Technical data/accessories

Demag DC-Com chain hoist

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Distributed by Tri-State Equipment Company Inc.

Email: [email protected]
Web: www.tsoverheadcrane.com
PH: 314-869-7200 | FAX: 314-869-7226
191213 en GB 203 571 44 714 IS 817
 Manufacturer Demag Cranes & Components GmbH
PO Box 67 · 58286 Wetter, Germany
Phone +49 (0)2335 92-0
Telefax +49 (0)2335 92-7676

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➚

20357144.indd/191213

Guided 3D CAD geometry selection

2
 Contents 1 Chain hoist 4
1.1 General 4
1.2 Product characteristics at a glance 6
1.3 Selection criteria 8
1.4 Model code 10
1.5 DC documents 11
1.6 Design overview 12
1.7 Selection table 13
1.8 Hoist chains 14
1.9 Electric key data 15
1.10 Dimensions 18
1.11 Suspension 20

2 Trolleys 22
2.1 Track girder characteristics 22
2.2 General information on standard trolleys 22
2.3 Curve radii for standard trolleys 23
2.4 Cross and long-travel speeds 23
2.5 CF 5 trolley 24
2.6 U11 trolley 25
2.7 U22/U34 trolley 26
2.8 E11/E22-C/E34 travel drive 27
2.9 Dual-output gearbox for E11 - E34 travel drive 30
2.10 EU11 - EU34 trolley with ZBF three-phase motor 31
2.11 Hook dimension C with trolleys 32

3 Accessories 33
3.1 Mechanical options 33
3.1.1 Buffer stop 33
3.2 Electric options 34
3.2.1 Long and cross-travel limit switches 34
3.2.2 Power supply lines 36

DC chain hoist project engineering sheet 38

The following information can be found in our “Demag DC-Pro chain hoist technical data” document:

Chain hoist Operating conditions; size overview; long hook path > 8 m.

Trolleys EU 11 DK/EU 22 DK trolley with PKF AC motor; RU56/EU56 trolley; ZBF electric
key data; DRF 200 friction-wheel travel drive with travel motor for profile-section
girders.
Chain hoist modles Low-headroom hoist, double chain hoist, articulated trolley

Accessories – Chain hoists that have a horizontal chain lead-off; foot-mounted hoist, attached
Mechanical options from below; chain return arrangement; friction force checking device; hook
accessories; canopy; guard plates; trolley buffers; supporting roller fittings; link bar.
Accessories – Double brake; chain hoists for mobile entertainment systems
Chain hoists for special safety regula-
tions
Accessories – Geared limit switches; pluse encoder fittings; overload cut-off with ZMS strain
Electric options gauge carrier link; electric enclosures and signal converters; installation parts for
electric enclosures; tandem operation
Control devices Control pendants, control cable, radio control, infrared control
20357144.indd/191213

The metric system is used in this document and all figures are shown with a comma as the decimal
separator.
3
 1 Chain hoist

1.1 General
Lifting loads High productivity, efficiency and operating reliability are the most important
requirements to be met by state-of-the-art material flow systems. Demag Cranes &
➔

Components develops and produces materials flow solutions for all industries and
companies of all sizes, from small workshops to major industrial corporations.
Demag DC-Com chain hoist
All inclusive: fully featured with no need for extras. Many features are already in-
➔

tegrated into the Demag DC-Com chain hoist as standard that have to be ordered
Perfect load handling and bought as extras elsewhere. DC-Com is a fully featured, highly versatile chain
hoist, which can be installed and put into service in a minimum of time.
➔

The industry standard Certified

made by Demag DC-Com chain hoists satisfy the relevant provisions of
● EC Machinery Directive 2006/42/EC,
● EC Low Voltage Directive 2006/95/EC and
● EC EMC Directive 2004/108/EC.
Electromagnetic compatibility is rated for interference immunity in industrial en-
vironments and for interference emissions in commercial and industrial environ-
ments.
In addition, an optional variant of these chain hoists meets the strict CCSAUS regu-
lations for Canada and the USA.

