620799 4 Hexagonal nut M16 HV 10 HV DIN 6915
92 31620299 4 Hexagonal nut M20 HV 10 HV DIN 6915
93 31621199 8 Washer 17 X 30 X 4 HV C 45 HV DIN 6916
93 81016844 8 Washer 21 X 37 X 8 HV C 45 V HV DIN 6916
95 65278944 1 Bolted plate DFW112 DRS 112
95 65374944 1 Bolted plate DFW200 DRS 200; Bu = 200 and 300
95 65287944 1 Bolted plate DFW200 DRS 200; Bu = 410 and 500
22273504.tbl
1) Enter item no. and page instead of 8-digit part no.

Component parts
Helical
D 10 D 20 D 30 D 40 D 50 D 60 D 70 D 80 D 90 -
gearboxes
Part number 229 220 49 229 221 49 229 222 49 229 223 49 229 224 49 229 225 49 229 226 49 229 227 49 229 228 49 -
Angular
W 10 W 20 W 30 W 40 W 50 W 60 W 70 W 80 W 90 W 100
gearboxes
Part number 229 230 49 229 231 49 229 232 49 229 233 49 229 234 49 229 235 49 229 236 49 229 237 49 229 238 49 229 239 49
Offset
A 10 A 20 A 30 A 40 A 50 A 60 A 70 A 80 A 90 -
gearboxes
Part number 229 210 49 229 211 49 229 212 49 229 213 49 229 214 49 229 215 49 229 216 49 229 217 49 229 218 49 -
Wheel block DRS 112 DRS 125 DRS 160 DRS 200 DRS 250 DRS 315 DRS 400 DRS 500 - -
Part number 229 204 49 229 205 49 229 206 49 229 207 49 229 281 49 229 277 49 229 282 49 222 941 44 - -

California South Carolina
5435 Industrial Parkway • San Bernardino, California 92407 BTC 560, Suite 150, 454 S. Anderson Road • Rock Hill, SC 29730
Georgia Ohio
254 Lake Ruby Drive • Suwanee, Georgia 30024 29201 Aurora Road • Cleveland, Ohio 44139
Telephone: (678) 546-0593 Telephone: (440) 248-2400 • Fax: (440) 248-3086
Illinois Ontario
12040 Raymond Court • Huntley, Illinois 60142 1155 North Service Road West • Oakville, Ontario L6M 3E3
Michigan Quebec
24541 Maplehurst Drive • Clinton Township, Michigan 48036 3257 Pitfield Blvd • St-Laurent, Quebec H4S 1H3
Missouri Texas
529 E. 5th Street • Washington, Missouri 63090 16430 Aldine-Westfield Road • Houston, Texas 77032
Washington
Telephone: (425) 883-4668 • Fax: (425) 883-4828
29201 Aurora Road
Telephone: (440) 248-2400
Fax: (440) 248-3086
Spare parts list
DRS 160 wheel block
160311 enGB 222 920 44 721 IS 845.5

Further spare parts list
Helical gearboxes D11 D21 D31 D41 D50 D60 D70 D80 D90 -
Part number 217 027 44 217 001 44 217 005 44 217 009 44 222 757 44 222 761 44 222 765 44 222 769 44 222 773 44 -
Angular
W 10 W 20 W 30 W 40 W 50 W 60 W 70 W 80 W 90 W 100
gearboxes
222 780 222 784 222 788 222 792 222 796 222 800 222 804 222 808 222 812 222 816
Part number
44_en 44_en 44_en 44_en 44_en 44_en 44_en 44_en 44_en 44_en
Offset gearboxes A 10 A 20 A 30 A 40 A 50 A 60 A 70 A 80 A 90 -
222 824 222 840 222 844 222 952

Part number 222 821 44 222 829 44 222 833 44 222 837 44 222 849 44 -
44_en 44_en 44_en 44_en
Wheel block DRS 112 DRS 125 DRS 160 DRS 200 DRS 250 DRS 315 DRS 400 DRS 500 - -
222 912 222 916 222 920

Part number 222 925 44 222 929 44 222 933 44 222 937 44 222 941 44 - -
44_en 44_en 44_en
Z 90B
Z 63 Z 80 Z 112 Z 160 Z 180B
Motor Z 100 Z 225 KB 71-140 KB 160-225
Z 71 Z 90A Z 132 Z 180A Z 200
Z 112AK4
217 039
Part number 222 857 44 222 865 44 222 877 44 222 885 44 222 893 44 222 897 44 222 901 44 200 333 84
44_en
22285707.tbl/emf
22292144_en_160311

Example
2 # 8 75333233 1 Housing set DRS 160

Contents
Page
DRS 160 wheel block also driven / non driven / driven 4

Torque bracket for AME 20/30/40 offset gearboxes and
WUE 20/30/40 angular gearboxes with Top-, and Side connection 6
Individual drive unit AMK 40 and WUK 40 7
Central drive unit AME 30 and AMK 40 8
Central drive unit WUE 30 and WUK 40 9
Central drive unit with shaft protction on the inside AM 30/40 and WU 30/40 10
Buffer arrangement 11
Horizontal guide roller assembly, standard/ with Buffer arrangement 11
Horizontal guide roller assembly on compensating side 12
Top connection 13
Side connection 13
Pin connection for A-/W-Getriebe 14
Torque bracket for A-/W-Getriebe 14
End connection also driven / non driven / driven 14
Universal shaft, typ F with top connection 16
Universal shaft, typ F with side connection 16
Universal shaft, typ F with pin connection 16
22292144_en_160311
3
DRS 160 wheel block also driven / non driven / driven
1 75264233 1 Travel wheel set A, 47, N45 1)

2 75265233 1 Travel wheel set B, N45
2 75275233 1 Travel wheel set B, N35
3 75267633 1 Travel wheel set 180 A35 C 1)
4 75254633 1 Travel wheel set 160 NA D47 1)
4 75254833 1 Travel wheel set 160 NA D65 1)
5 75256433 1 Travel wheel set 183 NA E 1)
6 75266033 1 Travel wheel set 180 A45 F 1)
8 75253233 1 Housing set DRS 160
12 75259933 1 Assembly set DRS 160
22292001.tbl
22292144_en_160311
1) For travel wheels with variable tread please indicate the model code when placing an order
4 Example: travel wheel 160 - A45 - A - 52
22292144_en_160311
5
Torque bracket for AME 20/30/40 offset gearboxes and
WUE 20/30/40 angular gearboxes with Top-, and Side connection
1 75269644 1 Torque arm set MA160-1 AM20

2 75269144 1 Torque arm set MA160-2 AM30/40
3 75279044 1 Torque arm set MW160-1 WU20/30
4 75279144 1 Torque arm set MW160-2 WU40
22292004.tbl
22292144_en_160311
6
Individual drive unit AMK 40 / WUK 40
AMK 40
3 86029046 1 Drive element DRS160/AMK40
22292017.tbl
WUK 40

22292144_en_160311
3 86029546 1 Drive element DRS160/WUK40
22292018.tbl
7
Central drive unit AME 30 and AMK 40
AME 30
3 86020146 1 Drive element DRS160/AME30 for track gauge 1000

22292019.tbl
AMK 40
3 86021146 1 Drive element DRS160/AMK40 for track gauge 1000

22292020.tbl
22292144_en_160311
8
Central drive unit WUE 30 and WUK 40
WUE 30
3 86022146 1 Drive element DRS160/WUE30 for track gauge 1000

22292021.tbl
WUK 40
3 86023146 1 Drive element DRS160/WUK40 for track gauge 1000

22292022.tbl
22292144_en_160311
9
Central drive unit with shaft protection on the inside for
AM 30/40 und WU 30/40
2 30039484 1 Shaft protection W45-RS/DRS SPW 1000 - 1400 1)

2 30039584 1 Shaft protection W45-RS/DRS SPW 2240 - 3150 1)
22292023.tbl
22292144_en_160311
10 1) The part no. includes a long shaft protection tube which has to be simply cut to the required length by the customer.
Buffer arrangement
3 86081046 1 Buffer set DPZ 70

