DEMAG DC-Com 1 User manual

Operating instructions / Accessories /
Component parts
Demag DC-Com 1 – 10 chain hoist
181209 en GB 21480244 720 IS 817
Distributed by Tri-State Equipment Company Inc.
Email: [email protected]
Web: www.tsoverheadcrane.com
PH: 314-869-7200 | FAX: [phone]

Original operating instructions
Manufacturer
Demag Cranes & Components GmbH
P.O. Box 67
58286 Wetter
Please fill in the following table before first putting the unit into service. This provides you with a definitive documentation of your
Demag DC chain hoist and important information if you ever have to contact the manufacturer or his representative.
Owner
Where in use
Size
Serial number
Year of manufacture
Operating voltage
Control voltage
Frequency
Wiring diagram number
Tab. 1
Fig. 1 Example type plate
Item Designation
1Manufacturer see above
2Chain hoist type ⇒ "Model code", Page 17,
⇒ "Selection table", Page 18
3Serial no., calendar week, year
of manufacture
4SWL, group of mechanism ⇒ "Model code", Page 17,
⇒ "Selection table", Page 18
5Chain type, hook path
⇒ "Available hoist chains", Page 83,
⇒ "Model code", Page 17,
⇒ "Selection table", Page 18
6Voltage, frequency ⇒ "Hoist motor data ", Page 20
7Type of enclosure, insulation
class
⇒ "Operating conditions", Page 28,
⇒ "Hoist motor data ", Page 20
8Ambient temperature ⇒ "Operating conditions", Page 28
9Motor type ⇒ "Selection table", Page 18,
⇒ "Hoist motor data ", Page 20
10 Electrical key values ⇒ "Hoist motor data ", Page 20
11 Conformity symbol
12 Manufacturer address see above
Tab. 2
2
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Table of contents
General........................................................................................................................................................................ 7
DC-Com chain hoist .................................................................................................................................................... 7
DC-Com documentation.............................................................................................................................................. 7
Symbols/signal words.................................................................................................................................................. 7
Information on the operating instructions .................................................................................................................... 8
Liability and warranty................................................................................................................................................... 8
Copyright ..................................................................................................................................................................... 9
Use of spare parts ....................................................................................................................................................... 9
Definition of personnel................................................................................................................................................. 9
Test and inspection booklet....................................................................................................................................... 10
After-sales service..................................................................................................................................................... 10
Safety ........................................................................................................................................................................ 11
General...................................................................................................................................................................... 11
Safety signs on the equipment .................................................................................................................................. 11
Intended use.............................................................................................................................................................. 11
Hazards which may be caused by the machine ........................................................................................................ 12
Responsibility of the owner ....................................................................................................................................... 13
Operating personnel requirements ............................................................................................................................ 13
Personal protection equipment.................................................................................................................................. 14
Emergency stop device ............................................................................................................................................. 14
Regular inspections................................................................................................................................................... 14
Technical data ........................................................................................................................................................... 16
Design overview ........................................................................................................................................................ 16
Model code................................................................................................................................................................ 17
Selection table........................................................................................................................................................... 18
Electrical key values.................................................................................................................................................. 20
Hoist motor data ....................................................................................................................................................... 20
Mains connection delay fuse links............................................................................................................................. 23
Supply lines ............................................................................................................................................................... 23
Hook dimensions C ................................................................................................................................................... 24
Noise emission / sound pressure level...................................................................................................................... 26
Transport, packing and storage................................................................................................................................. 26
Safety instructions ..................................................................................................................................................... 26
Scope of delivery....................................................................................................................................................... 26
Transport inspection.................................................................................................................................................. 26
Packing...................................................................................................................................................................... 26
Storage ..................................................................................................................................................................... 27
Surface protection and painting................................................................................................................................. 27
Operating conditions ................................................................................................................................................. 28
Technical description................................................................................................................................................. 29
Drive and brake ......................................................................................................................................................... 29
Gearbox and slipping clutch ..................................................................................................................................... 29
Chain drive ............................................................................................................................................................... 30
Housing .................................................................................................................................................................... 30
Electrical equipment .................................................................................................................................................. 30
Control....................................................................................................................................................................... 30
7-segment display for operating status and error display.......................................................................................... 31
Software version, operating hours, number of cycles, operating statuses ................................................................ 31
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
3.1
3.2
3.3
3.4
3.4.1
3.4.2
3.4.3
3.5
3.6
3.7
3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
3.8
3.9
4
4.1
4.2
4.3
4.4
4.5
4.5.1
4.5.2
4.5.3
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3