Safety-related functions:
A performance level of at least PL = c is achieved for the safety-related functions
specified in EN 14492-2. This applies to these functions included in DC-Pro,
DCS-Pro and DC-Com units (not DC/CC/FC):
● Emergency stop
● Lifting and lowering limiters
● Overload protection (as of 1 t)
for travelling hoists to EN 15011:
● Emergency stop
● Travel limiters (right/left)
and for tandem operation with two hoist units by means of tandem box:
● Interlocking of the hoist units

20357144.indd/191213

4
 Main differences between the product types
DCS-Pro (DCMS-Pro) DC-Pro (DCM-Pro) DC-Com DC-ProDC / CC
Control, control voltage Contactor, 24 V Direct/conventional
Inverter, 24 V
Tri-state signal transmission contactor
Group of mechanisms 1Am to 4m 2m to 4m
Standard lifting speed up to 125 kg, [m/min] 0,15-30/30 8/2; 16/4; 24/6 8/2
Standard lifting speed 160-500 kg, [m/min] 0,15-16/30; 0,08-8/15 8/2; 12/3; 16/4; 24/6 6/1,5; 4,4/1,1
Standard lifting speed 630-2000 kg, [m/min] 0,04-4/7; 0,06-6/11; 0,11- see DC-Pro
4/1; 6/1,5; 8/2, 12/3; 24/6 4/1
12/22
Standard lifting speed 2500-5000 kg, [m/min] 0,04-4/7 for 2500 kg 4/1; 6/1,5; 8/2 ---
Duty factor [CDF%] 60 (20 at vsmin) 60 (40/20) 60 (40/20); 40 (25/15)
Speed ratio Variable 1:100 F4
Hook path (standard) [m] 5; 8 (Manulift 2,8; 4,3) 4
Hook path (order-specific) [m] >8 >4 see DC-Pro
Type of enclosure: chain hoist, trolley IP55, IP55
Height-adjustable control pendant, plug connections Yes, yes No
Hook assembly Pro Com see DC-Pro
Control pendant (can be fitted) DSC, DSE, DSM, DSK, DST DSC, DSE, DSK, DST DSK, DST
Limit-switch cut-off for DC 1-10 1/1 Yes Optional
Optional (lifting)
Limit-switch cut-off for DC 10 2/1 to DC 25 Yes
Elapsed operating time counter Yes, under elec. equip.
Yes (can be read from the outside) No
cover
Diagnostic interface Yes, under elec. equip.
Yes (can be read from the outside) No
cover
Gearbox Maintenance-free for up to 10 years
Slipping clutch Maintenance-free for up to 10 years
Brake Maintenance-free for up to 10 years (DC 10-25 brake No
5 years)
Adjustable brake Not required Yes
Speed monitoring Yes No
Regenerative braking main to 0 via creep speed --- Yes No
Wide voltage range input Yes Yes
Pro-Hub: Vmax in partial load range Yes No
Fast-to-slow cut-off Yes No
V, acc., dec. parameters adjustable via control
Yes No
pendant
Motor temperature monitoring Yes Optional Optional
Electric equipment cover Aluminium (DC16/25
Aluminium Plastic Partly extended cover
plastic)
Surface of aluminium parts Powder-coated
20357144.indd/191213

