DEMAG DIC 002 Series User manual

Quick-step operating instructions
Dedrive Compact STO frequency inverters DIC-x-002 to DIC-x-210
Valid for software version 5.4.2/050-10 and higher with DIC-x-xxx-X-0000-x3 hardware
290623 en GB 211 170 44 720 IS 922

Original operating instructions
Manufacturer
Demag Cranes & Components GmbH
Forststrasse 16
40597 Düsseldorf, Germany
www.demagcranes.com
Email: [e-mail]
General accompanying documents Part no.
DE EN FR ES
Dedrive Compact STO frequency inverter quick-step operating instructions 211 170 44
Dedrive Compact STO frequency inverter application notes/operating instructions 211 171 44
DIC Safe Torque Off operating instructions 211 172 44
DIC positioning operating instructions 211 174 44
DIC function table operating instructions 211 175 44
CM – PDP (Profibus-DP) communication module operating instructions 214 769 44 214 770 44 -
CM – CAN (CANopen) communication module operating instructions 214 773 44 214 774 44 -
CM2-PNC and CM-PROFINET communication module operating instructions 211 244 44 -
EM – UNI - 01 extension module operating instructions 211 124 44 211 125 44 211 126 44 211 127 44
EM – ABS - 01 extension module operating instructions 211 245 44 -
DIC system bus operating instructions 211 255 44 -
Operating instructions for Z motor range 214 227 44 214 228 44 214 229 44 214 230 44
Operating instructions for Z motor encoders 214 371 44 214 372 44 214 373 44 214 374 44
Technical data for frequency inverter accessories 203 815 44
Software and product documentation Dedrive Compact STO, including application notes/oper‐
ating instructions and operating instructions for optional modules available for download * -
Tab. 1
*Download:
DE: https://www.demagcranes.de/dedrive-compact-sto-produktdokumentation
EN: https://www.demagcranes.com/en/dedrive-compact-sto-frequency-inverter-product-documentation
DE EN
Fig. 1
Fig. 2
Inspection report on the safety function
The concept for the STO "safe torque off" safety function described in
these instructions has been evaluated and certified.
Inspection body Institute for Occupational Safety and Health of the German Social
Accident Insurance
Certificate EC Type Examination Certificate no. IFA 1601152,
Drawing approval no. IFA 1603006
Valid until 30.06.2021
Product designation Dedrive Compact STO frequency inverter
Basis of the inspec‐
tion
DIN EN 61800-5-1 : 2008-04
DIN EN 61800-5-2 : 2008-04
DIN EN ISO 13849-1 : 2016-06
DIN EN ISO 13849-2 : 2013-02
Assessment Dedrive Compact STO frequency inverters with the integrated STO
(Safe Torque Off) safety function meet the requirements of:
- PL e to DIN EN ISO 13849-1
- Cat 3 to DIN EN ISO 13849-1
- SIL 3 to DIN EN 61800-5-2
Tab. 2
The metric system is used in this document and all figures are shown with a comma as the decimal separator.
2
211 170 44/290623