Central service enclosure.......................................................................................................................................... 32
Control pendant height adjustment / control cable .................................................................................................... 33
Control pendant ........................................................................................................................................................ 33
Suspension................................................................................................................................................................ 34
Trolley........................................................................................................................................................................ 36
Fitting......................................................................................................................................................................... 39
General...................................................................................................................................................................... 39
Safety instructions for assembly................................................................................................................................ 39
Tightening torques DC-Com chain hoist ................................................................................................................... 41
Assembly procedure.................................................................................................................................................. 41
Connecting the control pendant ................................................................................................................................ 42
Suspending the chain hoist ....................................................................................................................................... 43
Supporting structure .................................................................................................................................................. 43
Suspension bracket................................................................................................................................................... 44
Control cable ............................................................................................................................................................. 45
Techncal data of the control cable ............................................................................................................................ 45
Handling the control cable......................................................................................................................................... 45
Height adjustment of the control pendant.................................................................................................................. 46
Mobile control system................................................................................................................................................ 47
Line connection ......................................................................................................................................................... 48
Circuit diagrams and control cards............................................................................................................................ 50
Circuit diagram DC-Com 1 - 10 solo hoist................................................................................................................. 50
Circuit diagram with E 11 - E 34 travel drive ............................................................................................................ 53
Control card............................................................................................................................................................... 53
Setting parameters with the control pendant............................................................................................................. 55
General...................................................................................................................................................................... 55
Meaning of keys ........................................................................................................................................................ 55
Meaning of parameters ............................................................................................................................................. 55
Starting parameter setting mode ............................................................................................................................... 56
Setting the lower hook position ................................................................................................................................. 58
Putting into service for the first time .......................................................................................................................... 59
Safety instructions when first putting the unit into service......................................................................................... 59
Inspection regulations ............................................................................................................................................... 59
Inspection prior to putting into service for the first time ............................................................................................. 60
Inspections when first putting into service, handing over .......................................................................................... 60
Operation................................................................................................................................................................... 61
Safety instructions for operation................................................................................................................................ 61
Switching on .............................................................................................................................................................. 62
Inspections when starting work ................................................................................................................................. 62
Functional tests ......................................................................................................................................................... 62
Operation................................................................................................................................................................... 63
General...................................................................................................................................................................... 63
Emergency stop ........................................................................................................................................................ 66
Taking out of service ................................................................................................................................................. 67
Taking out of service in the case of faults ................................................................................................................. 67
Taking the hoist out of service on finishing work....................................................................................................... 67
Taking the unit out of service for maintenance and repairs....................................................................................... 67
Maintenance/repair.................................................................................................................................................... 68
4.6
4.7
4.8
4.9
4.10
5
5.1
5.2
5.3
5.4
5.5
5.6
5.6.1
5.6.2
5.7
5.7.1
5.7.2
5.7.3
5.7.4
5.8
5.9
5.9.1
5.9.2
5.9.3
5.10
5.10.1
5.10.2
5.10.3
5.10.4
5.11
6
6.1
6.2
6.3
6.4
7
7.1
7.2
7.2.1
7.2.2
7.3
7.3.1
7.4
7.5
7.5.1
7.5.2
7.5.3
8
4
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Safety Instructions for maintenance/repair ................................................................................................................ 68
Basic information on maintenance ............................................................................................................................ 69
Routine inspections ................................................................................................................................................... 70
Prescribed inspections .............................................................................................................................................. 70
Service life of the contactor ....................................................................................................................................... 70
Measures for achieving safe working periods S.W.P. ............................................................................................... 71
General...................................................................................................................................................................... 71
Calculating the actual duration of service S .............................................................................................................. 71
Example: DC-Com 10-1000 1/1 H5 V4/1 in 1Am ...................................................................................................... 72
General overhaul GO ................................................................................................................................................ 74