4 86081446 1 Buffer set DPZ100
7 86083446 1 Buffer set DPG 63
8 86083846 1 Buffer set DPG 80
9 86084246 1 Buffer set DPG100
22292005.tbl
Horizontal guide roller assembly, standard/ with Buffer arrangement
8 75261833 1 Guide roller DRS160

13 75251144 1 Roller guide set DRS160 NR
15 86081146 1 Buffer set DPZ 70
15 86081546 1 Buffer set DPZ100
15 86081946 1 Buffer set DPZ130
15 86082346 1 Buffer set DPZ160
17 86083546 1 Buffer set DPG 63
22292144_en_160311
17 86083946 1 Buffer set DPG 80

17 86084346 1 Buffer set DPG100
22292006.tbl
11
Horizontal guide roller assembly on compensating side
15 86081246 1 Buffer set DPZ 70

15 86081646 1 Buffer set DPZ100
15 86082046 1 Buffer set DPZ130
15 86082446 1 Buffer set DPZ160
17 86083646 1 Buffer set DPG 63
17 86084046 1 Buffer set DPG 80
17 86084446 1 Buffer set DPG100
22292008.tbl
22292144_en_160311
12
Top connection
1 75252044 1 Top connection set DRS160/200
22292010.tbl
Side connection

22292144_en_160311
1 75252244 1 Side member connection set DRS160

2 75252744 1 Side member connection set DRS160 NR
22292009.tbl
13
Pin connection for A-/W-gearboxes
Torque bracket for A-/W-gearboxes
End connection also driven / non driven / driven
Pin connection (standard)
Pin connection with weld-on plate
driven
also driven / non driven

22292144_en_160311
14
Pin connection for A-/W-gearboxes
Torque bracket for A-/W-gearboxes
End connection also driven / non driven / driven
1 75263844 1 Pin connection set DRS160B

2 75263744 1 Pin connection set DRS160 standard
3 75214144 1 Spacer plate set DRS160
4 75214844 1 Threaded pin set DRS160/200
5 75269744 1 Torque arm set MA160-1
7 75279244 1 Torque arm set MW160-1
8 75279444 1 Torque arm set MW160-2
11 75272944 1 Welded plate DRS160 UW
22292011.tbl
22292144_en_160311
15
Universal shaft, typ F with top connection
1 75272044 1 Universal shaft set DRS160 K

22292013.tbl
Universal shaft, typ F with side connection
1 75272144 1 Universal shaft set DRS160 W

22292014.tbl
22292144_en_160311
16
Universal shaft, typ F with pin connection
1 75272244 1 Universal shaft set DRS160 B

22292015.tbl
22292144_en_160311
17
18
22292144_en_160311
22292144_en_160311
19
www.demagcranes.com Contact and Demag worldwide

Drives
P.O. Box 67 · 58286 Wetter (Germany)
Telephone +49 (0)2335) 92-0 · Telefax +49 (0)2335) 92-7298
Printed in Germany
www.demagcranes.com
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, 58286 Wetter (Germany) Not liable for errors or omissions. Subject to change.
Component Parts &
Installation Instructions
Duratrack - KBK 25 Tagline System
0900 US 930 107 49 721 IS 963

Duratrack Onsite Installation Instructions (Single Girder Cranes)
1. For under flange girder mounting of retainer arms, skip to Step 5. If top mounting, continue. At the end of the girder where
the panel box will be installed, make a mark on the top of the girder for the first panel retainer arm. This distance can be found
on the installation drawing for the girder. Also, refer to the girder installation drawing to determine the placement of the mark
for the second panel retainer arm.
2. Determine the distance of the first runway retainer arm from the second panel retainer arm from the girder installation drawing.
Make a mark on the top of the girder at this position. Again referring to the installation drawing, determine the spacing
between the runway retainer arms. Then from the first runway retainer arm, make marks at this distance along the length of the
girder where the rest of the runway retainer arms will be mounted. Also, make a mark for the last runway retainer arm referring
to the installation drawing.
3. Position the panel retainer arms on the top of the girder. The back clamp (Item 1, Figure 1) should be positioned as in Figure
1, with the vertical leg a quarter to a half inch from the end of the arm. The retaining bolt should be vertical and just contacting
the girder flange. Slide the front clamp (Item 2, Figure 1) to fit the girder, with the bolt vertical and just contacting the girder
flange. With the square carriage bolt heads in the opening of the retainer arm, tighten the nylon insert locknuts.
4. Position the runway retainer arms on the top of the girder, and clamp to the girder as done with the panel retainer arms. Move
on to Step 6.
5. Put the two panel retainer arms into the first two support sockets, referring to the girder installation drawing to determine
which side of the girder to mount the panel. Then put the runway retainer arms in all remaining socket supports. Tighten all
socket support arm/ retaining bolts (Item 3, Figure 2).
6. Slide all of the nut bars (Item 4, Figure 3) to the center of the extended panel and runway retainer arms.
7. Install the KBK inside (power) track, starting at the panel retainer arm nearest the endtruck. This inside KBK track will start
two inches from the edge of the endtruck. Place the KBK track into the clamp, and ONLY tighten the nut/bolt listed as Item 5
(Figure 4). DO NOT tighten the bolt/washers listed as Item 6 (Figure 4) – you will have to adjust the track distance from the
girder before Item 6 is tightened. After the end clamp Item 5 is tightened, place the track in subsequent clamps and ONLY
tighten the clamp Item 5, leaving the bolt/washers (Item 6) loose.
8. As you install subsequent track sections, keep the track ends flush with each other so the splices are easily installed. Also,
using a pair of pliers (approximately 5 mm wide), bend up the top ends of the sections being joined with a track connecting
clamp about two to three millimeters in the middle (Figure 5). These bent–up ends are held in the middle groove of the clamp.
9. When you have finished installing the inside (power) track, take the panel box, and mount the box to the panel retaining arms
with pre-attached bolt/washers (Item 7, Figure 6). TIGHTEN Item 7 to prevent the box from coming lose and falling, causing
injury. You will remove the box before final assembly.
10. Install the KBK outside (control) track. Position the first track section so that it is against the panel box, and then clamp the
track into the first runway retainer arm clamp. As before, ONLY tighten the nut/bolt listed as Item 5 (Figure 4). DO NOT tighten
the bolt/ washers listed as Item 6 (Figure 4) – you will have to adjust the track distance from the girder before Item 6 is
tightened. When you have finished installing the first section of (control) track, remove the panel box and set it aside for
future installation. After the end clamp (Item 5, Figure 4) is tightened, place the track in subsequent clamps and ONLY tighten
the clamp (Item 5), leaving the bolt/washers (Item 6) loose.
PAGE 2
11. As you install subsequent track sections, keep the track ends flush with each other so the splices are easily installed. Also,
using a pair of pliers (approximately 5 mm wide), bend up the top ends of the sections being joined with a track connecting
clamp about two to three millimeters in the middle (Figure 5). These bent–up ends are held in the middle groove of the clamp.
12. Go to the end of the girder opposite the panel box. Cut both the inside and outside KBK tracks two inches from the endtruck.
Then measure the unsupported track distance from the last runway retainer arm. If this distance is greater than 24” ± 2”
inches, you must add one more runway support arm. Install this arm as previously described.
13. Install splices between all adjacent track sections on both the inside (power) and outside (control) KBK track runs.
14. (a) Measure the distance that the tow arm extends from the top girder flange. Position all nut bars (Item 4, Figure 3)
so that the inside (power) track is 2” closer to the girder flange than the tow arm extension. (b) Once all nut bars
are in position, tighten all the bolt/washers (Item 6, Figure 7). When you have finished tightening bolt/washers (Item
6), take the panel box and remount to the panel retaining arms with pre-attached bolt/washers (Item 7, Figure 7) below.
5/16 X 18 GRADE 5
TORQUE 13 FT-LB
PAGE 3
EDKE, EKKE, EXKE Beam & Box Girder Festoon Systems
Trolley System
Item No. Description Ident. No.
1 Duratrack, KBK Support, Top Mount 00200885
Duratrack, KBK Support, Under Flange 00201085
2 Duratrack, Panel Support, Top Mount 00200985
Duratrack, Panel Support, Under Flange 00201285
3 Duratrack, Support Weld On (Under Flange Only) 00201185
4* Track Hanger – Horiz 98154044
5* Hex Screw M8 X 35 30743099
6* Hex Nut M8 33207699
7 Track 8.2 ft. (2.5m) KBK25 00638349
8 Track 16.4 ft. (5m) KBK25 98151544
9 Track Splice KBK25 98152044
10 Cable Trolley KBK25 98103044
11 Endstop w/Cable Clamp KBK25 98115144
12 Cable Towing Trolley KBK25 98142044
17 Track Endstop KBK25 00700185
* Included with Item 1 or 2
Sliding Control System