Table of contents
General ....................................................................................................................................................................... 6
Dedrive Compact STO frequency inverter .................................................................................................................. 6
Symbols/signal words.................................................................................................................................................. 6
Information on the operating instructions .................................................................................................................... 6
Liability and warranty................................................................................................................................................... 7
Copyright ..................................................................................................................................................................... 7
Use of spare parts ....................................................................................................................................................... 7
Definition of personnel................................................................................................................................................. 7
After-sales service....................................................................................................................................................... 8
Safety.......................................................................................................................................................................... 9
General information on safety ..................................................................................................................................... 9
Safety signs on the equipment .................................................................................................................................... 9
Intended use................................................................................................................................................................ 9
Hazards that can be caused by the frequency inverter............................................................................................. 10
Notice on the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) ................................ 12
Responsibility of the owner ....................................................................................................................................... 12
Operating personnel requirements............................................................................................................................ 13
Personal protection equipment.................................................................................................................................. 13
Technical data ......................................................................................................................................................... 14
STO "safe torque off" safety function data ................................................................................................................ 14
Mechanical resistance to vibration ............................................................................................................................ 14
Model code................................................................................................................................................................ 14
DIC-4-xxx-C frequency inverter................................................................................................................................. 14
Selection table........................................................................................................................................................... 15
DIC-2-003 to 018 frequency inverters ....................................................................................................................... 15
DIC-4-002 to 009 frequency inverters ....................................................................................................................... 16
DIC -4-014 to 040 frequency inverters ...................................................................................................................... 17
DIC-4-045 to 120 frequency inverters ....................................................................................................................... 18
DIC-4-150 to 210 frequency inverters ....................................................................................................................... 19
Operating diagrams................................................................................................................................................... 20
Scope of delivery, transportation and storage..................................................................................................... 21
Scope of delivery....................................................................................................................................................... 21
General information on the scope of delivery............................................................................................................ 21
DIC-2-003 to 010 and DIC-4-002 to 009 frequency inverters.................................................................................... 21
DIC-2-018 and DIC-4-014 to 040 frequency inverters............................................................................................... 22
DIC-4-045 to 120 frequency inverters ....................................................................................................................... 23
DIC-4-150 to 210 frequency inverters ....................................................................................................................... 24
Transport, packing and storage................................................................................................................................. 25
Project engineering................................................................................................................................................. 26
General information on project engineering .............................................................................................................. 26
Assembly/installation ............................................................................................................................................. 27
Safety instructions for assembly/installation.............................................................................................................. 27
Fitting the hardware modules .................................................................................................................................... 27
Checking the installation location .............................................................................................................................. 29
Mechanical installation .............................................................................................................................................. 29
General information on mechanical installation......................................................................................................... 29
DIC-2-003 to 010 and DIC-4-002 to 009 frequency inverters.................................................................................... 30
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
3
3.1
3.2
3.3
3.4
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.6
4
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.2
5
5.1
6
6.1
6.2
6.3
6.4
6.4.1
6.4.2
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DIC-x-xxx-E ............................................................................................................................................................... 30
DIC-4-xxx-C............................................................................................................................................................... 31
DIC-2-018 and DIC-4-014 to 040 frequency inverters............................................................................................... 32
DIC-x-xxx-E ............................................................................................................................................................... 32
DIC-4-xxx-C............................................................................................................................................................... 33
DIC-4-045 to 120 frequency inverters ....................................................................................................................... 34
DIC-4-150 to 210 frequency inverters ....................................................................................................................... 36
Electric cabling and wiring......................................................................................................................................... 37
Safety instructions for electric cabling and wiring...................................................................................................... 37
Conditions for connection.......................................................................................................................................... 38
EMC notes................................................................................................................................................................. 38
Modified connection assignment for Dedrive Compact STO units compared to previous equipment without STO.. 39
Block diagram............................................................................................................................................................ 40
External 24 V power supply....................................................................................................................................... 41
Information on the pulse generator ........................................................................................................................... 41
Mains connection ...................................................................................................................................................... 42
DIC-2-003 to 010 and DIC-4-002 to 009 frequency inverters.................................................................................... 42
DIC-2-018 and DIC-4-014 to 040 frequency inverters............................................................................................... 42
DIC-4-045 to 060 frequency inverters ....................................................................................................................... 43
DIC-4-075 to 120 frequency inverters ....................................................................................................................... 44
DIC-4-150 to 210 frequency inverters ....................................................................................................................... 44
Motor connection....................................................................................................................................................... 45
General information on motor connection and cable lengths .................................................................................... 45
DIC-2-003 to 010 and DIC-4-002 to 009 frequency inverters.................................................................................... 45
DIC-2-018 and DIC-4-014 to 040 frequency inverters............................................................................................... 46
DIC-4-045 to 060 frequency inverters ....................................................................................................................... 46
DIC-4-075 to 120 frequency inverters ....................................................................................................................... 47
DIC-4-150 to 210 frequency inverters ....................................................................................................................... 47
Control terminals ....................................................................................................................................................... 48
High voltage test........................................................................................................................................................ 50
Putting the equipment into service........................................................................................................................ 51
Safety instructions when putting the equipment into service..................................................................................... 51
General information on commissioning ..................................................................................................................... 52
Programming parameters with the KP500 keypad unit ............................................................................................. 53
Key assignment and displays.................................................................................................................................... 53
Actual value menu (VAL)........................................................................................................................................... 54
Parameter menu (PARA) .......................................................................................................................................... 55
Programming parameters with Parcom Compact software....................................................................................... 56
General information on programming parameters with Parcom Compact software.................................................. 56
Language selection ................................................................................................................................................... 56
Window layout ........................................................................................................................................................... 57
Commissioning in practice ........................................................................................................................................ 57
General information on commissioning in practice.................................................................................................... 57
Switching on the power supply.................................................................................................................................. 58
Setup ......................................................................................................................................................................... 58
Parameters/functions.............................................................................................................................................. 64
General information on parameters/functions ........................................................................................................... 64
Reset ......................................................................................................................................................................... 64
Brake application time ............................................................................................................................................... 64
Error acknowledgement ............................................................................................................................................ 66
Digital inputs and outputs .......................................................................................................................................... 66
6.4.2.1
6.4.2.2
6.4.3
6.4.3.1
6.4.3.2
6.4.4
6.4.5
6.5
6.5.1
6.5.2
6.5.3
6.5.4
6.5.5
6.5.6
6.5.7
6.5.8
6.5.8.1
6.5.8.2
6.5.8.3
6.5.8.4
6.5.8.5
6.5.9
6.5.9.1
6.5.9.2
6.5.9.3
6.5.9.4
6.5.9.5
6.5.9.6
6.5.10
6.5.11
7
7.1
7.2
7.3
7.3.1
7.3.2
7.3.3
7.4
7.4.1
7.4.2
7.4.3
7.5
7.5.1
7.5.2
7.5.3
8
8.1
8.2
8.3
8.4
8.5
4
211 170 44/290623

General information on digital inputs and outputs ..................................................................................................... 66
Function assignment of the digital inputs .................................................................................................................. 66
Function assignment of the relay and digital outputs ................................................................................................ 67
Setpoint value generation in steps (SOST) ............................................................................................................... 68
Stepless setpoint value generation with memory function (SOSP) ........................................................................... 69
Rotary encoder.......................................................................................................................................................... 71
General information on the rotary encoder................................................................................................................ 71
Operation Mode Encoder 1 ....................................................................................................................................... 71
Operation Mode Encoder 2 ....................................................................................................................................... 71
Division Marks Encoder 1.......................................................................................................................................... 71
Encoder Filter time constant...................................................................................................................................... 72
Frequency Switch-off Limit ........................................................................................................................................ 72
Max. frequency deviation .......................................................................................................................................... 72
Diagnosis ................................................................................................................................................................. 73
General...................................................................................................................................................................... 73
Status display ............................................................................................................................................................ 73
Warning message ..................................................................................................................................................... 74
Error message........................................................................................................................................................... 74
Repairs ..................................................................................................................................................................... 76
General information on repairs.................................................................................................................................. 76
Parameters............................................................................................................................................................... 77
Extract from the list of parameters ............................................................................................................................ 77
Accessories ............................................................................................................................................................. 79
Line reactors, line filters, output filters....................................................................................................................... 79
General...................................................................................................................................................................... 79
DIC-2-003 to 018....................................................................................................................................................... 79
DIC-4-002 to 210....................................................................................................................................................... 79
Optional Modules/Options ......................................................................................................................................... 80
Block wiring diagram .............................................................................................................................................. 81
Circuit diagram .......................................................................................................................................................... 81
8.5.1
8.5.2
8.5.3
8.6
8.7
8.8
8.8.1
8.8.2
8.8.3
8.8.4
8.8.5
8.9
8.10
9
9.1
9.2
9.3
9.4
10
10.1
11
11.1
12
12.1
12.1.1
12.1.2
12.1.3
12.2
13
13.1
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5