Inspection and maintenance schedule ...................................................................................................................... 74
Maintenance work ..................................................................................................................................................... 76
Suspension................................................................................................................................................................ 76
Electrical equipment cover ........................................................................................................................................ 76
Dismantling the chain collector box........................................................................................................................... 77
Operating limit switch (as standard for DC-Com 10 reeving 2/1) .............................................................................. 77
Checking the operating limit switches ....................................................................................................................... 77
Checking the operating limit switch actuator ............................................................................................................. 78
Chain drive ................................................................................................................................................................ 79
Checking the sprocket wheel .................................................................................................................................... 79
Checking the chain guide .......................................................................................................................................... 79
Checking the guide plate........................................................................................................................................... 79
Checking the hoist chain ........................................................................................................................................... 79
Scope of supply chain set ......................................................................................................................................... 82
Available hoist chains................................................................................................................................................ 83
Replacing the chain set ............................................................................................................................................. 84
Lubricating the hoist chain......................................................................................................................................... 87
Load hook.................................................................................................................................................................. 88
Checking the load hook ............................................................................................................................................. 88
Checking the return sprocket .................................................................................................................................... 88
Replacing the hook assembly, reeving 1/1................................................................................................................ 89
Replacing the (standard) bottom block with internal switch-off springs, reeving 2/1................................................. 90
Replacing the (optional) bottom block with external switch-off springs, reeving 2/1 ................................................. 91
Buffer (only with optional operating limit switches for DC-Com 1-10 reeving 1/1) .................................................... 91
Checking the swich-off buffer / switch-off spring ....................................................................................................... 91
Buffer design ............................................................................................................................................................. 92
Brake ......................................................................................................................................................................... 94
Brake assignment...................................................................................................................................................... 94
Check brake wear ..................................................................................................................................................... 94
Slipping clutch ........................................................................................................................................................... 96
Checking the slipping clutch...................................................................................................................................... 96
Adjusting the slipping clutch ...................................................................................................................................... 96
Gearbox / oil change ................................................................................................................................................. 97
Replacing the contactor on the control card.............................................................................................................. 98
Replacing cables ..................................................................................................................................................... 100
Replacing the control cable ..................................................................................................................................... 100
Faults / Warnings .................................................................................................................................................... 102
Safety instructions for faults / warnings................................................................................................................... 102
7-segment display ................................................................................................................................................... 103
General messages .................................................................................................................................................. 103
Warning messages.................................................................................................................................................. 104
Error messages ....................................................................................................................................................... 105
Disassembly / Disposal ........................................................................................................................................... 106
General.................................................................................................................................................................... 106
8.1
8.2
8.3
8.3.1
8.3.2
8.3.3
8.3.3.1
8.3.3.2
8.3.3.3
8.3.4
8.4
8.5
8.5.1
8.5.2
8.5.3
8.5.4
8.5.4.1
8.5.4.2
8.5.5
8.5.5.1
8.5.5.2
8.5.5.3
8.5.5.4
8.5.5.5
8.5.5.6
8.5.5.7
8.5.5.8
8.5.6
8.5.6.1
8.5.6.2
8.5.6.3
8.5.6.4
8.5.6.5
8.5.7
8.5.7.1
8.5.7.2
8.5.8
8.5.8.1
8.5.8.2
8.5.9
8.5.9.1
8.5.9.2
8.5.10
8.5.11
8.5.12
8.5.12.1
9
9.1
9.2
9.3
9.4
9.5
10
10.1
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5

Accessories ............................................................................................................................................................. 107
Assemblies .............................................................................................................................................................. 107
Spare parts.............................................................................................................................................................. 108
Overview ................................................................................................................................................................. 108
Motor ....................................................................................................................................................................... 109
Parts on gearbox ..................................................................................................................................................... 110
Chain drive .............................................................................................................................................................. 112
Hook assembly........................................................................................................................................................ 114
Bottom block with internal switch-off springs (standard) ......................................................................................... 115
Bottom block with external switch-off springs (option) ............................................................................................ 116
Electrical equipment cover ...................................................................................................................................... 117
Control pendant, control cable, service cover ......................................................................................................... 118
Index......................................................................................................................................................................................... 119
11
11.1
12
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
6
21480244/181209

1 General
1.1 DC-Com chain hoist
You have purchased a Demag quality product.
