Académique Documents
Professionnel Documents
Culture Documents
This document must always be used together with our DC chain hoist operating instructions
Contents 0 Foreword 3
1 Safety instructions 3
2 Installation diagrams 4
3 Electrical enclosures 10
3.1 3TK signal converter 10
3.2 KT3 signal converter 13
3.3 DT3 signal converter 16
3.4 DC Polu-Box 18
3.5 DC terminal box 20
3.6 3T3 terminal box 21
3.7 Manual crab terminal box 22
3.8 DC terminal box 2 23
3.9 Diode terminal box 26
3.10 KRBG crane bridge enclosure 28
3.11 KRBG2 crane bridge enclosure with DC Polu-Box 29
4 Accessories 30
20365644.indd/040906
2
0 Foreword
The electrical equipment serves to convert signals between DC chain hoists with
Tri-State signal transmission and crane systems that are fitted with conventional
electrical contactor interfaces. Furthermore, the terminal boxes are described
which are required when differing conductor cross-sections are connected and for
parallel operation of chain hoists. The DC Polu-Box is used as a contactor control
arrangement for AC drives (for example for slewing cranes with a slewing drive).
The signal converter, terminal box and DC Polu-Box can be fitted to the DC chain
hoist motor. It may be necessary to fit them in a different position depending on
any other equipment (Harting connector in the power supply line, for example).
All sub-assemblies are described in detail and provided with connection diagrams
for application examples in the relevant sections.
1 Safety instructions
This document must always be used together with our DC chain hoist operating
instructions.
20365644.indd/040906
3
2 Installation diagrams
Old
Long-travel motor 1 Long-travel motor 2
Crane enclosure,
DK 5-20 Cross-travel also incl. transformer
motor and contactor
Line
New
Long-travel motor 1 Long-travel motor 2
Crane enclosure,
DC E11, E22, E34 also incl. transformer
trolley and contactor
Line and signal
Line
42691944.jpg
New 2 Control cable 10-pole 1,5m 720 070 45 Travel unit cable
3 Control cable 10-pole 1,5m 772 062 45 Plug connection, to DC chain hoist -X31
4 Round cable YMHYK-J 4x1,5 504 931 44 to the trolley
KT3 box 772 077 45 42 - 115 V control voltage
5 Signal converter
4 DT3 box 772 066 45 230 V control voltage
DK5 to DK20 with contactor control, mobile control pendant, pole-changing travelling hoist
42 - 115 V control voltage, see section 3.2, 3.4 for description and wiring example
230 V control voltage, see section 3.3, 3.4 for description and wiring example
Old
Long-travel motor 1 Long-travel motor 2
Line
New
Long-travel motor 1 Long-travel motor 2
Crane enclo-
sure, also incl.
DC DC Polu-Box transformer and
contactor
Cross-travel motor
with trolley
Line
42692044.jpg
Old Item Designation Part no. Function
1 Connection cable 720 072 45 Line cable
New 2 Control cable 10-pole 1,5m 720 070 45 Travel unit cable
20365644.indd/040906
3 Control cable 10-pole 1,5m 772 062 45 Plug connection, to DC chain hoist -X31
4 Round cable YMHYK-J 4x1,5 504 931 44 to the trolley DC Polu-Box
KT3 box 772 077 45 42 - 115 V control voltage
5 Signal converter
DT3 box 772 066 45 230 V control voltage
6 Housing DC Polu-Box 720 080 45 5
DK5 to DK20 with contactor control, control pendant on the chain hoist
42 - 230 V control voltage, see section 3.1 for description and wiring example
Old
Long-travel motor 1 Long-travel motor 2
Crane enclosure,
DK 5-20 Cross-travel also incl. transformer
motor and contactor
Line
New
Long-travel motor 1 Long-travel motor 2
Crane enclosure,
DC E11, E22, E34 also incl. transformer
trolley and contactor
Line and signal
3TK
42-230 V
Line
DSE 8-C
height adjustable
42692144.jpg
20365644.indd/040906
Old
Long-travel motor 1 Long-travel motor 2
Crane enclosure,
Cross-travel also incl. transformer
DK 5-20
motor and contactor
Line
New
Long-travel motor 1 Long-travel motor 2
Crane enclo-
sure, also incl.
DC DC Polu-Box transformer and
contactor
Cross-travel motor
with trolley
Line and signal
3TK
42-230 V
Line
DSE 8-C
height adjustable
42693744.jpg
DC 1 DC 2
E11, E22, E34 E11, E22, E34
DC 1 DC 2
trolley trolley
DC terminal
Line and signal ○
11
DC terminal
box box
4-pole line
Signal
9
3 Electrical enclosures
1 4
2 6
3 5
Description Is used for converting “tri-state” signals into floating contacts. Includes the For-
ward, Reverse, Fast, Right, Left, Fast, Special signal_1, Special signal_2, Emer-
gency-stop (safety relay) contacts. Transformer for control voltage connection: 42
V, 48 V, 115 V, 230 V. Wiring via RJ45 sockets and cage clamp terminals.