1 General
1.1 Dedrive Compact STO frequency inverter
You have purchased a Demag quality product.
This frequency inverter is built in accordance with European standards and regulations and state-of-the-art engi‐
neering principles.
1.2 Symbols/signal words
Important safety information and instructions are marked by corresponding symbols and signal words in these in‐
structions.
Safety warnings and instructions must be followed. Exercise particular caution to ensure that accidents, injuries
and damage are avoided in such cases.
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.
DANGER
This symbol indicates an immediate hazard which can result in serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.
WARNING
This symbol indicates a possibly hazardous situation which might result in serious injury or death.
– Follow these instructions at all times and be particularly careful and cautious.
CAUTION
This symbol indicates a possibly hazardous situation which might result in medium to light injury or damage.
– Follow these instructions at all times and be particularly careful and cautious.
Operating hazard for the machine.
● This symbol indicates information on appropriate use of the machine.
● This symbol indicates all warnings which, if not complied with, can result in malfunctions or damage.
1.3 Information on the operating instructions
These operating instructions are designed to provide the owner and operator with useful instructions for transport‐
ing, installing, commissioning, operating and maintaining our frequency inverters.
Persons entrusted with the various types of work must know and comply with the safety regulations and the oper‐
ating instructions.
The installation may only be operated by personnel who are fully familiar with the operating instructions. In partic‐
ular, they contain the "Safety" section and the relevant safety instructions in the working sections of these operat‐
ing instructions.
The operating instructions must be available to operating personnel at all times to prevent operating errors and to
ensure smooth and trouble-free operation of our products. They must be kept in the immediate vicinity.
6
211 170 44/290623

1.4 Liability and warranty
All information included in these instructions has been compiled on the basis of the relevant regulations, state-of-
the-art engineering principles and our many years of experience.
These instructions must be read carefully before starting any work on and with the frequency inverter, especially
before it is put into service for the first time. The manufacturer assumes no liability for any damage which results
from the following:
● non-compliance with the instructions,
● incorrect use,
● untrained personnel,
● unauthorised conversions,
● 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 product.
1.5 Copyright
These instructions are only intended to be used by the people who work with or on the frequency inverter.
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.
All industrial rights reserved.
1.6 Use of spare parts
We urgently recommend that only spare parts and accessories approved by us be used. Only then can we ensure
the safety and normal service life of the equipment.
Spare parts not approved by us may cause unpredictable hazards, damage, malfunctions or complete failure of
the frequency inverter.
The use of unauthorised spare parts may render null and void any claims for warranty, service, damages or liabili‐
ty against the manufacturer or his appointed personnel, dealers and representatives.
1.7 Definition of personnel
The manufacturer is the person who:
1. manufactures the equipment under his or her own name and places it on the market for the first time;
2. resells other manufacturers' equipment under his or her own name, whereby the reseller is not considered to
be the manufacturer provided the name of the manufacturer (as in 1.) appears on the equipment;
3. imports the equipment into the country and places it on the market for the first time or
4. exports equipment to another member state of the European Union and hands it over direct to a user in that
country.
Owner
Owners (employer, company) are defined as persons who own the machine and who use it as intended or allow it
to be operated by suitable and trained persons.
Operating personnel/operator
Operating personnel or machine operators are defined as persons assigned by the owner of the machine to oper‐
ate the machine. This person must be trained by the owner in accordance with the tasks to be performed.
211 170 44/290623
7

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 inappropriate conduct. Personnel must be informed about the required pro‐
tective devices, protective measures, relevant regulations, codes of practice, accident prevention regulations and
operating conditions and must provide verification of their competence. This person must be trained by the owner
in accordance with the tasks to be performed.
Specialist personnel
Specialist personnel are defined as persons assigned by the owner of the machine to carry out special tasks,
such as installation, setting-up, maintenance and fault elimination. This person must be trained by the owner in
accordance with the tasks to be performed.
Qualified electrician
Qualified electricians are defined as persons who, owing to their technical training, knowledge and experience of
electric machines as well as knowledge of the relevant valid standards, codes of practice and regulations, are
able to assess the tasks given to them and to identify and eliminate potential hazards. This person must be
trained by the owner in accordance with the tasks to be performed.
Experienced technician
Experienced technicians are defined as persons who, owing to their technical training and experience, have suffi‐
cient knowledge in the field of the machine. They must be familiar with the relevant national industrial safety regu‐
lations, codes of practice, accident prevention regulations, directives and generally accepted engineering stand‐
ards enabling them to judge the safe operating condition of machines.
Assigned expert engineer (where the rules and regulations of the German Social Accident Insurance
(DGUV) apply in the Federal Republic of Germany)
An assigned expert engineer is defined as an experienced technician specifically assigned by the manufacturer to
determine the remaining service life of the machine (S.W.P. = safe working period) and to carry out a general
overhaul of the machine.
Authorised expert engineer (where the rules and regulations of the German Social Accident Insurance
(DGUV) apply 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.
1.8 After-sales service
If you have any questions about our products, need technical information or wish to place spare parts orders, etc.,
please contact our after-sales service. Please keep a note of the serial or order number (see log book, load ca‐
pacity plate on the crane). Specifying this data ensures that you receive the correct information or the required
spare parts.
The current addresses of our sales offices in Germany and our subsidiaries and agencies worldwide can be found
on our homepage at www.demagcranes.com
8
211 170 44/290623