This chain hoist was manufactured to European standards and regulations in accordance with state-of-the-art en‐
gineering principles. The requirements of the EC directive are complied with.
1.2 DC-Com documentation
Further documents are available for sub-assemblies/components in addition to these operating instructions. If re‐
quired, the corresponding documents are supplied or can be ordered separately, even if special designs or additional
options deviating from these operating instructions are ordered.
Documents1) Part no.:
Technical data / Catalogues
Demag DC-Pro 1 - 25 chain hoist
Demag DCS-Pro 1 - 10 chain hoist 203 525 44
Demag DC-Com chain hoist 203 571 44
CF5-DC/DCM trolley 203 568 44
U11-DC/DCM/DK trolley 203 569 44
E11-E34 DC travel drive (circuit diagrams) 203 698 44
RU/EU56 trolley 203 691 44
Electrical accessories DC 203 656 44
Electrical accessories POLU box 203 682 44
Clamp-fitted buffers 203 313 44
Operating instructions
DC-Pro 1 - 10 chain hoist 214 741 44
DC-Pro 16 - 25 chain hoist 211 033 44
DC-Com chain hoist 214 802 44
DCS-Pro chain hoist 214 827 44
DC-Di chain hoist 211 068 44
DC-Wind chain hoist 211 010 44
KDC chain hoist 211 017 44
Assembly - Setting - Dimensions
E11-E34 DC travel drive 214 810 44
DRC-DC radio remote control 214 689 44
DRC-DC brief instructions 211 045 44
DC geared limit switch 211 011 44
PGS parallel grippers 214 095 44
Friction force checking device 206 973 44
DC PWM/3ST signal converter 211 094 44
DSC-EX control pendant 214 832 44
DSE10-C control pendant 214 998 44
DC protective sleeve 203 673 44
DC tandem box 211 108 44
VG11-34 EU11-34 dual-output gearbox 211 122 44
DSC strain relief 211 092 44
DC test and inspection booklet 214 745 44
Certificates 235 309 44
Tab. 3
1.3 Symbols/signal words
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.
1) The documents can be ordered from the relevant Demag office.
21480244/181209
7

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.
– 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 the appropriate use of the machine.
● This symbol in the operating instructions indicates all warnings which, if not complied with, may result in mal‐
functions or damage.
1.4 Information on the operating instructions
These operating instructions are an integral part of the machine. They describe the safe and appropriate use of the
machine.
These operating instructions are designed to provide the owner and operator with useful instructions for transpor‐
tation, putting into service, operation and maintenance of our chain hoists.
Persons entrusted with this work must know and comply with the safety regulations and the operating instructions.
The machine may only be operated by personnel who are fully familiar with the operating instructions. In particular,
this includes the "Safety" chapter and the relevant safety instructions in the working sections of these operating
instructions. 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 immediate vicinity.
1.5 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 chain hoist, especially
before it is put into service for the first time. The manufacturer does not assume any liability for damage resulting
from the following:
● non-compliance with the operating instructions,
● inappropriate use,
● untrained personnel,
● unauthorized conversions,
● technical modifications.
Wearing parts are not subject to liability for defects.
8
21480244/181209

We reserve the right to incorporate technical modifications within the scope of improving the operating characteristics
and further development of the product.
1.6 Copyright
These operating instructions are only intended to be used by people who work with or on the chain hoist.
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 damages.
Further rights reserved.
All industrial rights reserved.
1.7 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 installation.
Spare parts not approved by us may cause unpredictable hazards, damage, malfunctions or complete failure of the
chain hoist.
The use of unauthorized spare parts may render any claims for guarantee, service, damages or liability against the
manufacturer or his appointed personnel, dealers and representatives null and void.