1 Duratrack, KBK Support, Top Mount 00200885
Duratrack, KBK Support, Under Flange 00201085
2 Duratrack, Panel Support, Top Mount 00200985
Duratrack, Panel Support, Under Flange 00201285
3 Duratrack, Support Weld On (Under Flange Only) 00201185
4* Track Hanger – Horiz 98154044
5* Hex Screw M8 X 35 30743099
6* Hex Nut M8 33207699
8 Connector Hood 16PKPL (Male) 89516944
9 Connector Base 16PKPL (Female) 89517044
12 Track 8.2 ft. (2.5m) KBK25 00638349
13 Track 16.4 ft. (5m) KBK25 98151544
* Included with Item 1 or 2
PAGE 4
Trolley System
PAGE 5
ZKKE Beam & Box Girder Festoon Systems
Trolley System
1 Track Hanger – Vert. VR 98153544
2 Track 8.2 ft. (2.5m) KBK25 00638349
3 Track 16.4 ft. (5m) KBK25 98151544

6 Connector Hood 16PKPL (Male) 89516944
7 Connector Base 16PKPL (Female) 89517044
8 Track Hanger – Vert. VR 98153544
11 Track 8.2 ft. (2.5m) KBK25 00638349
12 Track 16.4 ft. (5m) KBK25 98151544
20 Sliding J-Box Option (Not Shown) 17861350
PAGE 6
Trolley System
PAGE 7
British Columbia Ohio
19292 60th Ave., Suite 116 • Surrey, British Columbia V3S 8E5 29201 Aurora Road • Cleveland, Ohio 44139
Telephone: (604) 530-5155 • Telefax: (604) 530-5189 Telephone: (440) 248-2400 • Telefax: (440) 248-3086
California Ontario
5435 Industrial Parkway • San Bernardino, California 92407 1155 North Service Road West • Oakville, Ontario L6M 3E3
Connecticut Pennsylvania
99 Rainbow Road, Suite C • East Granby, CT 06026 2148 Embassy Drive • Lancaster, Pennsylvania 17603
Georgia Quebec
3625 Swiftwater Park Drive • Suwanee, Georgia 30174 2700 Sabourin • St-Laurent, Quebec H4S 1M2
Illinois Texas
12040 Raymond Court • Huntley, Illinois 60142 16430 Aldine-Westfield Road • Houston, Texas 77032
Michigan Washington
24541 Maplehurst Drive • Clinton Township, Michigan 48036 16771 N.E. 80th Street, Suite 205 • Redmond, Washington 98052
North Carolina
14001 South Lakes Drive • Charlotte, NC 28273
Telephone: (704) 716-2807 • Telefax: (704) 716-2815
Mannesmann Dematic Corporation

29201 Aurora Road
Telephone: (440) 248-2400
Telefax: (440) 248-3086
Internet: http://www.dematic-us.com
0900 US 930 107 49 721 IS 963

Spare parts list
Demag rope hoist EZDR-Pro 10
220910 enGB 217 124 44 721 IS 813

2
21712444_en_220910
Contents
Page
Hoist drive 4
Hoist unit, 2/1, 4/1 and 4/2 reeving 6
Crab frame, 2/1 reeving, H12 - H20 - H40 8
Crab frame, 4/1 reeving, H12 - H20 10
Crab frame, 4/1 reeving, H40 12
Crab frame, 6/1 reeving, H20 - H40 14
Crab frame, 4/2 reeving, H12 - H20 - H40 16
Rope wedge crosshead, 2/1 reeving, H12 - H20 - H40 18
Rope wedge crosshead/Return sheave, 4/1 reeving, H12 - H20 20
Rope wedge crosshead/Return sheave, 4/1 reeving, H40 22
Rope wedge crosshead/Return sheave, 6/1 reeving, H20 - H40 24
Compensating sheave, 4/2 reeving, H12 - H20 - H40 26
230/13 bottom block, 2/1 reeving, 2m, 3m 28
280/14 bottom block, 2/1 reeving, 4m 30
230/13 bottom block, 4/1 reeving, 2m, 3m 32
280/14 bottom block, 4/1 reeving, 4m 34
280/13 bottom block, 6/1 reeving 36
225/11 bottom block, 4/2 reeving 38
# ZBR 132 hoist motor 40
# ZB 71 travel motor , 2/1, 4/1, 4/2 reeving 42
# ZB 80 travel motor , 6/1 reeving 42
B003 brake, ZB 71 44
# B007 brake, ZB 80 44
B050, B140 brakes, ZBR 100/132 44
# Electrical components 46
21712444_en_220910

Example
# 1 70410133 1 Lifting drive ZBR132D12/ 2V1 3
Hoist drive EZDR-Pro 10
21712444_en_220910
4
Hoist drive EZDR-Pro 10
2/1-4/2 reeving
1 70410133 1 Lifting drive ZBR132D12/ 2V1 2m-4m, 10/1,7 m/min, 1) 3)
1 70410233 1 Lifting drive ZBR132C 4 V2 2m, 18/1 m/min, 1) 3)
1 70409133 1 Lifting drive ZBR132B 4 V2 3m-4m, 18/1 m/min, 1) 3)
1 70409233 1 Lifting drive ZBR132C 4 V3 3m-4m, 60%, 1-25 m/min, 1) 3)
1 70410333 1 Lifting drive ZBR132C 4 V3 2m, 1-25 m/min, 1) 3)
6/1 reeving
1 70410533 1 Lifting drive ZBR132D12/ 2V1 2m-4m, 2,7/0,4 m/min, 1) 3)
1 70410233 1 Lifting drive ZBR132C 4 V2 2m, 18/1 m/min, 1) 3)
1 70409133 1 Lifting drive ZBR132B 4 V2 3m-4m, 18/1 m/min, 1) 3)
4/1 reeving
1 70410133 1 Lifting drive ZBR132D12/ 2V1 2m-4m, 5/0,8 m/min, 1) 3)
1 70410233 1 Lifting drive ZBR132C 4 V2 2m, 0,5-9 m/min, 1) 3)
1 70409133 1 Lifting drive ZBR132B 4 V2 3m-4m, 0,5-9 m/min, 1) 3)
1 70409233 1 Lifting drive ZBR132C 4 V3 3m-4m, 60%, 1-25 m/min, 1) 3)
1 70410333 1 Lifting drive ZBR132C 4 V3 2m, 0,5-12,5 m/min, 1) 3)
2/1-4/2 reeving
Spare part sets for hoist motors see page 40.
3 70590533 1 Lifting motor set ZBR132D12/2V1 2m-4m, 10/1,7 m/min, 1) 3)
3 70590633 1 Lifting motor set ZBR132C 4 V2 2m, 18/1 m/min, 1) 3)
3 70585533 1 Lifting motor set ZBR132B 4 V2 3m-4m, 18/1 m/min, 1) 3)
3 70585733 1 Lifting motor set ZBR132C 4 V3 3m-4m, 1-25 m/min, 1) 3)
3 70590733 1 Lifting motor set ZBR132C 4 V3 2m, 1-25 m/min, 1) 3)
6/1 reeving
3 70580233 1 Lifting motor set ZBR132D12/2V1 2m-4m, 2,7/0,4 m/min, 1) 3)
3 70590633 1 Lifting motor set ZBR132C 4 V2 2m, 18/1 m/min, 1) 3)
3 70585533 1 Lifting motor set ZBR132B 4 V2 3m-4m, 18/1 m/min, 1) 3)
4/1 reeving
3 70590533 1 Lifting motor set ZBR132D12/2V1 2m-4m, 5/0,8 m/min, 1) 3)
3 70590633 1 Lifting motor set ZBR132C 4 V2 2m, 0,5-9 m/min, 1) 3)
3 70585533 1 Lifting motor set ZBR132B 4 V2 3m-4m, 0,5-9 m/min, 1) 3)
3 70585733 1 Lifting motor set ZBR132C 4 V3 3m-4m, 0,5-12,5 m/min, 1) 3)
3 70590733 1 Lifting motor set ZBR132C 4 V3 2m, 0,5-12,5 m/min, 1) 3)
4 70590033 1 Seal set DR10 2)