2Safety
2.1 General information on safety
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 equipment.
When it is placed on the market, the frequency inverter is built according to generally accepted engineering stand‐
ards and is considered to be safe to operate. It 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 frequency inverter safely and reliably.
Any conversions, modifications or additions to the machine are prohibited unless approved by Demag Cranes &
Components GmbH in writing.
2.2 Safety signs on the equipment
Any pictograms, signs or labels on the frequency inverter must be obeyed and must not be removed. Pictograms,
signs or labels that are damaged or no longer legible must be replaced immediately.
2.3 Intended use
The frequency inverter may only be used as intended and in compliance with the requirements for the owner and
the following limitations as specified in these operating instructions. Any other use may result in a danger to life
and limb and/or cause damage to the frequency inverter and/or load.
● Frequency inverters are electric drive components which are intended to be incorporated into industrial equip‐
ment or machines. Frequency inverters are available to a limited extent and only intended as components for
professional use in the sense of the standard EN 61800-3.
● The frequency inverters are marked with the CE symbol and thus meet the requirements of Low Voltage Direc‐
tive 2014/35/EC and comply with standard EN 50178/DIN VDE 160.
● The owner is responsible for compliance with EMC directive 2014/30/EU.
● The requirements of CSA Standard C22.2 No. 14-95 are also fulfilled with the granting of UL approval in ac‐
cordance 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.
● The frequency inverter may only be installed, used, operated, maintained and removed by trained personnel
when it is in perfect working order. Personnel must meet the requirements according to  "Operating person‐
nel requirements", Page 13.
● Intended use includes compliance with the safety warnings as well as any other instructions on assembly and
disassembly, commissioning, function and operation, maintenance and fault elimination as well as compliance
with the instructions on the equipment safety devices, any possible (remaining) hazards and protection against
hazards.
● The frequency inverter must be maintained and inspected regularly and appropriately by correspondingly
trained personnel in accordance with relevant deadlines.
● National occupational health and safety regulations must be observed and followed.
No liability for inappropriate use
The manufacturer is exempt from any liability for use other than the purpose which is technically possible and ac‐
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 frequency inverter in the sense of the "Intended use" sec‐
tion.
No liability for structural modifications
The manufacturer is not liable for any unauthorised structural modifications which have not been agreed with him.
This includes incorrect connection of the frequency inverter to devices or equipment that do not belong to our
scope of delivery, or the installation or use of third-party accessories, equipment or components that are not ap‐
proved by the manufacturer.
Prohibited practices, 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.
211 170 44/290623
9