1.8 Definition of personnel
Manufacturer
The manufacturer is the person who
– manufactures equipment under his name and places it on the market for the first time;
– resells equipment of others under his name; however the reseller shall not be considered as manufacturer, if
the name of the manufacturer (under 1.) appears on the equipment;
– imports equipment to Germany and places it on the market for the first time or
– exports equipment into another member state of the European Union and makes it directly available to a user.
Owner
Owners (employer, company) are defined as persons who own the machine and who use it appropriately or allow
it to be operated by suitable and trained persons.
Operating personnel/operator
Operating personnel or machine operators are defined as persons entrusted by the owner of the machine with
operation of the equipment. The person must be trained by the owner in accordance with the tasks to be performed.
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. The 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. The person must be trained by the owner in accordance
with the tasks to be performed.
21480244/181209
9

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 valid standards, codes of practice and regulations, are
able to assess the tasks given to them and to identify and eliminate potential hazards. The 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 sufficient
knowledge in the field of the machine. They must be 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 machines.
Assigned expert engineer (in the Federal Republic of Germany according to BGV D8, § 23, for determining 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 (S.W.P. = safe working period) and to carry out a general overhaul of
machines.
Authorized expert engineer (according to BGV D6, § 28 in Germany)
In addition to the expert engineers of the Technical Supervisory and Inspection Board, an authorized expert engineer
for the inspection of machines is defined as an expert engineer authorized by the Industrial Employers’ Mutual
Insurance Association.
1.9 Test and inspection booklet
A test and inspection booklet filled in with all details must be available for the hoist (in the Federal Repblic of Germany
according to BGV D6, § 28). The results of the regular tests and inspections must be entered into the test and
inspection booklet and must be certified by the inspector. Test and inspection booklet ident. no.: ⇒ Tab. 3, Page
7
1.10 After-sales service
Our after-sales service will provide you with technical information on our products, 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 these data ensures that you receive the correct information or the
required spare parts.
Demag Cranes & Components GmbH
Telefon +49 (0)180 / 5 - 741268
www.demagcranes.com
10
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2Safety
2.1 General
The "Safety" chapter provides an overview of all important safety aspects for optimum protection of personnel as
well as for safe and reliable operation of the machine.
At the time of placing it on the market the machine has been built according to the state-of-the-art and is considered
as safe to operate. However, it may cause hazards if it is used inappropriately by personnel which have not been
trained specially.
Knowledge of the contents of the operating instructions are one of the requirements necessary to protect personnel
from hazards and to avoid malfunctions and, therefore, to operate the machine safely and reliably.
Modifications of any kind and additions to or conversions of the machine must not be carried out without the written
consent of Demag.
2.2 Safety signs on the equipment
43229044.eps
Fig. 2
Any pictograms, signs or labels on the machine must be obeyed and must
not be removed. Pictograms, signs or labels that are damaged or no lon‐
ger legible must be replaced immediately.
2.3 Intended use
The machine may only be used as intended and in compliance with the requirements for the owner resulting from
these operating instructions and the following limitations. Any other use may result in a danger to life and limb and/
or cause damage to the machine and/or the load.
● Chain hoists are only intended for lifting, lowering and moving loads and may be used as stationary or travelling
units.
● The suspension/support structure for the chain hoist must be designed for loads caused by operation of the chain
hoist. The maximum safe working load is the load capacity specified on the capacity plate. This must not be
exceeded. The maximum permitted load of the chain hoist includes the load and the load handling attachment.
● The machine may only be installed, operated, maintained and removed when in perfect working order by trained
personnel. The personnel must meet the requirements according to ⇒ "Operating personnel requirements",
Page 13.
● Appropriate use includes compliance with the safety instructions as well as any other instructions on assembly
and disassembly, commissioning, function and operation, maintenance and fault elimination as well as compli‐
ance with the instructions on the machine safety devices, any possible remaining hazards and protection against
hazards.
● The machine may only be used in compliance with the permissible technical data, ⇒ "Technical data",
Page 16.