5 70590433 1 Gearbox housing set DR10 2)
21712401.tbl
21712444_en_220910
1) When ordering this sub-assembly (individual component parts are not supplied), please indicate the DR hoist serial number and order number.
These data are specified on the rating plates. Replaceable sub-assemblies will be supplied
that depend on the gearbox transmission ratio and the motor frame size.
2) Quantity 7,2 litre, part no. 472 902 44 (1,0 kg).
3) Suitable for 380/415V50Hz and 460/480V60Hz operating voltage. 5
Hoist unit EZDR-Pro 10 - H12 - H20 - H40
2/1 - 4/1 - 4/2 reeving - MGS - ZMS
21712444_en_220910
6
Hoist unit EZDR-Pro 10 - H12 - H20 - H40
2/1 - 4/1 - 4/2 reeving - MGS - ZMS
1 70590833 1 Set of pins DR10 H12

1 70590933 1 Set of pins DR10 H20
1 70594333 1 Set of pins DR10 H40
5 70596733 1 Rope drum single-groove DR10 H12
6 70597033 1 Rope drum double-groove DR10 H12
8 70595833 1 Wire rope set DR10 H12 2/1 2m
8 70599633 1 Wire rope set DR10 H12 2/1 3m, 4m
9 70596433 1 Wire rope set DR10 H12 4/2
9 70596533 1 Wire rope set DR10 H20 4/2
9 70596633 1 Wire rope set DR10 H40 4/2
15 70485033 1 Rope guide left set DR 10/13 Acid-Resistant
# 15 70447133 1 Rope guide left set DR 10/13V Acid-Resistant, reinforced
16 70484533 1 Rope guide left set DR 10/ 9 Acid-Resistant
# 16 70447333 1 Rope guide left set DR 10/ 9V Acid-Resistant, reinforced
17 70484733 1 Rope guide right set DR 10/ 9 Acid-Resistant
# 17 70447533 1 Rope guide right set DR 10/ 9V Acid-Resistant, reinforced
18 Electrical equipment see page 46.
19 Cover sub-assemmbly see page 46.
20 71913933 1 Housing DR10 FU V2 2m Crane crab
20 71913633 1 Housing DR10 FU V2 2m Solo travelling hoist
21712402.tbl
21712444_en_220910
7
Crab frame EZDR-Pro 10 - H12 - H20 - H40
2/1 reeving - MGS - ZMS
21712444_en_220910
8
1 Wheel block set 125 A 1)

2 Wheel block set 125 NA 1)
3 70591133 1 Buffer set 70x 70
5 70506033 1 Thrust rocker Set EZDR
6 Rope wedge crosshead ZMS/MGS Set see page 18
7 70591033 1 Wheel set EZDR
8 70588833 1 Travel motor ZBA 71B4 B007 see page 42
9 70588633 1 Gearbox set
10 75239644 1 Torque arm set MA125-1
11 70589833 1 Travel drive EZDR c/w items 8, 9
21712403.tbl
21712444_en_220910
1) Spare parts see spare parts list 22291744. 9

Crab frame EZDR-Pro 10 - H12 - H20
21712444_en_220910
10

3 70591133 1 Buffer set 70x 70
10 75239644 1 Torque arm set MA125-1
12 Top block see page 20
21712404.tbl
21712444_en_220910

Crab frame EZDR-Pro 10 - H40
21712444_en_220910
12
Crab frame EZDR-Pro 10 - H40

3 70591133 1 Buffer set 70x 70
10 75239644 1 Torque arm set MA125-1
12 Top block see page 22
21712405.tbl
21712444_en_220910

21712444_en_220910
14

3 75201433 1 Buffer set 100x100
7 70581033 1 Wheel set 160 6/1
8 Top block set 6/1 see page 24
10 70585833 1 Travel motor ZBA80A4 B007 see page 42
12 47993933 1 Travel drive ZBA80A4 AME20 c/w items 10,11
21712406.tbl
21712444_en_220910

4/2 reeving - ZMS
21712444_en_220910
16
4/2 reeving - ZMS

3 70591133 1 Buffer set 70x 70
6 Compensating sheave ZMS Set see page 26
10 75239644 1 Torque arm set MA125-1
21712407.tbl
21712444_en_220910

Rope wedge crosshead - MGS - ZMS
2/1 reeving - H12 - H20
21712444_en_220910
18
Rope wedge crosshead - MGS - ZMS
2/1 reeving - H12 - H20
6 47985433 1 Cr.beam overl.prot.dev. MGS 2/1 2m c/w items 7, 23

6 70593333 1 Rope wedge crosshead EZDR 10 ZMS c/w items 7, 22
7 70591733 1 Rope anchorage set DR10
22 70591833 1 Strain gauge car.link set ZMS DR10 2/1
23 71912733 1 Overload cut-off DR 10 2m MGS
21712414.tbl
21712444_en_220910
19
Rope wedge crosshead/Return sheave - MGS - ZMS
4/1 reeving - H12 - H20
21712444_en_220910
20
4/1 reeving - H12 - H20
6 47989033 1 Cr.beam overl.prot.dev. MGS H12 4/1 2m c/w items 7, 23

6 70594633 1 Rope wedge crosshead H12 4/1 ZMS 2m, 3m, c/w items 7, 22
6 70594733 1 Rope wedge crosshead H20 4/1 ZMS 2m, 3m, c/w items 7, 22
6 70594433 1 Rope wedge crosshead H12 4/1 ZMS 4m, c/w items 7, 22
6 70594533 1 Rope wedge crosshead H20 4/1 ZMS 4m, c/w items 7, 22
12 70594833 1 Top block set EZDR10 4/1 2m, 3m, c/w item13
12 70595133 1 Top block set EZDR10 4/1 4m c/w item 13
13 70595233 1 Rope sheave set DR10 4/1 2m, 3m 1)
13 70595333 1 Rope sheave set DR10 4/1 4m 1)
21712412.tbl
21712444_en_220910
1) The rope sheaves for the 4/1 bottom block are included in the delivery. 21
4/1 reeving - H40
21712444_en_220910
22
4/1 reeving - H40

6 70584033 1 Rope wedge crosshead H40 ZMS 2m, 3m, c/w items 7, 22
6 70584133 1 Rope wedge crosshead H40 ZMS 4m 4m, c/w items 7, 22
12 70594833 1 Top block set EZDR10 4/1 2m, 3m, c/w item13
12 70595133 1 Top block set EZDR10 4/1 4m c/w item 13
13 70595233 1 Rope sheave set DR10 4/1 2m, 3m 1)
21712413.tbl
21712444_en_220910
1) The rope sheaves for the 4/1 bottom block are included in the delivery. 23
6/1 reeving - H20 - H40
21712444_en_220910
24
6/1 reeving - H20 - H40

6 70586333 1 Rope wedge crosshead 6/1 ZMS 2m, 3m, c/w items 7, 22
6 70586433 1 Rope wedge crosshead 6/1 ZMS 4m c/w items 7, 22
8 70585433 1 Top block set 6/1
21712415.tbl
21712444_en_220910
25
Compensating sheave ZMS
4/2 reeving
21712444_en_220910
26
Compensating sheave ZMS
4/2 reeving
6 70595733 1 Compensating sheave set EZDR10

7 70591833 1 Strain gauge car.link set ZMS DR10 2/1 4/2
8 70595433 1 Rope sheave set DR10 4/2 1)
21712408.tbl
21712444_en_220910
1) The rope sheaves are pins for the 4/2 bottom block are included in the delivery. 27
Bottom block 230/13
DR 10
2/1 reeving -2m, 3m
21712444_en_220910
28
Bottom block 230/13
DR 10
2/1 reeving -2m, 3m
1 71321033 1 Single-sheave bott.block 230/13