CAUTION
Prohibited activities
Damage to / malfunction of the frequency inverter
Under certain conditions, operation of frequency inverters is prohibited as this can result in malfunctions, equip‐
ment failure or danger to life and limb, e.g. in the case of:
– acidic, corrosive air as coolant,
– operation outside the permitted temperature range,
– operation above the permitted site altitude,
– operation under conditions of high humidity or splashwater,
– Manipulation of electric components.
– Frequency inverters may only be connected to the line supply every 60 seconds. Flick-switching of the line
contactor is not permitted.
– Only AC may be applied to semi-conductor relay EM-S1OUTD on terminal X412 of extension module EM –
UNI-01. DC loads can result in dangerous malfunctions.
– Digital outputs EM-S1OUTD and EM-S2OUTD on terminal X410A of the EM – ABS-01 extension module
must not be programmed with the “41 - Release brake” and “103 – Inv. Error” function parameters. Danger‐
ous malfunctions can occur. These settings are blocked for EM – ABS-01 modules for software version
5.4.2/050-11 and higher.
Safety devices must not be rendered inoperable or modified or used in any way other than that for which they
have been designed.
2.4 Hazards that can be caused by the frequency inverter
WARNING
Non-compliance with the safety regulations/instructions
Failure to comply results in danger to life and limb
Relevant national accident prevention regulations, codes of practice and general safety regulations must always
be observed when our products are operated in order to avoid accidents and damage to machinery. Any failure
to follow the safety warnings in these operating instructions can result in death or personal injury.
DANGER
Electric shock, live components
Contact with live components may 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 you have checked all cables, motor terminals and capacitors with a voltmeter to ensure that they are at
zero potential before starting any work on the frequency inverter. If the light emitting diodes go out or fail,
this does not indicate that the frequency inverter is de-energised.
– with insulated tools.
To ensure that the frequency inverter is switched off independently of the mains supply, a circuit interrupter or a
line contactor must be installed between the power supply and the inverter.
Control, power supply and motor leads must be laid separately.
STO "safe torque off" safety function
See "DIC Safe Torque Off operating instructions"  Tab. 1, Page 2 for further information.
10
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The STO "safe torque off" safety function according to DIN EN 61800-5-2 protects people from personal injury
and the installation and operation from mechanical damage if the system is correctly specified.
This function does not disconnect the installation from the power supply.
The STO "safe torque off" safety function can be used to implement "emergency stop" according to EN 60204 –
the line voltage can remain connected to the frequency inverter.
Follow the personal safety and accident prevention instructions below.
DANGER
Inappropriate assembly and installation work
Danger to life and limb. Risk of material damage.
– The STO "safe torque off" safety function may only be installed and put into service by qualified personnel.
– The STO "safe torque off" safety function does not provide an emergency off according to the EN 60204
standard. Emergency off can be achieved by installing a line contactor.
– Emergency stop according to EN 60204 must function in all of the frequency inverter operating modes. Re‐
setting an emergency stop must not allow the drive to start up without any control.
– The drive will restart when the STO "safe torque off" safety function is no longer triggered. To comply with
standard EN 60 204, external measures must be taken to ensure that the drive will only restart after ac‐
knowledgement is given.
– The drive can run on if no mechanical brake is used; the motor will coast to a standstill. If this results in a
risk of personal injury or damage, additional protective devices must be installed.
– If the STO "safe torque off" safety function results in a risk of personal injury following cut-off of the motor
power supply, access to any hazard areas must be prevented until the drive comes to a standstill.
– Check the STO "safe torque off" safety function at regular intervals according to the results of your risk
analysis. We recommend that the check be carried out after one year at the latest.
– The STO "safe torque off" safety function is single-fault tolerant. In rare cases, however, component fail‐
ures may cause the motor shaft to jolt (maximum of 180°/pair of poles, e.g. sudden movement of 90° for a
4-pole motor, 180°/2). A check must be carried out to establish whether this causes a dangerous move‐
ment of the machine.
– If the STO "safe torque off" safety function is employed, special safety, installation and operating instruc‐
tions must be followed.
DANGER
Live components
Danger to life and limb.
The STO "safe torque off" safety function is only suitable for mechanical work on driven machines and not suita‐
ble for work on live parts.
– After an external 24 V DC power supply is switched off, the supply voltage is still applied to the DC link of
the frequency inverter.
– High voltages may still be applied to the motor terminals even if the power supply to the motor is switched
off and if the motor is running down or at standstill.
– If the light emitting diodes go out or fail, this does not indicate that the frequency inverter is de-energised.
– The system must be disconnected from the mains power supply (main switch) before any work (e.g. main‐
tenance) is carried out on live parts. This must be documented on the installation.
– Only carry out maintenance and installation work when all cables, motor terminals and capacitors are at
zero potential (check with a voltmeter).
– The motor is not disconnected from the DC link of the frequency inverter when the STO "safe torque off"
safety function is triggered. The motor may carry high voltages.
– Do not touch live terminals.
Except for its implemented "STO safe torque off" function, the frequency inverter and its control system must not
be used as safety components in the sense of Machinery Directive 2006/42/EC. The unit must not be put into
211 170 44/290623
11

operation (i.e. designated/intended operation must not commence) until it has been established that the installa‐
tion/machinery complies with the provisions of Machinery Directive 2006/42/EC. In this respect, please also con‐
sider the required risk assessment of your installation/machine and the relevant product standards. Employ suit‐
able monitoring systems or mechanical protective devices as safety protection or to meet the requirements of
any safety-related functions in order to avoid any possible personal injury or material damage.
● The Demag “Demag SCU” safety control unit can be used with suitable sensors and actuators to implement
further safety-related functions.
● Depending on the application, other relevant regulations (e.g. Lift Directive 95/16/EC) may apply as an alter‐
native to Machinery Directive 2006/42/EC.
2.5 Notice on the Registration, Evaluation, Authorization and Restriction of
Chemicals (REACH)
Demag Cranes & Components GmbH is fully aware of its obligations under Regulation (EC) No 1907/2006 of the
European Parliament and of the Council of 18 December 2006 concerning the Registration, Evaluation, Authori‐
zation and Restriction of Chemicals (REACH). Twice a year the EU publishes a Candidate list of Substances of
Very High Concern (“SVHC”) for Authorization. Producers and EU-importers have the duty to inform their EU cus‐
tomers when a product contains SVHCs in a concentration above 0.1 % weight by weight. Some Demag products
do include small quantities of SVHCs, such as lead which is typically used in brass and in certain steel materials.
These cases are exemptions, as there are currently no satisfactory alternatives available for such substances. We
are actively searching for alternatives to substitute articles including SVHCs.
For a list of SVHCs, please see https://www.demagcranes.com/en/company/reach-notice.
2.6 Responsibility of the owner
The owner is obliged to ensure that the specified health and safety measures comply with the latest rules and
regulations and to observe new regulations during the entire service life of the frequency inverter. Local industrial
safety legislation and regional regulations and codes of practice applicable at the site of operation of the frequen‐
cy inverter must be observed outside the European Union.
General safety, accident prevention and environmental protection regulations that apply where the frequency in‐
verter 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 equipment 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 can 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 organisation of work, working procedures, authorised personnel, supervising and reporting
obligations, etc.
Furthermore, the owner must ensure that
● any further working instructions and safety warnings resulting from the hazard assessment of the workplaces
at the installation are specified in operating procedures.
● personnel who work with or on the installation are provided with appropriate first-aid equipment. 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 equipment for installation,
operating, maintenance and cleaning personnel.
● personnel are trained in accordance with the work to be performed.
● the equipment is only operated when in safe and proper working order.
● safety devices are always kept freely accessible and are checked regularly.
● national regulations are observed.
● any specified regular checks and inspections are carried out on time and are documented.
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.
12
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The owner is obliged to ensure that
● the rules and regulations of the German Social Accident Insurance (DGUV) are applied in the Federal Repub‐
lic of Germany.
● national occupational safety and health regulations are observed and followed.
Extract from the transfer list of the rules and regulations of German Social Accident Insurance (DGUV)
Previous no. New no. Title
BGV D6 DGUV Regulation 52 Cranes
BGV D8 DGUV Regulation 54 Winches, lifting and towing devices
BGG/GUV-G 905 DGUV Policy 309-001 Inspection of cranes
Tab. 3
2.7 Operating personnel requirements
Only authorised and trained specialist personnel may work on the installation. Personnel must have received in‐
struction on the installation functions and any hazards that can occur.
Every individual given the task of working on or with the equipment must have read and understood the instruc‐
tions before any work starts.
Persons under the influence of drugs, alcohol or medicines which affect their reactions must not work on or with
the equipment.
Age and job-specific regulations relevant at the equipment operating location must be observed for the selection
of any personnel.
Personnel are obliged to report to the owner without delay any changes to the installation that impair safety.
For independent operation (operator) or maintenance (trained maintenance fitter) of the installation, 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 installation and who have proven their quali‐
fication to the owner in this respect.
2.8 Personal protection equipment
When work is carried out on or with the installation, the following protective equipment is recommended to be
worn according to the owner’s hazard assessment:
● Protective equipment, 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;
● Safety helmet to be worn by everybody in the danger zone;
● Use suitable protection (fuse puller with hand and arm protection and helmet with face protection mask and
insulation mat) when isolating by pulling low-voltage high-breaking-capacity fuses.
211 170 44/290623
13