5
 1.2 Product characteristics at a glance
DC-Com (2 hoist speeds) The DC-Com chain hoist standard scope of delivery already includes the following
features:
● Load capacities up to 2000 kg,
● FEM classification from 2m to 4m (1600 – 6300 full load hours of operation),
● 24 V contactor control with internal tri-state signal transfer, can be extended
with modules,
● Operating limit switches for the upper and lower hook position for DC-Com 10
with 2/1 reeving,
● Elapsed operating time counter,
● Slipping clutch with automatic cut-out by means of speed monitoring (no con-
tinuous slipping),
● Gearbox maintenance-free for up to 10 years,
● Height-adjustable control pendant:
The control cable is available in 3 different lengths and is adjustable in height
(H5: 0,8–3,8 m/H8: 3,8–6,8 m/H11: 6,8–9,8 m), enabling the position of the
control pendant to be adjusted without the need for any wiring. The length of
control cable that is not required is accommodated under the service cover,
● “Plug & Lift” and “Plug & Drive” plug-in electric connections:
- Mains connection on the chain hoist,
- Control cable on the chain hoist/control pendant,
A Drives B Brakes
1 Slipping clutch 4 Speed detection - Signal and power cable between the chain hoist and trolley,
2 Motor 5 Brake ● 7-segment display (beneath the electric equipment cover) to enable operating
3 Chain drive 6 Gearbox hours and operating statuses to read off,
● Infrared diagnostic interface (to read out and manage specific data by means of
Demag IDAPSY software),
● Surface protection for the aluminium housing parts provided by UV-resistant
powder coating (resistant to scratches),
● Two speeds with main and creep lifting with F4 ratio,
● Various lifting speeds available: 4/1; 4,5/1,1; 6/1,5; 8/2,
● Duty factor: 60% (40%/20%), switching operations/hour: 360 (120/240),
operation permitted without any reduction in the duty factor from -20 °C to
+45 °C,
● Hoist motor rated to insulation class F,
● Chain hoist and travel drive enclosure: IP 55.

Even longer service life, improved ● Slipping clutch, hoist motor and brake are monitored by means of integrated
safety and reduced wear speed sensors,
● Low-wearing brake thanks to regenerative braking from main to creep lifting
until standstill, mechanical braking from creep lifting to standstill,
● The brake does not need to be adjusted,
● The brake arranged before the slipping clutch prevents the from load sinking
when the unit is at rest,
● Automatic braking if the control system fails,
● Up to 1000 kg only 1/1 reeving: reduced chain wear, improved ergonomics,
● Robust cylindrical-rotor motor with fan and separate DC brake beneath the
electric equipment cover (brake double encapsulated for enclosure type, no
brake sticking).
20357144.indd/191213

6
 Simple commissioning and optimum ● Ergonomic DSC/DSE control pendants with gentle actuation force,
ergonomics ● Length of the control cable or position of the control pendant individually adapt-
able on site without any need for wiring (can be extended or shortened at any
time),
● Control cable and control board signals designed for 3-axis applications,
● Pivoting suspension bracket enables the chain hoist to be attached when the
trolley has been fitted.

Service-friendly ● Elapsed operating time counter, status and error messages shown on 7-seg-
ment display,
● Infrared diagnostic interface (to read out and manage specific data by means of
IDAPSY software),
Everything in one place under the service cover – rapid access for commissioning
and service:
● Plug-and-socket connections (for power cable, control cable, limit switches,
trolley connection),
● Strain relief (for power supply and trolley supply cables),
● Storage for 3 m of control cable,
● Chain drive (fitted to output shaft),
● Chain lubrication (through lubrication opening in the chain guide for improved
lubrication between the chain lonks links on DC 1-10),
● Reduced downtimes as the entire chain drive can be replaced without
dismantling motor or gearbox parts.
20357144.indd/191213

7
 1.3 Selection criteria The size of the hoist is determined by the load spectrum, average operating time
per working day, load capacity and reeving.
1. What are the operating conditions?
2. What is the specified safe working load?
3. To what height must the load be lifted?
4. What is the required lifting speed?
5. Do the loads need to be lifted and lowered with great accuracy?
6. Is horizontal load travel necessary?
7. How is the hoist to be controlled?