2 70598033 1 Rope sheave hood set 2/1 c/w items 4, 10
3 34182633 1 Hook safety catch set 2,5 DIN 15106
4 71389033 1 Capacity plate set Neutral
5 70585233 1 Rope sheave set DR10 2/1
6 70398433 1 Load hook set RSN 2,5 c/w item 3 1)
7 71293033 1 Double load hook set RSN 2,5T c/w item 8 1)
8 34187433 1 Double hook safety flap Set
10 71314533 1 Rope sheave cover set 230
21704112.tbl
21712444_en_220910
# 1) When fitting the load hook, ensure that opening „X“ of spring ring item 13 is arranged at least 45°
away from openings „Y“ in hook trunnion block item 9. (See figure)
When replacing the load hook, always also replace the spring ring (item 13). 29
Bottom block 280/14
DR 10
4/1 reeving -4m
21712444_en_220910
30
Bottom block 280/14
DR 10
4/1 reeving -4m
1 82921933 1 Single-sheave bott.block 280/14

2 70587933 1 Rope sheave hood set 2/1 4m c/w item 21
6 70585333 1 Rope sheave set DR10 2/1
10 82920933 1 Pin bottom block DH400
14 15084333 1 Simple hook with cross beam ASN 2,5S c/w item 15
16 15084533 1 Double load hook BSN 2,5S+TRAV c/w item 19
21773016.tbl
21712444_en_220910
31
Bottom block 230/13
DR 10
4/1 reeving - 2m, 3m
21712444_en_220910
32
Bottom block 230/13
DR 10
4/1 reeving - 2m, 3m
1 71323033 1 Bottom block 2-sheave 230/13

2 70598133 1 Rope sheave hood set 4/1 c/w items 3, 10
4 34182733 1 Hook safety catch set 4 DIN 15106
6 70598433 1 Load hook set RSN 4 c/w item 4 1)
7 71295033 1 Double load hook set RSN 4 T c/w item 8 1)
10 71314533 1 Rope sheave cover set 230
21704113.tbl
21712444_en_220910
1) When fitting the load hook, ensure that opening „X“ of spring ring item 13 is arranged at least 45°
away from openings „Y“ in hook trunnion block item 9. (See figure)
When replacing the load hook, always also replace the spring ring (item 13).
2) The rope sheave for the top block is included in the delivery. 33
Bottom block 280/14
DR 10
4/1 reeving - 4m
21712444_en_220910
34
Bottom block 280/14
DR 10
4/1 reeving - 4m

2 70598333 1 Rope sheave hood set 4/1 4m c/w item 20
11 47932333 1 Set of pins 280 55x369 4/1
15 82926133 1 Simple hook with cross beam GSN 5-S c/w item 16
16 34182833 1 Hook safety catch set 5 DIN 15106
17 82926933 1 Double load hook GSN 5-S +TRAV c/w item 18
21705607.tbl
21712444_en_220910
1) The rope sheave for the top block is included in the delivery. 35
Bottom block 280/13
DR 10
6/1 reeving
21712444_en_220910
36
Bottom block 280/13
DR 10
6/1 reeving
1 71324033 1 Bottom block 3-sheave 280/13 5V

2 Bottom block 3-sheave 280/13 5V D 1)
3 71324233 1 Rope sheave hood set 6/1 c/w item 5
4 Rope sheave set DR10 6/1 1)
6 71323433 1 Hook safety catch set GR. 5
7 Simple hook with cross beam Gr.5 1)
8 Hook safety catch set GR.5 D 1)
9 Double load hook set GR.5 D 1)
21712411.tbl
21712444_en_220910
1) on request. 37
Bottom block 225/11
DR 10
4/2 reeving
21712444_en_220910
38
Bottom block 225/11
DR 10
4/2 reeving

3 70598233 1 Rope sheave hood set 4/1, 4/2 c/w item 24
17 15084333 1 Simple hook with cross beam ASN 2,5S c/w item 18
19 15084533 1 Double load hook BSN 2,5S+TRAV c/w item 22
21705608.tbl
21712444_en_220910
1) The rope sheave for the compensating sheave is included in the delivery. 39
ZBR 132 hoist motor
21712444_en_220910
40
ZBR 132 hoist motor
# 24 75221833 1 Rotor set ZBR132B 4 C 4 1Am-4m, 1-18 m/min

# 24 75222033 1 Rotor set ZBR132C 4 2m-4m, 1-25 m/min
# 25 75222533 1 Rotor set ZBR132D12/2 2m-4m, 10/1,7 m/min
# 25 75222633 1 Rotor set ZBR132D12/2 1Am, 8/1,4 m/min
# 26 26535133 1 Stator set ZBR132D12/2 1)
# 26 26535233 1 Stator set ZBR132B 4 1)
# 26 26535333 1 Stator set ZBR132C 4 1)
# 31 26089484 1 Brake control GS 1 AC
# 32 26090184 1 Voltage relay VE 42-149V AC
35 31816633 1 Terminal box set Z112 /132
# 36 06988184 1 VDR resistor <= 400V
# 36 06988284 1 VDR resistor 401-500V
39 47074033 1 Unit IMP RS422/5V Set EGS 1 (TTL)
39 47074133 1 Unit IMP RS422-30VSet EGS 2 (TTL)
39 47074233 1 Unit IMP HTL-30V Set EGS 3 (HTL)
40 48556633 1 Product documents 10POL 250M20
40 48556733 1 Product documents 10POL 350M20
# 41 26080784 1 Control cabinet set BRBS
# 42 23882533 1 Terminal box cover Z132 -225
43 34247433 1 Mounting parts set Z112 /132
49 B140 brake 3)
50 26019333 1 Microswitch V4NO Set
51 23866333 1 End shield set BS ZB112/132 B140 2)
54 46982333 1 Built-in pulse encoder EG/Z 132
71 73056633 1 Rotary transducer AG2 TTL5/24 12/2-pole
# 71 20444284 1 Rotary transducer AG2 TTL5/24
# 71 20444384 1 Rotary transducer AG3 HTL24/24
72 23848133 1 Mounting elements AG1-3/ Z132
72 23848433 1 Mounting elements AG1-3/ Z132 AL-DG
73 23848533 1 Mounting elements AG1-3/ Z132 AL-SG
78 23871733 1 Fan set Z112/132 schw. option
80 23871533 1 Fan set Z112/132leicht
81 23874033 1 Fan cover set ZB112/132 c/w item 80, DG, long
81 23874133 1 Fan cover set Z112/132 c/w item 80, heavy type
21712809.tbl
21712444_en_220910
# 1) Suitable for 380/415V50Hz and 460/480V60Hz operating voltage.

2) State option "integrated pulse generator" when ordering, if requiered.
# 3) Spare parts see chapter "Brakes". 41
ZB 71 travel motor , 2/1, 4/1, 4/2 reeving
ZB 80 travel motor , 6/1 reeving
21712444_en_220910
42
ZB 71 travel motor , 2/1, 4/1, 4/2 reeving
ZB 80 travel motor , 6/1 reeving
1 Sub-assembly Motor 3)
17 36687533 1 Bearing and sealing set Z63/71
17 36646433 1 Bearing and sealing set Z80/90A
26 Stator 1)
# 31 26089084 1 Brake control GE 3 A
# 31 26089184 1 Brake control GP 3 A
# 31 26089284 1 Brake control GE 1,5A
# 31 26089384 1 Brake control GP 1,5A
# 31 26089484 1 Brake control GS 1 AC
# 31 26094384 1 Brake control GF 0,8A
# 32 26086484 1 Current relay SE0,25-4,0A AC ZB71
# 32 26087084 1 Current relay SE 0,4-16A AC ZB80
35 79499233 1 Terminal box set Z 63 / 71
35 79499133 1 Terminal box set Z 80 / 90A
# 36 06988184 1 VDR resistor <= 400V
# 36 06988284 1 VDR resistor 401-500V
# 41 26080784 1 Control cabinet set BRBS
# 42 21882533 1 Terminal box cover Z 63- 90
43 34247033 1 Mounting parts set Z 63 / 71
43 34250333 1 Mounting parts set Z 80 / 90A
49 B003 brake 4)
# 50 B007 brake 4)
51 20867233 1 End shield set BS ZB 63/ 71 2)
51 21866233 1 End shield set BS ZB 80/ 90 2)
78 20871733 1 Fan set Z63/71 schwer option
78 21871733 1 Fan set Z80/90A schwer option
80 20871533 1 Fan set Z63/71 leicht
80 21871533 1 Fan set Z80/90 leicht
# 81 20874033 1 Fan cover set ZB 63/ 71 c/w item 80
# 81 21874033 1 Fan cover set ZB 80/90A c/w item 80
21712409.tbl
21712444_en_220910
2) State option "integrated pulse generator" when ordering, if requiered.
3) When ordering this sub-assembly (individual component parts are not supplied), please indicate the DR hoist serial number and order number.
These data are specified on the rating plates. Replaceable sub-assemblies will be supplied
that depend on the gearbox transmission ratio and the motor frame size.
# 4) Spare parts see chapter "Brakes". 43
B003 brake, ZB 71
B007 brake, ZB 80
B050, B140 brakes, ZBR 132
21712444_en_220910
44
B003 brake, ZB 71
B007 brake, ZB 80
B050, B140 brakes, ZBR 132
53 26003033 1 Extension set IP55 B003 Option, ZB 71