● The machine must be maintained appropriately at the specified regular intervals and inspected according to
⇒ "Inspection and maintenance schedule", Page 74 by specially trained personnel. Wear parts must be ex‐
changed in good time.
● The accident prevention regulations UVV/BGV D8 §23 (2) and/or BGV D6 (1) must be complied with.
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 machine in the sense of the "Intended use" section.
No liability in the case of structural modifications
21480244/181209
11

The manufacturer is not liable for unauthorized 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 delivery, or
the installation or use of accessories, equipment or sub-assemblies of other manufacturers that are not approved
by the manufacturer.
Depending on the type and scope of the machine, an inspection must be carried out by an expert engineer before
handing it over to the owner.
DC-Com chain hoist are designed for operation at temperatures of -20 °C up to +40 °C. At extreme temperatures
and in aggressive atmophere or under conditions deviating from the section "Operating conditions", special meas‐
ures must be taken by the owner in agreement with Demag.
Use of the control pendant
Powered lifting and lowering and, if applicable, cross-travel and long-travel motions are controlled by means of the
corresponding 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, as it causes increased wear and load sway.
2.4 Hazards which may be caused by the machine
The machine has been subject to a risk assessment. The design and execution based on this analysis corresponds
to state-of-the-art engineering principles. Nevertheless there are residual risks!
The machine is operated at high electrical voltage.
DANGER
Live components
Danger to life and limb.
Electrical energy may cause serious injuries. If the insulation or individual components are damaged, there is
danger to life caused by electrical current.
– Before carrying out maintenance, cleaning or repair work, switch off the machine and secure against restarting.
– Switch off the power supply when carrying out any work on the electrical installation. Check the components
to be replaced for being de-energized.
– Do not remove safety equipment or render it inoperative by modifications.
WARNING
Crushing hazard
The lifting or lowering of loads may cause crushing hazards for parts of the body.
When lifting or lowering loads, it must be ensured that no persons are in the immediate danger zone.
WARNING
Suspended load! Falling parts!
There is danger to life and limb, when suspended loads fall down.
Persons must keep out of the danger zone.
– Keep a sufficient safety distance.
– Do not walk under the 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. Please note the safety instructions in the chapters:
●⇒ "Fitting", Page 39
●⇒ "Putting into service for the first time", Page 59
12
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●⇒ "Operation", Page 61
●⇒ "Maintenance/repair", Page 68
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 man‐
ufactured. 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 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 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 the organization of work, working procedures, authorized personnel, supervising and reporting
obligations, etc. For further information please refer to ⇒ "Safety instructions for operation", Page 61.
Furthermore, the owner must ensure that
● any futher working and safety instructions resulting from 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 the operation of cranes and lifting applinces are observed.
● the specified regular checks and inspections are carried out on time and are documented.
The owner is urged to develop procedures and guidelines to cover malfunction situations, to instruct users and to
apply these instructions at a suitable place in a readily legible manner.
2.6 Operating personnel requirements
Only authorised and trained personnel may operate 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 is started.
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 (trained maintenance fitter) of the DC-Com chain,
the owner may only employ persons
● who are at least 18 years of age,
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● who are mentally and physically suitable,
● who have been instructed in the operation and maintenance of chain hoists and who have proven their qualification
to the owner in this respect.
2.7 Personal protection equipment
When work is carried out on or with the machine, the following must always be worn:
● Protective clothing, closely-fitting working clothes (low tear strength, no loose sleeves, no rings or any other
jewellery, etc.);
● Safety shoes to protect against heavy falling parts and against slipping;
● Safety helmet to be worn by everybody in the danger zone;
2.8 Emergency stop device
Fig. 3 Position of the emergency stop device (1)
To prevent damage and injuries, the machine is fitted with an emergency-stop device (1). This is located on the
control unit. The emergency-stop operating function must be checked regularly.
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, lifting and
towing devices (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.
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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.