The load spectrum

(in most cases estimated) can be evaluated in accordance with the following
definitions:
L1 Light
Hoist units which are usually subject to very small loads and in exceptional cases
only to maximum loads.
L2 Medium
Hoist units which are usually subject to small loads but rather often to maximum
loads.
L3 Heavy
Hoist units which are usually subject to medium loads but frequently to maximum
loads.
L4 Very heavy
Hoist units which are regularly subject to maximum and almost maximum loads.

Example:
Load capacity 250 kg
Load spectrum from table “Medium”
Lifting speed 4 m/min
42699344.eps Reeving 1/1
Average hook path 3m
m = Load capacity
t = Operating time
No. of cycles/hour 9
a = Full load Working time/day 8 hours
b = Medium partial load
c = Small to medium partial load The average operating time per working day is estimated or calculated as follows:
d = Small dead load
e = Small to medium dead load Operating time/ 2 x average hook path x no. of cycles/h x working time/day
=
f = Heavy dead load day 60 x lifting speed
g = Very heavy dead load
2●4●9●8
=
60 ● 4

= 1,8 hours

For the medium load spectrum and an average daily operating time of 1,8 hours,
the table shows group 1Am. For a load capacity of 250 kg, the diagram shows size
DC-Com 2–250.
20357144.indd/191213

8
 The chain hoist group of mechanisms is determined by the load spectrum and operating time.
Load spectrum Average operating time per working day in hours
L1 Light 2-4 4-8 8-16 More than 16
L2 Medium 1-2 2-4 4-8 8-16
L3 Heavy 0,5-1 1-2 2-4 4-8
L4 Very heavy 0,25-0,5 0,5-1 1-2 2-4
Group of mechanisms to FEM 9.511 1Am 2m 3m 4m
Load capacity for reeving Product type and Lifting speed
1/1 2/1 size at 50 Hz
[kg] [kg] [m/min]
80 80
100 DC-Com 01 8/2 100
125 125
160 160
DC-Com 02
200 6/1,5 200
250 DC-Com 02 250
315 315
400 DC-Com 05 4,5/1,1 400
500 500
630 630
800 800
1000 1000
DC-Com 10 4/1
1250 1250
1600 1600
2000 2000
20357144.indd/191213

9
 1.4 Model code
E K L D DC-Pro -D 10- 1000 XXX H5 V6/1,5 2/4- 2000 380 - 415 / 50 24/6 200 220 - 480
Travel drive voltage range/ voltage [V]
Max. flange width of the trolley [mm]
Travel speed [m/min]
Frequency [Hz]
Chain hoist voltage range [V]
Double chain hoist load hook centre distance
Double chain hoist load hook run-off position
Lifting speed [m/min]
V 2-stage = Main/creep lifting
VS Stepless = VS at rated load up to VSmax in the partial load range
Hook path [m]
1/1, 2/1 reeving LDC-D 2x1/1; 2x2/1
KLDC-D 2/2-2; 4/2-2
Total load capacity [kg]
Size 1)
Double chain hoist (2 chain lead-offs)
DC-Pro product range DC-Pro product range
DC-Pro 2-stage chain hoist (Demag chain hoist) DC-ProCC 2-stage chain hoist for conventional contactor
DCM-Pro 2-stage Manulift control
DCS-Pro Variable-speed chain hoist DC-ProDC 2-stage chain hoist for direct control
DCMS-Pro Variable-speed Manulift DC-ProFC Variable-speed chain hoist for control by means of
DCRS-Pro Stepless rocker switch an external frequency inverter
DC-Com product range
DC-Com 2-stage chain hoist
D Articulated trolley
L Long trolley
K Low-headroom travelling 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)

Not all features of the mounting code can be combined.