3 Technical data
3.1 STO "safe torque off" safety function data
PL Cat SIL MTTF
d
DC CCF
e 3 3 164 years 90% 75%
Tab. 4
See "DIC Safe Torque Off operating instructions"  Tab. 1, Page 2 for further information.
3.2 Mechanical resistance to vibration
Mechanical resistance to vibration according to DIN EN 60068-2-6 : 2008 amounts to max. 5 g (10 - 60 Hz fre‐
quency range for mechanical oscillation, 0,35 mm amplitude). See also  "General information on mechanical
installation", Page 29.
3.3 Model code
Dedrive Compact STO D I C – x – xxx – X – 0000 – x3
1x
x3
Design index
with varnished PCBs (only available as -C)
with safe torque off
0000
Design variant
Frequency inverter with I/O,
other control methods via communication modules
E
C
Model
Chassis unit
Cold plate
Current code
DIC-2- for E:
003, 005, 010, 018
DIC-4- for E:
002, 004, 006, 007, 009, 014, 017, 025, 032, 040, 045, 060, 075, 090, 120, 150, 180, 210
DIC-4- for C:
004, 007, 014, 025
2
4
Voltage code
230 V
380 ... 480 V
Compact STO
Inverter
Demag
Designation
Tab. 5
3.4 DIC-4-xxx-C frequency inverter
Unlike model DIC-4-xxx-E frequency inverters, the following dimensions and R
th max
thermal resistance values
apply for model DIC-4-xxx-C frequency inverters.
Size 1 2 3 4
Current code DIC-4-… 004 007 014 025
Mechanical
Dimensions HxWxD mm 211x82x140 271x82x140 260x125x144 260x150x144
Ambient conditions
Minimum heat sink thermal resistance R
th max
K/W 0,59 0,31 0,22 0,12
Tab. 6
14
211 170 44/290623

3.5 Selection table
3.5.1 DIC-2-003 to 018 frequency inverters
The following data refer to the nominal working point of the frequency inverter. The nominal working point is de‐
fined for a permissible supply voltage of 230 V and a modulation frequency of 2 kHz.
Size 1 2 3
Current code DIC-2-… 003 005 010 018
Motor-side output
Output current I A 3,0 5,4 1) 9,5 18,0
Output voltage U V 3 x 0 … line voltage
Overload capability at
2 kHz and 4 kHz --
1,5 for 60 sec.
2,0 for 10 sec.
1,35 for 60 sec.
1,48 for 10 sec.
1,5 for 60 sec.
2,0 for 10 sec.
1,46 for 60 sec.
1,83 for 10 sec.
(10 minute cycle)
Protection - - Short-circuit/earth-fault-proof
Output frequency f Hz 0 … 300
Modulation frequency f kHz 2 … 16
Braking resistor output
Min. braking resistance R Ω 100 100 37 24
Line-side input
Line current 2) 3ph/PE IA3,0
5,5 3) 9,5 18
Line voltage U V 230 + 15%/-20%
Line frequency f Hz 50/60 ±10%
Fuses 3ph/PE I A 6 10 16 25
Mechanical
Dimensions HxWxD mm 190x60x175 250x60x175 250x100x200
Weight (approx.) m kg 1,2 1,6 3,0
Type of enclosure - - IP20 (EN60529)
Connection terminals A mm
2
0,2 … 1,5 0,2 … 6
Mounting arrangement - - vertical
Ambient conditions
Power loss P W 43 73 115 200
Coolant temperature T
n
°C 0 … 40 (3K3 DIN IEC 721-3-3)
Storage temperature T
L
°C -25 … 55
Transport temperature T
T
°C -25 … 70
Rel. humidity - % 15 ... 85, non-condensing
Tab. 7
Depending on customer-specific requirements, the modulation frequency may be increased if the output current is
reduced. The standards and regulations must be observed for this operating point.
The modulation frequency can be automatically reduced as a function of the overload.
Modulation frequency 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz
Frequency inverter
Current code
Output current
003 3,0 3,0 3,0 2,5 2,0
005 5,4 3) 5,4 3) 1) 5,4 3)1) 4,5 3) 1) 3,7 1)
010 9,5 3) 9,5 3) 9,5 3) 8,0 3) 6,5
018 18,0 3) 18,0 3) 18,0 3) 15,1 3) 12,2
Tab. 8
1) Modulation frequency reduced in thermal limit range
2) Mains current with a relative line impedance of 1% (see  "Assembly/installation", Page 27)
3) Line reactor required for a duty factor > 60% CDF
211 170 44/290623
15