53 26013033 1 Extension set IP55 B007 Option, ZB 80
53 26033033 1 Extension set IP55 B050 Option, ZBR 100
53 26043033 1 Extension set IP55 B140 Option, ZBR 132
59 26096233 1 Wear and tear set B003 ZB 71
59 26097033 1 Wear and tear set B007 ZB 80
59 26098033 1 Wear and tear set B050 ZBR 100
59 26098433 1 Wear and tear set B140 ZBR 132
65 26001033 1 Brake spring set B003 ZB 71
65 26011033 1 Brake spring set B007 ZB 80 1)
65 26031033 1 Brake spring set B050 ZBR 100 1)
65 26041033 1 Brake spring set B140 ZBR 132 1)
66 26005033 1 Magnet body set B003 180V ZB 71
66 26015033 1 Magnet body set B007 180V ZB 80
66 26038533 1 Magnet body set B050 180V ZBR 100
66 26048533 1 Magnet body set B140 180VZ132 ZBR 132
86 26096033 1 Overhauling set B003 ZB 71
86 26096733 1 Overhauling set B007/ZB 80 ZB 80 2)
86 26097633 1 Overhauling set B050/ZB100
86 26098133 1 Overhauling set B140/ZB132
21712410.tbl
21712444_en_220910
1) Required quantity of brake springs dependent on the brake torque, see operating instructions 214 228 44.
# 2) The stronger armature plate must be replaced with the thinner armature plate plus damper plate included in Set 86 for B020 brakes. 45
Electrical components EZDR-Pro 10
21712444_en_220910
46
Electrical components EZDR-Pro 10
1 71198533 1 Cover sub-assemmbly set DR10T V1

1 71198633 1 Cover sub-assemmb./invert.set DR10T
2 73014333 1 Limit switch EZDR 5-10 Set
3 71989433 1 Power circuit breaker set 25A
4 71999333 1 Profiled joint Set 1,5 M
5 70599233 1 Electrical equipment Set DR10 1) 2)
6 71999633 1 Geared limit switch set SGG
7 71989233 1 Contactor set DR5V2-DR10
8 71999833 1 Patch cord set EZDR
9 71910633 1 Cover sub-assemmbly set DR10 PRO external electrics
10 71999533 1 Freq.inverter DIC-4-002-C-0003-01
10 71980433 1 Freq.inverter DIC-4-007-C-0005-01 6/1
11 71999733 1 Braking resistance set 470R
11 71997133 1 Braking resistance set 120R 6/1
12 71938533 1 Sub-assembly set DR Mod-ISS o. LS
13 71946833 1 Sub-assembly set DR Modul-ZMS
14 71938833 1 Sub-assembly set DR Modul-LS 10A 10A
15 71946633 1 Sub-assembly set DR Modul-HSS
16 71947033 1 Sub-assembly set DR Modul-Hub
17 71938633 1 Sub-assembly set DR Modul-ISS 14A 14A
17 71938733 1 Sub-assembly set DR Modul-ISS 25A 25A
17 71946433 1 Sub-assembly set DR ISS-Modul 10A
18 71408633 1 Adapter mod.Elek Set
19 71944533 1 Antenna set DR3-DR20
21 71955833 1 Patch cord ZBG100D2/12
21 71915733 1 Patch cord Z132D2/12 H40
21 71915833 1 Patch cord ZBR132D2/12
21712416.tbl
21712444_en_220910
1) The bolted connections to DIN 912 must be secured with Loctite 290. Order no. 007 275 84.
2) Enclosure not included in the set. 47
www.demagcranes.com Contact and Demag worldwide

P.O. Box 67 · D-58286 Wetter
Telephone (+49/2335) 92-0 · Telefax (+49/2335) 927676
Printed in Germany
www.demagcranes.com
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Not liable for errors or omissions. Subject to change.
Section IV - Log Book
DEMAG
WARRANTY POLICY
WARRANTY BASICS
Demag Cranes and Components Corporation (DCC) warrants that the goods sold by DCC shall be free from defects in material and workmanship for a
time period dependent on the type of product as listed in the following table:
Crane 2 years or 4000 hours of operation from date of delivery, whichever comes first
DR & DH Wire Rope Hoist 2 years or 4000 hours of operation from date of delivery, whichever comes first
DC Chain Hoist 2 years or 4000 hours of operation from date of delivery, whichever comes first
KBK 2 years or 4000 hours of operation from date of delivery, whichever comes first
Drives 2 years or 4000 hours of operation from date of delivery, whichever comes first
Parts 1 year or 2000 hours of operation from date of delivery, whichever comes first
Delays between shipment and placing the equipment in operation will not extend the warranty period unless authorized by DCC at the time of shipment.
All parts replaced, as set forth above shall become the property of DCC, and DCC may request their return.
Field labor will only be covered for cranes and wire rope hoists and only for 1 year from the start of the warranty period per the "Reimbursement / Credit
Policy for Warranty Service Labor, Travel and Other Site Expenses" section of this document.
Such warranty obligations are contingent upon the Buyer giving notice and satisfactory proof of any defect concerning quantity or quality of the goods
sold to DCC in writing within 10 days after delivery, or if the defect was latent, within 10 calendar days after discovery of the defect.
It is hereby expressly agreed that the time periods referred to in the previous sentence shall be deemed reasonable periods for the discovery and
notification of such claims.
Buyer shall, at its expense, furnish DCC with proof of the defect satisfactory to DCC.
Instructions on contacting DCC in Warranty matters to file a claim, and obtaining reimbursement / credit for cost incurred are addressed in the section
entitled “Submitting Warranty Claims”.
Except as otherwise provided in this warranty, no warranty shall apply with respect to any performance specification or performance guarantee (if there
be any) once Buyer is deemed to have accepted goods.
Anything to the contrary herein not withstanding, DCC’s warranty with respect to goods for parts not manufactured by DCC or its affiliates shall further be
limited to the warranty DCC receives from the supplier.
DISCLAIMER OF IMPLIED WARRANTY OF MERCHANTABILITY: DCC and buyer agree that implied warranty of merchantability is excluded from
warranty coverage.
DISCLAIMER OF IMPLIED WARRANTY OF FITNESS: DCC and buyer agree that the implied warranty of fitness for particular purpose is excluded
from this transaction and shall not apply to the goods involved in this transaction.
DISCLAIMER OF EXPRESS WARRANTY: DCC’s agents, dealers’ agents, distributors’ agents, or OEMs’ agents may have made oral statements about
the machinery and equipment described in a sales transaction. Such statements do not constitute warranties, and buyer agrees not to rely on such
statements. Buyer also agrees that such statements are not part of a warranty claim. DCC and buyer agree that any claim made by buyer,
inconsistent with warranty remedies herein, and in particular consequential and incidental damages, are expressly excluded from warranty coverage.
DEALER OR DISTRIBUTOR NOT AN AGENT: DCC and buyer agree that buyer has been put on notice that dealer or distributor is not DCC’s agent in
any respect or for any reason. DCC and buyer also agree that buyer has been put on notice that dealer, distributor, or OEM is not authorized to incur
any obligations or to make any representations or warranties on DCC’s behalf other than those specifically set forth in the warranty DCC issues with
such specific machinery and equipment covered under this warranty policy.
MERGER: This warranty agreement constitutes a final written expression of all the terms and conditions of this warranty and is a complete and
exclusive statement of those terms. Failure to comply with the stipulations of this Warranty Policy shall be deemed a waiver by buyer of all claims
related to the occurrence of a particular defect.
ITEMS NOT COVERED AS PART OF WARRANTY