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3 Technical data
3.1 Design overview
Fig. 4 Single-fall design
Item Designation Item Designation Item Designation
1Electrical equipment cover 11 Chain guide 21 Adjusting mechanism for control cable
2Control 12 Sprocket 22 Switch-off buffer for operating limit
switch 2)
3Operation hours counter 13 Round section steel chain 23 Hook assembly with capacity plate 2)
4Window 2) 14 Slipping clutch 24 Motor shaft
5Pulse wheel for speed monitoring 15 Dished washer pack 25 Winding head cap
6Magnet brake 16 Slipping clutch adjusting nut 26 Stator
7Brake disk with linings 17 DC 1 - 5 two-stage helical gearbox
DC 10 three-stage helical gearbox 27 Rotor
8Brake springs 18 Suspension bracket 28 Fan
9Brake magnet 19 Suspension bolt 29 Fan cover
10 Gearbox housing 20 Service cover 30 Mounting points
Tab. 4
2) Figure deviating from scope of supply
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3.2 Model code
E K L D DC-Com 10 - 2000 2/1 H5 V6/1,5 380 - 415 / 50 24/6 200 220 - 480
Voltage range / Voltage
travel drive[V]
Max. flange width of trolley [mm]
Travel speed [m/min]
Frequency [ Hz ]
Voltage range chain hoist [V]
Hoist speed [m/min]
V2-stage = Main / creep lifting
VS Stepless = VS at nominal load up to VS
max
in the partial load range
Hook path [m]
Reeving
Load capacity [kg]
Size 3)
DC-Pro 2-stage chain hoist (Demag chain hoist) DC-ProDi 2-stage chain hoist for direct control
DCM-Pro 2-stage Manulift DC-ProFi Variable speed chain hoist for control by
means of an external frequency inverter
DCS-Pro Variable speed chain hoist
DCMS-Pro Variable speed Manulift
DCRS-Pro Rocker switch stepless DC-Com 2-stage chain hoist basic version
DArticulated curve-running trolley
L Long monorail hoist
K Low headroom monorail hoist
U Standard-headroom monorail hoist
11 Trolley size load capacity [kg • 100]
22
34
56
R Push-travel trolley
E Travel drive
C F 5 Click-Fit (push-travel trolley)
Tab. 5
Not all features of the mounting code can be combined.
3) The designations of sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1 since 04/2006.
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3.3 Selection table
SWL Size 4) Reeving Group of mecha‐
nisms
Hoist speed Standard
hook path5)
Motor size 6) Max. weight
at hook path
Chain hoist DIN EN 14492 at 50 Hz at 60 Hz H4 m 5 m 8 m
[kg] DC-Com FEM / ISO [m/min] [m/min] [m] [kg] [kg] [kg]
80
1
1/1
3m/M6
8,0/2,0 9,6/2,4
4, 5 and 8
ZNK 71 A 8/2 7)
21 22 24
100
2m/M5125
160
26,0/1,5 7,2/1,8 ZNK 71 B 8/2200 1Am/M4
250
315
5
2m/M5
4,5/1,1 5,4/1,3 ZNK 80 A 8/2 27 28 30400 1Am/M4
500
630
10
2m/M5
4,0/1,0 4,8/1,2
ZNK 100 A 8/2 47 48 52800 1Am/M4
1000
1250
2/1
2m/M5
ZNK 100 B 8/2 63 65 731600 1Am/M4
2000
Tab. 6
Hoist speeds until 09/2008 (no longer available)
SWL Size Reeving Group of mecha‐
nisms
Hoist speed Standard
hook path5)
Motor size 6) Max. weight
at hook path
Chain hoist DIN EN 14492 at 50 Hz at 60 Hz H4 m 5 m 8 m
[kg] DC-Com FEM / ISO [m/min] [m/min] [m] [kg] [kg] [kg]
160
2
1/1
2m/M5
4,0/2,0 4,8/2,4 4, 5 and 8
ZNK 71 B 8/4 21 22 24
200 1Am/M4
250
315
5
2m/M5
ZNK 80 A 8/4 27 28 30
400 1Am/M4
500
Tab. 7
4) The designations of sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1 since 04/2006.
5) Larger hook paths on request.
6) Motor data ⇒ "Hoist motor data ", Page 20.
7) ZNK 71 A 8/2 with 380-415 V / 50 Hz only for initial delivery; for replacement requirements, the motor is replaced by the ZNK 71 B 8/2 motor.