3.5.2 DIC-4-002 to 009 frequency inverters
The following data refer to the nominal working point of the frequency inverter. The nominal working point is de‐
fined for a permissible supply voltage of 400 V and a modulation frequency of 2 kHz.
Size 1 2
Current code DIC-4-… 002 004 006 007 009
Motor-side output
Output current I A 2,4 3,8 5,8 7,8 9,0
Output voltage U V 3 x 0 … line voltage
Overload capability at
2 kHz and 4 kHz -- 1,5 for 60 sec.; 2,0 for 10 sec. (10 minute cycle)
Protection - - Short-circuit/earth-fault-proof
Output frequency f Hz 0 … 300
Modulation frequency f kHz 2 … 16
Braking resistor output
Min. braking resistance R Ω 300 220 136 110 92
Line-side input
Line current 4) 3ph/PE IA2,4
3,3 5) 5,8 6,4 5) 7,8 5)
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
Weight (approx.) m kg 1,3 1,7
Type of enclosure - - IP20 (EN60529)
Connection terminals A mm
2
0,2 … 1,5
Mounting arrangement - - vertical
Ambient conditions
Power loss P W 46 68 87 108 130
Coolant temperature T
n
°C 0 … 40 (3K3 DIN IEC 721-3-3)
Storage temperature T
L
°C -25 … 55
Transport temperature T
T
°C -25 … 70
Rel. humidity - % 15 ... 85, non-condensing
Tab. 9
Depending on customer-specific requirements, the modulation frequency may be increased if the output current is
reduced. The standards and regulations must be observed for this operating point.
The modulation frequency can be automatically reduced as a function of the overload.
Modulation frequency 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz
Frequency inverter
Current code
Output current
002 2,4 A 2,4 A 2,4 A 2,0 A 1,6 A
004 3,8 A 5) 3,8 A 5) 6) 3,8 A 5) 6) 3,2 A 5) 6) 2,6 A 6)
006 5,8 A 5,8 A 5,8 A 4,9 A 3,9 A
007 7,8 A 5) 7,8 A 5) 7,8 A 5) 6,6 A 5) 5,3 A
009 9,0 A 5) 9,0 A 5) 6) 9,0 A 5) 6) 7,6 A 5) 6) 6,1 A 6)
Tab. 10
4) Mains current with a relative line impedance of 1% (see  "Assembly/installation", Page 27)
5) Line reactor required for a duty factor > 60% CDF
6) Modulation frequency reduced in thermal limit range
16
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3.5.3 DIC -4-014 to 040 frequency inverters
The following data refer to the nominal working point of the frequency inverter. The nominal working point is de‐
fined for a permissible supply voltage of 400 V and a modulation frequency of 2 kHz.
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
Output voltage U V 3 x 0 … line voltage
Overload capability at 2 kHz - - 1,5 for 60 sec.; 2,0 for 10 sec. 1,4 for 60 sec.
1,6 for 10 sec.
(10 minute cycle)
Overload capability at 4 kHz - - 1,5 for 60 sec.; 2,0 for 10 sec. 1,4 for 60 sec.
2,0 for 10 sec.
1,3 for 60 sec.
1,6 for 10 sec.
(10 minute cycle)
Protection - - Short-circuit/earth-fault-proof
Output frequency f Hz 0 ... 300 depending on the modulation frequency
Modulation frequency f kHz 2 … 16
Braking resistor output
Min. braking resistance R Ω 48 48 32 24 24
Line-side input
Line current 7) 3ph/PE IA 14,2 14,5 8) 26 28,2 8) 35,6 8)
Line voltage U V 3 x 380 to 480 + 10%/-15%
Line frequency f Hz 50/60 ±10%
Fuses 3ph/PE I A 16 20 35 50
Mechanical
Dimensions HxWxD mm 250x100x200 250x125x200
Weight (approx.) m kg 2,7 3,8
Type of enclosure - - IP20 (EN60529)
Connection terminals A mm
2
0,2 … 6 0,2 … 16
Mounting arrangement - - vertical
Ambient conditions
Power loss P W 145 200 240 310 420
Coolant temperature T
n
°C 0 … 40 (3K3 DIN IEC 721-3-3)
Storage temperature T
L
°C -25 … 55
Transport temperature T
T
°C -25 … 70
Rel. humidity - % 15 ... 85, non-condensing
Tab. 11
Depending on customer-specific requirements, the modulation frequency may be increased if the output current is
reduced. The standards and regulations must be observed for this operating point.
The modulation frequency can be automatically reduced as a function of the overload.
Modulation frequency 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz
Frequency inverter
Current code
Output current
014 14,0 A 14,0 A 14,0 A 11,8 A 9,5 A
017 16,5 A 8) 16,5 A 8) 9) 16,5 A 8) 9) 13,9 A 8) 9) 11,2 A 9)
025 25,0 A 25,0 A 25,0 A 21,0 A 17,0 A
032 32,0 A 8) 32,0 A 8) 32,0 A 8) 26,9 A 8) 21,8 A
040 40,0 A 8) 38,3 A 8) 9) 35,0 A 8) 9) 29,4 A 8) 9) 23,8 A 8) 9)
Tab. 12
7) Mains current with a relative line impedance of 1% (see  "Assembly/installation", Page 27)
8) Line reactor required for a duty factor > 60% CDF
9) Modulation frequency reduced in thermal limit range
211 170 44/290623
17