20357144.indd/191213

10 1) Since 04/2006, the designation for sizes DC 10 and DC 20 have been changed to DC 10 1/1 and DC 10 2/1, respectively.
 1.5 DC documents
Documents Part no.
Demag DC-Pro 1 – 25 chain hoist
203 525 44
Demag DCS-Pro 1 – 15 chain hoist
Demag DC-Com chain hoist 203 571 44
CF5-DC/DCM trolley 203 568 44
U11-U34/DC/DCM/DK trolley 203 569 44
RU/EU56 trolley 203 691 44
DC electric accessories 203 656 44
Technical data/catalogues
POLU box electric accessories 203 682 44
KBK classic (steel, powder-coated) 202 976 44
KBK Aluline (anodised) 203 245 44
KBK trailing cable 202 617 44
KBK pillar and wall-mounted slewing jib cranes 203 565 44
DCL-Pro conductor line 203 751 44
Clamp-fitted buffer 203 313 44
DC-Pro 1 - 15 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
Operating instructions/component parts DC-ProDC/CC/FC 1-15 chain hoist 211 191 44
DC-ProDC/CC/FC16-25 chain hoist 211 163 44
DC-Wind chain hoist 211 010 44
PGS parallel grippers 214 095 44
DPM permanent magnet 206 623 44
Z motor external pulse generator 214 372 44
Braking resistor for DCS-Pro 211 166 44
Dedrive Compact STO (frequency inverter quick-step operating
211 170 44
instructions)
DC double brake 211 217 44
LDC-D double chain hoist 211 162 44
KDDC/UDDC articulated trolley 211 159 44
Limit switch 211 210 44
DRF 200 travel drive 214 395 44
E11-E34 DC travel drive (I) 214 810 44
E11-E34 DC travel drive (II) (circuit diagrams) 211 229 44
DCS + E22-C parameter programming 211 247 44
EU 11 DK trolley 206 604 44
EU 22 DK trolley 206 605 44
DRC-DC radio control system 214 689 44

Assembly instructions DRC-DC quick-step instructions 211 045 44

(Adjustment/dimensions) DC geared limit switches 211 011 44
DCM-Pro, DCMS-Pro, DKM, PM, PMV Manulift chain twist element 211 164 44
KDC chain hoist 211 017 44
DC protective sleeve 211 227 44
ZNA, ZBA, ZBF motors 214 228 44
Friction force checking device 206 973 44
DC 1 - 25 safety hook 211 228 44
DC PWM/3ST signal converter 211 094 44
DCS analogue/PWM signal converter 214 951 44
DSC-EX control pendant 214 832 44
DSE10-C control pendant 214 998 44
DC 1 - 25 tandem 211 108 44
DSK+DST support sleeve 211 207 44
VG11-34 EU11-34 dual-output gearbox 211 122 44
Long hook path accessories 211 178 44
DSC strain relief device 211 092 44
20357144.indd/191213

DC test and inspection booklet 214 745 44

Test and inspection booklet
Certificates 235 309 44

The documents can be ordered from the relevant Demag office.

11
 1.6 Design overview
Single-fall design, e.g. DC-Com 5

Item Designation Item Designation Item Designation

1 Electric equipment cover 11 Chain guide 21 Adjusting mechanism for control cable
2 Control system 12 Chain sprocket 22 Cut-off buffer for operating limit switch
3 Elapsed operating time counter 13 Round section steel chain 23 Hook assembly with load capacity plate
14 Slipping clutch 24 Motor shaft
5 Pulse wheel for speed monitoring 15 Dished washer pack 25 Winding head cap
6 Magnet brake 16 Slipping clutch adjusting nut 26 Stator
7 Brake disc with linings 17 DC 1 - 5 two-stage helical gearbox 27 Rotor
DC 10 three-stage helical gearbox
8 Brake springs 18 Suspension bracket 28 Fan
9 Brake magnet 19 Suspension pin 29 Fan cover
20357144.indd/191213