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3.4 Electrical key values
3.4.1 Hoist motor data
Size Motor size No. of
poles
P
N
CD
F
n
N
Starts/h Min. / max. currents and starting current
I
N min.
I
N max.
I
max
8) I
A
/I
N max.
cos
φN
[kW] [%] rpm [A] [A] [A]
220-240 V, 50 Hz, 3 ~ (CE) 9)
DC-Com 1 ZNK 71 B 8/2 80,05 20 720 240 1,75 2,10 2,10 1,45 0,48
20,18 40 2950 120 2,10 2,80 2,80 2,75 0,46
DC-Com 2 ZNK 71 B 8/2 80,07 15 695 240 1,80 2,10 2,35 1,45 0,52
20,30 25 2880 120 2,30 2,80 3,20 2,75 0,55
DC-Com 5 ZNK 80 A 8/2 80,10 15 720 240 1,90 1,90 2,15 2,50 0,46
20,41 25 2910 120 3,60 4,70 5,50 4,70 0,49
DC-Com 10
ZNK 100 A 8/2 80,19 15 705 240 2,80 3,10 3,65 1,90 0,48
20,75 25 2850 120 3,50 4,00 4,50 4,85 0,65
ZNK 100 B 8/2 80,37 15 735 240 -
21,50 25 2955 120
380-415 V, 50 Hz, 3 ~ (CE) 9)
DC-Com 1
ZNK 71 A 8/2 10) 80,05 20 700 240 0,95 1,10 1,10 1,20 0,66
20,18 40 2840 120 1,20 1,40 1,40 2,60 0,57
ZNK 71 B 8/2 80,05 20 700 240 1,00 1,20 1,20 1,45 0,48
20,18 40 2840 120 1,20 1,60 1,60 2,75 0,46
DC-Com 2 ZNK 71 B 8/2 80,10 20 675 240 1,00 1,20 1,35 1,45 0,52
20,37 40 2825 120 1,30 1,60 1,85 2,75 0,55
DC-Com 5 ZNK 80 B 8/2 80,18 20 665 240 1,10 1,10 1,25 2,50 0,46
20,72 40 2745 120 2,10 2,70 3,20 4,70 0,49
DC-Com 10
ZNK 100 A 8/2 80,27 20 690 240 1,60 1,80 2,10 1,90 0,48
21,10 40 2745 120 2,00 2,30 2,60 4,85 0,65
ZNK 100 B 8/2 80,57 20 675 240 3,90 4,60 5,40 2,30 0,42
22,30 40 2790 120 5,40 6,30 7,70 5,10 0,49
500-525 V, 50 Hz, 3 ~ (CE/CSA) 9)
DC-Com 1 ZNK 71 B 8/2 80,05 20 720 240 0,75 0,95 0,95 1,45 0,48
20,18 40 2925 120 0,90 1,25 1,25 2,75 0,46
DC-Com 2 ZNK 71 B 8/2 80,10 20 675 240 0,80 0,95 1,10 1,45 0,52
20,37 40 2825 120 1,10 1,25 1,45 2,75 0,55
DC-Com 5 ZNK 80 B 8/2 80,18 20 665 240 0,90 0,90 1,00 2,50 0,46
20,72 40 2745 120 1,70 2,15 2,55 4,70 0,49
DC-Com 10
ZNK 100 A 8/2 80,27 20 690 240 1,30 1,40 1,70 1,90 0,48
21,10 40 2745 120 1,70 1,80 2,00 4,85 0,65
ZNK 100 B 8/2 80,57 20 675 240 3,30 3,70 4,30 2,27 0,42
22,30 40 2790 120 4,15 5,00 6,10 5,13 0,49
Tab. 8
8) I
max
= maximum rated current for lowering operation.
9) The tolerance of the voltage range must not exceed ± 10%. Motors are designed in compliance with insulation class F.
10) ZNK 71 A 8/2 with 380-415 V / 50 Hz only for initial delivery; for replacement requirements, the motor is replaced by the ZNK 71 B 8/2 motor.
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