Application Use: For replacing DK and existing contactor control, control pendant on DC.
10
DK5 to DK20 Wiring example for 115 V control voltage, control pendant on the chain hoist,
with contactor control system replacement of the travelling hoist
Emergency stop
Control voltage
Back
Fast
Forwards
Reference
(115 V)
42693144.jpg
11
DK5 to DK20 Wiring example for 42 - 230 V control voltage, control pendant on the chain hoist,
with contactor control system pole-changing travelling hoist, replacement of the hoist (travel drive is kept)
Emergency stop
Control voltage
Back
Fast
Forwards
Reference
(115 V)
Trolley with
DC-Polu
42693144.jpg
12
3.2 KT3 signal converter
KT3 → Conventional To 3-state
1
4
Description Is used for converting control pendant contacts into tri-state signals. Creates float-
ing Lift, Lower, Right (forwards), Left (reverse) tri-state signals. Permissible volt-
ages: 42, 48, 110 and 115 V. Wiring via RJ45 sockets and cage clamp terminals.
Application Use: For replacing DK and existing contactor control, travelling control pen-
dant.
13
DK5 to DK20 Wiring example for 42 / 48 V control voltage, mobile control pendant,
with contactor control system replacement of the travelling hoist
42 / 48 V signals
Reference (42-48 V)
42693244.jpg
DK5 to DK20 Wiring example for 110 / 115 V control voltage, mobile control pendant,
with contactor control system replacement of the travelling hoist
42 / 48 V signals
Reference (42-115 V)
Fast
Left
Right
Fast
Lowering
Lifting
42693344.jpg
14
DK5 to DK20 Wiring example for 42 / 48 V control voltage, mobile control pendant,
with contactor control system pole-changing travelling hoist, replacement of the hoist (travel drive is kept)
42 / 48 V signals
Reference (42-115 V)
42693544.jpg
DK5 to DK20 Wiring example for 110 / 115 V control voltage, mobile control pendant,
with contactor control system pole-changing travelling hoist, replacement of the hoist (travel drive is kept)
42 / 48 V signals
Fast
Left
Right
Fast
Lowering
Lifting
42693644.jpg
1
4
Description Is used for converting control pendant contacts into tri-state signals. Creates float-
ing Lift, Lower, Right (forwards), Left (reverse) tri-state signals. Permissible volt-
age: 230 V. Wiring via RJ45 socket and cage clamp terminals.
16
DK5 to DK20 Wiring example for 230 V control voltage, mobile control pendant,
with contactor control system replacement of the travelling hoist
230 V signals
400 V signals
Lifting
Lowering
Fast
Right
Left
Fast
Reference (230 V)
42693244.jpg
DK5 to DK20 Wiring example for 230 V control voltage, mobile control pendant,
with contactor control system pole-changing travelling hoist, replacement of the hoist (travel drive is kept)
230 V signals
400 V signals
Lifting
Lowering
Fast
Right
Left
Fast
Reference (230 V)
42693544.jpg
3 6
7
1
2
9
4
8
10
42692644.jpg
Description Intelligent contactor control for DC systems with Tri-state control signals. Connec-
tion for power distribution, limit and fast-to-slow switches, pole-changing motor and
control signals to the chain hoist via RJ45 plug connection. The power supply can
be adjusted by ± 10% between 230 V and 575 V.
Application Use: Travel applications with squirrel-cage rotor motors, e.g. DRF 200
(Max. connection rating 1,5 kW; max. rated current 3,0 A).
18
Terminal No. Signal Terminal No. Signal
1 L3 1 Reference (24 V~)
2 L3 2 24 V~
3 L2 Control penadant input 3 Var. switches
-X7 signals via single con-
Power supply connec- 4 L2 ductors 4 Emergency stop
-X1
tion and routing 5 L1 5 Forwards
6 L1 6 Back
7 PE 1 Reference (24 V~)
8 PE Control pendant signals 2 Emergency stop
-X8
1 PE to the crane 3 Forwards
2 U1/U2 4 Back
3 V1 1 Fast-to-slow RIGHT -
-X3 Motor connection 4 W1 2 Fast-to-slow RIGHT +
5 V2 3 Lim. sw. RIGHT -
6 W2 4 Lim. sw. RIGHT +
-X9 Limit switch connection
7 Brake 5 Fast-to-slow LEFT -
1 Sensor + 6 Fast-to-slow LEFT +
-X4 Thermo contact
2 Sensor - 7 Lim. sw. LEFT -
-X5 Earth connection PE Flat pin 8 Lim. sw. LEFT +
1 Special 1 1 575V
2 Forwards 2 460V
Input voltage range
3 Back -X10 3 400V ±15%
setting
4 Emergency stop 4 230V
The terminals marked in grey are fitted with wire bridges when they leave the fac-
tory.