10 Gearbox housing 20 Service cover

12
 1.7 Selection table
Load Chain hoist Reeving Group of Chain size Lifting speed Standard Motor size 2) Max. weight
capacity size mechanisms hook path 1) for hook path
DIN EN 14492 at 50 Hz at 60 Hz H 4m 5m 8m
[kg] DC-Com FEM / ISO [mm] [m/min] [m/min] [m] [kg] [kg] [kg]
80 4m / M7
100 1 8,0/2,0 9,6/2,4 ZNK 71 B 8/2
125 3m / M6
4,2x12,2 21 22 24
160
200 2 6,0/1,5 7,2/1,8 ZNK 71 B 8/2
2m / M5
250
1/1
315 3m / M6
400 5 5,3x15,2 4,5/1,1 5,4/1,3 4, 5 and 8 ZNK 80 A 8/2 27 28 30
2m / M5
500
630 3m / M6
800 ZNK 100 A 8/2 47 48 52
2m / M5
1000
10 7,4x21,2 4,0/1,0 4,8/1,2
1250 3m / M6
1600 2/1 ZNK 100 B 8/2 63 65 73
2m / M5
2000
20357144.indd/191213

1) Larger hook paths on request.

2) See electric key data page for key motor data. 13
 1.8 Hoist chains Genuine Demag chain is a round-section steel chain tested to EN 818-7 which is
subject to the regulations for round-section steel chains used in hoist applications
issued by the Main Association of Industrial Employers' Mutual Insurance
Societies, Central Department for Accident Prevention and the test criteria for
round-section steel chains used in hoist applications and the inspection regulations
to DIN 685 part 5 of Nov. 1981 as well as BGV D8 and BGV D6.

Pay attention to reduced load capacities.

For non-standard operating conditions, the special chains listed below are available for special ambient
conditions.

Chain hoist Max. load capacity for reeving Dimension Stamp, chain Weight Production Minimum Minimum
Size quality per test force breaking elongation
1/1 2/1 metre force at rupture
[kg] [kg] [mm] [kg] [kN] [kN] [%]
Demag RDC/TDK standard chain
DC 1 - 2 250 - 4,2 x 12,2 0,38 13,8 22
DAT
DC 5 500 - 5,3 x 15,2 0,62 22 35 10
RDC/TDK
DC 10 1250 2500 7,4 x 21,2 1,20 43 70
High-strength ageing-resistant material with a high degree of surface hardening, galvanised with additional surface treatment, blue-
Properties
chromated, colour: silver
Material Ni-Mo special chain steel to EN 818-7, part 5.3.1
Lubrication GP00H-30REN.SO-GFB grease
Demag Corrud special chain

Application, DC 1 - 2 250 - 4,2 x 12,2 0,38 13,8 22

DAT
e.g.galvanising, elec- DC 5 500 - 5,3 x 15,2 0,62 22 35 10
RDC/TDK
troplating facilities DC 10 1250 2500 7,4 x 21,2 1,20 43 70
Properties Ageing-resistant, corrosion-free, “Corrud DS” micro-layer corrosion protection, black-coated, colour: black, Stabylan 2001
Material Ni-Mo special chain steel to EN 818-7, part 5.3.1
Lubrication Acid-resistant chain grease, e.g. GLEITMO 582
Demag HS7 special chain

Application, DC 1 - 2 160 - 4,2 x 12,2 0,38 12,5 19,3

e.g.foundry, dust, DC 5 400 - 5,3 x 15,2 RSX / DS 0,62 19,8 30,8 5
emery, blasting DC 10 800 1600 7,4 x 21,2 1,20 38,7 60
Properties Ageing-resistant, blue-chromated, with deeper surface hardening
Material Ni-Mo special chain steel to EN 818-7, part 5.3.1
Lubrication Dry or with dry lubricant, e.g. Ceplatlyn 300
Demag RS6 special chain
DC 1 - 2 125 1) - 160 2) - 4,2 x 12,2 0,38 10 16
Application,
DC 5 200 1) - 250 2) - 5,3 x 15,2 RSA / S 0,62 16 25 15
e.g.foodstuffs sector
DC 10 400 1) - 500 2) 800 3) - 1000 4) 7,4 x 21,2 1,20 32 50
Properties Non-rusting chain, not hardened, bright
Material Stainless steel AISI 316 (V4A) 1,4401
Lubrication Food-safe lubricant, e.g. Paraliq chain spray
20357144.indd/191213