3.5.4 DIC-4-045 to 120 frequency inverters
The following data refer to the nominal working point of the frequency inverter. The nominal working point is de‐
fined for a permissible supply voltage of 400 V and a modulation frequency of 2 kHz.
Size 5 6
Current code DIC-4-… 045 060 075 090 120
Motor-side output
Output current I A 45 60 75 90 120
Output voltage U V 3 x 0 … line voltage
Overload capability at 2 and 4 kHz - - 1,5 for 60 sec.; 2,0 for 10 sec.
(10 minute cycle)
Protection - - Short-circuit/earth-fault-proof
Output frequency f Hz 0 ... 300 depending on the modulation frequency
Modulation frequency f kHz 2 … 8
Braking resistor output
Min. braking resistance R Ω 15 7,5
Line-side input
Line current 10) 3ph/PE IA 52
58 11) 72 86 11) 116 11)
Line voltage U V 3 x 380 to 480 + 10%/-15%
Line frequency f Hz 50/60 ±10%
Fuses 3ph/PE I A 63 80 100 125
Mechanical
Dimensions HxWxD mm 250x200x260 400x275x265
Weight (approx.) m kg 8,9 21,2
Type of enclosure - - IP20 (EN60529)
Connection terminals A mm
2
1,5 … 25 Max. 70 (threaded studs)
Mounting arrangement - - vertical
Ambient conditions
Power loss P W 420 540 660 770 1060
Coolant temperature T
n
°C 0 … 40 (3K3 DIN IEC 721-3-3)
Storage temperature T
L
°C -25 … 55
Transport temperature T
T
°C -25 … 70
Rel. humidity - % 15 ... 85, non-condensing
Tab. 13
The modulation frequency can be automatically reduced as a function of the overload.
Modulation frequency 2 kHz 4 kHz 8 kHz
Frequency inverter
Current code
Output current
045 45,0 A 45,0 A 45,0 A
060 60,0 A 11) 60,0 A 11) 60,0 A 11)
075 75,0 A 75,0 A 75,0 A
090 90,0 A 11) 90,0 A 11) 90,0 A 11)
120 120,0 A 11) 120,0 A 11) 12) 120,0 A 11) 12)
Tab. 14
10) Mains current with a relative line impedance of 1% (see  "Assembly/installation", Page 27)
11) Line reactor required for a duty factor > 60% CDF
12) Modulation frequency reduced in thermal limit range
18
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3.5.5 DIC-4-150 to 210 frequency inverters
The following data refer to the nominal working point of the frequency inverter. The nominal working point is de‐
fined for a permissible supply voltage of 400 V and a modulation frequency of 2 kHz.
Size 7
Current code DIC-4-… 150 180 210
Motor-side output
Output current I A 150 180 210
Output voltage U V 3 x 0 … line voltage
Overload capability at 2 and 4 kHz - - 1,5 for 60 sec.; 1,8 for 10 sec.
(10 minute cycle)
Protection - - Short-circuit/earth-fault-proof
Output frequency f Hz 0 ... 300 depending on the modulation frequency
Modulation frequency f kHz 2 … 8
Braking resistor output
Min. braking resistance R Ω 4 2,7
Line-side input
Line current 13) 3ph/PE IA 143 14) 172 14) 208 14)
Line voltage U V 3 x 380 to 480 + 10%/-15%
Line frequency f Hz 50/60 ±10%
Fuses 3ph/PE I A 160 200 250
Mechanical
Dimensions HxWxD mm 510x412x351
Weight (approx.) m kg 45 48
Type of enclosure - - IP20 (EN60529)
Connection terminals A mm
2
Max. 2x95 (threaded studs)
Mounting arrangement - - vertical
Ambient conditions
Power loss P W 1600 1900 2300
Coolant temperature T
n
°C 0 … 40 (3K3 DIN IEC 721-3-3)
Storage temperature T
L
°C -25 … 55
Transport temperature T
T
°C -25 … 70
Rel. humidity - % 15 ... 85, non-condensing
Tab. 15
The modulation frequency can be automatically reduced as a function of the overload.
Modulation frequency 2 kHz 4 kHz 8 kHz
Frequency inverter
Current code
Output current
150 150,0 A 14) 150,0 A 14) 150,0 A 14)
180 180,0 A 14) 180,0 A 14) 180,0 A 14)
210 210,0 A 14) 210,0 A 14) 210,0 A 14) 15)
Tab. 16
13) Mains current with a relative line impedance ≥1% (see  "Assembly/installation", Page 27)
14) Line reactor required
15) Modulation frequency reduced in thermal limit range
211 170 44/290623
19

3.6 Operating diagrams
The technical data for the frequency inverter relates to the nominal working point that was selected for a wide
range of applications. Functionally safe and economical dimensioning (derating) of the frequency inverter may be
achieved by using the following diagrams for specific applications.
Fig. 3
Derating;
5%/1000 m above 1000 m above sea level; h
max
= 4000 m
Max. coolant temperature;
3,3 °C/1000 m above 1000 m above sea level
1 Output current in % 3 Coolant temperature in °C
2 Site altitude in m above sea level 4 Site altitude in m above sea level
Tab. 17
Fig. 4
Derating;
2,5%/K above 40 °C; T
max
= 55 °C
Derating;
0,22%/V above 400 V; U
max
= 480 V
Only applicable for DIC-4
5 Output current in % 7 Output current in %
6 Coolant temperature in °C 8 Line voltage in V
Tab. 18
20
211 170 44/290623