The wire bridge for the input voltage range -X10 muss must be assigned to the
available voltage, e.g. for 400V the bridge must be fitted from X10.5 to X10.3.
If the Polu-Box is used on a solo travelling hoist, a bridge must be fitted betwen
X7.2 and X7.3.
20365644.indd/040906
19
3.5 DC terminal box
Description Terminal strip with cage clamp terminals for power and control signals.
Application Use: e.g. connecting larger conductor cross-sections with smaller conductor
cross-sections (flat cable to RJ45 cable).
Power distribution, signal distribution
20
3.6 3T3 terminal box
Description Terminal strip with cage clamp terminals for power and control signals.
Application Use: e.g. connecting larger conductor cross-sections with smaller conductor
cross-sections (flat cable to RJ45 cable).
Power distribution
21
3.7 Manual crab
terminal box
Description Terminal strip with cage clamp terminals for power and control signals.
Application Use: e.g. connecting larger conductor cross-sections with smaller conductor
cross-sections (2 x busbar line connection or flat cable to RJ45 cable).
22
3.8 DC terminal box 2
Description Terminal strip with cage clamp terminals for power and control signals.
Application Use: Control pendant signals shared to two parallel chain hoists.
23
2 DC chain hoists parallel with monorail trolley
Line
Emergency
stop 1
Lowering 2
Lowering 1
Lifting 2
Lifting 1
V2
V2
V2
V2
42717745.jpg
Line
Emergency
stop 1
Selector
switch
20365644.indd/040906
Lowering 2
Lowering 1
Lifting 2
Lifting 1
Right 1
Right 2
Left 1
Left 2
V2
V2
V2
V2
V2
V2
V2
V2
24 42717744.jpg
Brief description of If 2 chain hoists are operated in parallel, hoist unit parameters 1 and 4 must be set
DC parameter programming to “y”.
(Issue 08/01/2004)
When parameter programming mode has been activated, the figures “0” – “9” are
each displayed successively for 4 seconds. Each figure represents a parameter.
The parameter is switched on with the “Lifting v2” key and switched off with the
“Lowering V2” key. The selected action is acknowledged with “Y” for “Yes or On”
or with an “N” for “No or Off”. In no key is actuated, the parameter remains un-
changed. If the parameter has sub-parameters, an “O” for “Open” is displayed. The
parameters are displayed with the characters “A”, “b”, “C”, “d”, “E” and “F”. Selec-
tion is also made with the “Lifting V2” or “Lowering V2” keys.
When the last parameter has been reached or when the “Emergency stop” key has
been actuated, the unit switches back to normal operation. All changes are first
saved.
25
3.9 Diode terminal box
1 2
Description Terminal strip with cage clamp terminals for power and control signals.
26
Terminal box with diode for hoist Wiring example
and trolley
By customer
Emergency stop
Lowering
Lifting
Right
Fast
Fast
Left
Supply cable
Emergency stop
Lowering
24 V AC
Lifting
Right
Left
1) Wire bridge
2) May consist of one cable
to the DC
42711144.jpg
27
3.10 KRBG crane bridge
enclosure
1 2 3
Description Is used to provide power supply for crane installations with DC systems (tri-state
signals) with crane switch contactor. Connection for power and signal distribution
to DC travel drives.
Application Use: Crane applications, e.g. KBK crane, pillar-mounted slewing jibs with DC
travel drives.
3 L3 10 Right
PE PE 11 Left
12 Lifting
13 Lowering
28
3.11 KRBG2 crane bridge
enclosure with DC
Polu-Box
1
Description Is used to provide power supply for crane installations with contactor control for DC
systems with tri-state control signals, crane switch contactor.
Connection for power distribution, limit and fast-to-slow switches, pole-changing
motor and control signals to the chain hoist via RJ45 plug connection.
Application Use: Crane applications, e.g. KBK crane, pillar-mounted slewing jibs with
squirrel-cage rotor motors.
3 L3 10 Right
PE PE 11 Left
12 Lifting
13 Lowering
14 Reference (24 V~) 29
4 Accessories
42717844.jpg
42718044.jpg
Size Motor l2 l3 h5
DC 1/2 ZNK 71 B 8/2 170 50
DC 5 ZNK 80 A 8/2 175
20365644.indd/040906
1
1
5 2
2
3
3
1 Connector enclosure
2 Plug adapter
3 Cable collector
4 Control pendant
5 Flat cable
42711244.jpg 42360744.jpg
31
Printed in Germany PDF 040906
Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Subject to change. No liability accepted for errors or omissions.