1) Normal wear of any part is not covered by warranty.
• Specifically excluded from warranty coverage are: brake linings, wire ropes, wire rope guides, chains, and chain guides.
• Replacement fuses are not covered unless it is clearly the result of a Demag equipment deficiency.
2) Damage due to abuse is not covered by warranty.
• Abuse from overloading beyond the rated capacity of equipment, and operating beyond the duty classification as specified in the original
order are not covered.
• Abuse from side-pulling of load, excessive jogging, damage to pushbuttons and operator control interfaces from impact, environmental
exposure not specified in original order, lack of proper maintenance, lack of lubrication and use of improper lubricants are not covered.
3) Damage from fire, accidents, acts of God or nature, improper storage, and/or improper handling of the equipment is not covered.
4) Damage from shipping is not covered by warranty.
• Shipping damage is excluded from warranty. It is the buyer’s responsibility to verify equipment condition upon receipt and pursue
damage claims with the shipping carrier.
5) This warranty shall be void and DCC shall not be responsible for any defects if Buyer has carried out modifications or reconditioning
work on the goods without DCC’s prior written consent.
WARRANTY POLICY
SUBMITTING WARRANTY CLAIMS:
End users of Demag equipment, as well as DCC’s distribution partners on behalf of their clients, can submit warranty claims.
A warranty claim can only be established and validated by the designated warranty function at the headquarter office in Solon, OH.
To obtain claim forms, please contact:
For Drives & KBK Rose Zavarella Phone: (440) 519-1149 E-mail: rosemarie.zavarella@demag-us.com
For Parts Traci Papp Phone: (440) 349-8207 E-mail: traci.papp@demag-us.com
For Cranes Lucy Rini Phone: (440) 349-8317 E-mail: lucy.rini@demag-us.com
For Chain & Wire Rope Hoists: Kellie Grodell Phone: (440) 349-8328 E-mail: kellie.grodell@demag-us.com
Claim forms can be mailed, faxed or e-mailed to the address below dependent on type of product.
Mail Claims to: Demag Cranes and Components Corporation

29201 Aurora Road
Solon, Ohio 44139 - 1895
For Drives & KBK Attn: Rose Zavarella E-mail: rosemarie.zavarella@demag-us.com Fax: (800) 945-7278
For Parts Attn: Traci Papp E-mail: traci.papp@demag-us.com Fax: (800) 945-7278
For Cranes Attn: Lucy Rini E-mail: lucy.rini@demag-us.com Fax: (800) 945-7278
For Chain & Wire Rope Hoists: Attn: Kellie Grodell E-mail: kellie.grodell@demag-us.com Fax: (800) 945-7278
This information must be submitted to the designated Warranty function using the “Warranty/ Rework Request Form”.
The proper "Warranty/Rework Request Form" to submit is Ident No. 900 222 49 Revised September 15, 2007.
All mandatory information asked for on the form must be provided to be compliant with DCC policy. Description of the Problem, Cause of the Problem
and Proposed Corrective Action must be filled in.
A warranty claim will not be considered authorized until all required information has been received by the warranty function and it passes a review for
compliance with DCC policy, technical merit and reasonable labor estimate. After passing this review, then an authorization number will be assigned.
Once a warranty authorization number has been assigned, it must be used as a reference with all further communication in that matter.
A new authorization number will be assigned for each new warranty claim as it is received.
WARRANTY CLAIMS FOR CHAIN HOISTS:
All warranty claims for chain hoists must be directed to the designated Warranty function at the Headquarter Office in Solon, OH.
Field labor is generally not provided for chain hoists unless prior authorization is given by DCC.
DCC reserves the option to have a chain hoist fixed in place or returned to the nearest Warranty Service Center.
In this case, transportation of Chain Hoists to the nearest Warranty Service Center is the responsibility of the claimant. DCC covers the reasonable
shipping cost back to the claimant from the nearest Warranty Service Center.
WARRANTY CLAIMS REQUIRING REPLACEMENT PARTS:
All requests for warranty replacement parts must be directed to the designated Warranty function at the Headquarter Office in Solon, OH.
Warranty Replacement Parts will be shipped once all information requirements for the warranty claim process have been met.
Outbound freight cost for UPS Ground and standard LTL shipments to a Dealer, Distributor, OEM, or end user will be pre-paid by DCC for any parts
ordered as Warranty Replacement Parts. Claimants may specify expedited shipping of replacement parts at claimant's expense.
The Warranty Coordinator and/or CSR may issue forwarding instructions to the claimant if it is deemed necessary to inspect an allegedly defective part
for further evaluation, or if it appears that a part can be rebuilt and reused.
Returned parts should be shipped freight prepaid by the sender.
If it is determined that the material is not covered under warranty or other aspects of the warranty haven’t been met, a debit will be issued against the
claimant's account for the replacement parts and shipping charges.
DCC reserves the right to replace, after start-up, any defective part(s) with reconditioned parts.
Reconditioned parts, as well as new replacement parts will carry the balance of the original equipment warranty period. This policy will apply throughout
the entire warranty period.
WARRANTY POLICY
WARRANTY CLAIMS REQUIRING SERVICE LABOR
If claimant is authorized by DCC to conduct service work:

All requests for warranty service labor must be directed to the designated Warranty function at the Headquarter Office in Cleveland, OH. DCC will not
accept the cost for warranty service labor obtained through processes other than a warranty claim.
An estimate for performing said work shall be made on the Warranty/Rework Request Form.
Proposed corrective actions and labor estimates shall be reviewed by the DCC Warranty Coordinator and/or CSR for technical merit, compliance with
the DCC warranty policy, and reasonable and customary amount of labor hours.
An issued warranty authorization number will serve as a purchase order for the end user, Dealer, Distributor or OEM with service capabilities to initiate
the work.
It is imperative that the service provider stay in contact with the respective DCC warranty function if the claim issue cannot be resolved within the
originally estimated and authorized cost.
Service labor associated with a warranty claim shall be reimbursed according to the Warranty Reimbursement / Credit Guidelines section.
Within 90 days of completion of the work, the service provider is required to submit to the designated Warranty function a detailed invoice for field labor
and expenses.
If the claimant is an end user, Dealer, Distributor, or OEM without service capabilities:
DCC will contact an authorized service provider, and will coordinate the warranty work to be performed according to the Warranty Reimbursement /
Credit Guidelines section.
A purchase order will then be issued by DCC to the service provider selected by DCC to carry out the service work. Description of the Problem, Cause
of the Problem and Proposed Corrective Action will then be reported to DCC. If findings dictate that the warranty claim is rejected, DCC will debit the
claimant's account for parts, labor, and freight expenses, or any other cost incurred.
REIMBURSEMENT/CREDIT POLICY FOR WARRANTY SERVICE LABOR, TRAVEL AND OTHER SITE EXPENSES
DCC will reimburse the on site costs of warranty repairs including labor, travel time, travel expenses, and rental of access equipment, for a period of 1
year after shipment for cranes and wire rope hoists per the following schedule:
a. DCC will reimburse / credit directly contracted service labor up to a maximum of $ 70.00 USD / hr. or $ 75.00 cdn / hr. Reimbursements for
directly contracted labor are contingent upon a detailed breakdown of dates, hours, rates, and actual work performed.
b. DCC will reimburse / credit third party service labor at cost, up to a maximum of $ 70.00 USD / hr. or $ 75.00 cdn / hr. Reimbursements for
subcontracted labor require submittal of a copy of the invoice showing a detailed breakdown of dates, hours, rates, and actual work
performed.
c. Warranty work will be performed during regular working hours, Monday through Friday per the rates above. General Overtime Charges and
Surcharges for Weekend / Holiday work will only be accepted after specific authorization by DCC before commencement of work.
d. DCC will reimburse / credit travel time at $ 55.00 USD / hr or $ 59.00 cdn / hr.
e. DCC will reimburse / credit travel mileage at 48 cents USD / mile or 48 cents cdn/ /km.
f. DCC will reimburse other travel expenses at cost. Reimbursements / credits for other expenses require submittal of copies of invoices
showing reasonable expense details.
g. DCC will reimburse / credit expenses for lift equipment and any other equipment rentals at cost. Reimbursements / credits for other expenses
require submittal of copies of invoices showing reasonable expense details.
h. Detailed invoices are required that show labor hours, travel time, travel mileage, travel expenses, lift equipment rental, and any other
equipment rental as separate items.
File Name: MPP-SD-SV-00003 WARRANTY POLICY.doc Version: 1 Release:

Creation Date: 04/03/2009 Original Author: Andy Rasch
Last Saved on: Last changed by:
Page: 3 of 3
Warranty / Rework Request Form
Identify the Person / Company making the claim
Name: Phone:
Customer: Fax:
Address: e-mail:
City / State / Zip:
Identify the Enduser of Equipment:

Contact Name: Phone:
Customer: Fax:
Address: e-mail
City / State / Zip:
Identify the Equipment:

Original Job Number: Crane Serial Number:
Hoist Model: Hoist Serial Number:
Description of Equipment: Delivery Date of Equipment:
Please provide this Mandatory Information:

Date of Claim: Date of Failure:
Description of Problem:
Cause of Problem:
Proposed Corrective Action:
(Note: All of the Mandatory Information section must be filled out! Noncompliant claims will be returned.)
Parts Request:
Quantity Part Number Part Name
Shipping Address:
Name: Phone:
Customer: Fax:
Address: e-mail:
City / State / Zip:
Select Shipping Mode: UPS Ground or LTL

Specify Expedited Shipping at Claimants Expense:
File Name: Warranty Claim Form.doc Version: 2 Release:

Last Saved on: 04/03/2009 Last changed by: Andy Rasch
Page: 1 of 2
Labor Estimate:
Labor estimated hrs. Travel time estimated hrs. Travel mileage estimated:
Travel expenses estimated: Lift equipment charges:
Other charges:
Return this form to:
For Drives and KBK e-mail: rosemarie.zavarella@demag-us.com Fax: (800) 945-7278

For Parts e-mail: traci.papp@demag-us.com Fax: (800) 945-7278
For Cranes e-mail: traci.papp@demag-us.com Fax: (800) 945-7278
For Chain and Wire Rope Hoists e-mail: kellie.grodell@demag-us.com Fax: (800) 945-7278
Or mail to: Demag Cranes and Components Corp.
29201 Aurora Road
Solon, Ohio 44139
This area for internal use only by Demag warranty personnel:
Warranty Number: Authorized by: (initials) Date: ___________
Product Hierarchy: Reason : __________
Review Process: Appropriate: Compliant: Reasonable: Timeline: _______
Comments:
File Name: Warranty Claim Form.doc Version: 2 Release:

Last Saved on: 04/03/2009 Last changed by: Andy Rasch
Page: 2 of 2
Crane installation check-off sheet
Installation Date: Job #: 502262
Crane Serial #(s): 13057 To 13058
Customer: AGGREKO INTERNATIONAL Enduser: AGGREKO INTERNATIONAL
Crane Type: ZKKE Capacity: 15.00TON Span: 41' - 11.5" Voltage: 460/3/60
Endtruck: DFW-L-Z 250/4000 Motor: ZBA 90B4 Gear: ADE40 39.9:1 Speed: 160 VFC
Hoist #1 Type: DR10-16 6/1-13.3 Z-0.7-6 Lifting Speed: 20 VFC FPM Serial #:
Hoist #2 Type: Lifting Speed: Serial #:
Hoist #3 Type: Lifting Speed: Serial #:
Trolley #1: EZDR Motor: ZBA 80A4 Gear: AMK20 44.1:1 Speed: 82 VFC FPM
Trolley #2: Motor: Gear: Speed:
Trolley #3: Motor: Gear: Speed:
See See
satisfactory Report satisfactory Report
Endtruck :
Torque girder bolts: refer to torque plate on crane Check endtruck bumper
Check for tight installation of AF gear/RF drives Install or open vent plugs
Runway collector bracket installation Proper oil level in gearboxes
Girder :
Trolley endstop installation Tagline installation
Trolley hook approach Condition of walkway/platform
Hoist/Trolley :
Check for tight installation of trolley drive Trolley towing arm installation
Install or open vent plugs Lubrication & inspection of wire rope,
Proper oil level (grease) in drive gear & rope guide
Check trolley bumper Check limit switch settings up & down
Electrical :
Tight electrical connection on all motors Check timers (if supplied) for 2 speed
and terminals bridge and trolley
Proper fittings and condition of all cables Supply voltage within +_ 5% when
Condition of pendant and taglines hoist operating. Voltage measured V
Proper function of masterswitches Amperage on all motors "equal" within
Proper function of electrical accessories ( _
+ 10%) on all phases
General :
Check power feed & collectors Runway rail alignment and splices
Runway end stops
Functions :
Test hoist brakes with full load Run crane in low and high speed
Run trolley in low and high full length of runway
speed full length of girder
Test accessories for proper function
Additional checks performed : Start up problems :
Customer/Enduser Date Installer Date
NOTE: Return 1 completed copy to: Demag Cranes & Components 29201 Aurora Rd. Solon, OH 44139

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Customer: AGGREKO INTERNATIONAL PROJECTS

Crane After Sale Manual

Date: April 25, 2013 Initials: TD & JC

Job Number 502262 Serial Numbers

Span 41' - 11.5" Control Sliding P/B - DSE-10R

Bridge Speed 160 VFC FPM Speed Control Infinitely Variable

Trolley Speed 82 VFC FPM Speed Control Infinitely Variable

HOIST #1: DR10-16 6/1-13.3 Z-0.7-6

SECTION I Mechanical & Electrical Drawings Sheet Demag ID

DR PARAMETERS (one set per crane):

Crane # 1 Serial # 13057

SECTION II Operating Instructions

SECTION III Component Parts List

DRS 160 WHEEL BLOCK 229 920 49

SECTION IV Log Book

0509 900 503 49

EKKE cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 2 - 8

EDKE cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 9 - 12

ZKKE cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 13 - 17

BRIDGE MOTOR WIRE

BRIDGE MOTOR WIRE FESTOON SUPPORTS

GIRDER MOUNTING PLATES

Supercedes Classification No.

Supercedes Classification No.

ASSURE PROPER ASSEMBLY ACCORDING TO THESE

Supercedes Classification No.

Supercedes Classification No.

Supercedes Classification No.

Supercedes Classification No.

Supercedes Classification No.

13. Mount runway collector bracket. (see Fig. 4, Pg. 12)

Supercedes Classification No.

Supercedes Classification No.

Supercedes Classification No.

Supercedes Classification No.

Supercedes Classification No.

ASSURE PROPER ASSEMBLY ACCORDING TO THESE

Supercedes Classification No.

Supercedes Classification No.

Supercedes Classification No.

Supercedes Classification No.

NEW DESIGN OLD DESIGN

TORQUE VALUES FOR HOT-DIP GALVANIZED HIGH TENSILE

NEW DESIGN OLD DESIGN

Supercedes Classification No.

TYPICAL ARRANGEMENT FOR VARIOUS GIRDER CONNECTIONS

DFW-L-E & Z DFW-L-Z & T

KTD-DK STYLE KTD-DH STYLE

Supercedes Classification No.

T HE BOTTOM BLOCK ASSEMBLY FOR HOIST

MODEL DR IS SHIPPED UNREEVED WITHOUT

THE CAPACITY MARKINGS .

REFER TO THE CAPACITY DECAL ON THE

CRANE GIRDER TO DETERMINE THE CORRECT

CAPACITY DESIGNATION TO PLACE ON THE

C RANE GIRDERS WITH THE CAPACITY

“METRIC TON” USE LOWER CASE “t”

“METRIC” TON (t) 2200 LBS / TON

Supercedes Classification No.

P EEL OFF D ECAL AND APPLY IN THE AREA SHOWN BELOW .

Supercedes Classification No.

DEMAG Cranes & Components

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