1) For max. 25-50 cycles per day

2) For max. 10 cycles per day
3) For max. 12-25 cycles per day
14 4) For max. 5 cycles per day
 1.9 Electric key data

DC-Com (2 hoist speeds)

Chain hoist size Motor size No. of PN CDF nN Starts/h Min./max. currents and start-up current
poles IN min. IN max. Imax. 1) IA/IN max. cos N
DC-Com [kW] [%] [rpm] [A] [A] [A]
220-240 V, 50 Hz, 3 ~ (CE) 2)
8 0,05 20 720 240 1,75 2,10 2,10 1,45 0,48
1 ZNK 71 B 8/2
2 0,18 40 2925 120 2,10 2,80 2,80 2,75 0,46
8 0,10 20 675 240 1,80 2,10 2,35 1,45 0,56
2 ZNK 71 B 8/2
2 0,37 40 2825 120 2,40 2,80 3,20 2,75 0,63
8 0,18 20 665 240 2,45 2,80 2,95 1,45 0,51
5 ZNK 80 A 8/2
2 0,72 40 2745 120 3,80 4,20 4,70 3,00 0,77
8 0,27 20 690 240 2,95 3,30 3,80 1,80 0,54
ZNK 100 A 8/2
2 1,10 40 2745 120 5,40 5,40 6,10 3,60 0,81
10
8 0,57 20 675 240
ZNK 100 B 8/2 -
2 2,30 40 2790 120
380-415 V, 50 Hz, 3 ~ (CE) 2)
8 0,05 20 720 240 1,00 1,20 1,20 1,45 0,48
1 ZNK 71 B 8/2
2 0,18 40 2925 120 1,20 1,60 1,60 2,75 0,46
8 0,10 20 675 240 1,00 1,20 1,35 1,45 0,56
2 ZNK 71 B 8/2
2 0,37 40 2825 120 1,40 1,60 1,85 2,75 0,63
8 0,18 20 665 240 1,40 1,60 1,70 1,45 0,51
5 ZNK 80 A 8/2
2 0,72 40 2745 120 2,20 2,40 2,70 3,00 0,77
8 0,27 20 690 240 1,70 1,90 2,20 1,80 0,54
ZNK 100 A 8/2
2 1,10 40 2745 120 3,10 3,10 3,50 3,60 0,81
10
8 0,57 20 675 240 3,00 3,40 3,90 1,85 0,58
ZNK 100 B 8/2
2 2,30 40 2790 120 5,50 6,20 6,40 4,15 0,77
500-525 V, 50 Hz, 3 ~ (CE) 2)
8 0,05 20 720 240 0,75 0,95 0,95 1,45 0,48
1 ZNK 71 B 8/2
2 0,18 40 2925 120 0,90 1,25 1,25 2,75 0,46
8 0,10 20 675 240 0,80 0,95 1,10 1,45 0,56
2 ZNK 71 B 8/2
2 0,37 40 2825 120 1,10 1,25 1,45 2,75 0,63
8 0,18 20 665 240 1,20 1,30 1,35 1,45 0,51
5 ZNK 80 A 8/2
2 0,72 40 2745 120 1,80 1,90 2,15 3,00 0,77
8 0,27 20 690 240 1,35 1,50 1,75 1,80 0,54
ZNK 100 A 8/2
2 1,10 40 2745 120 2,40 2,50 2,80 3,60 0,81
10
8 0,57 20 675 240 2,50 2,70 3,10 1,85 0,58
ZNK 100 B 8/2
2 2,30 40 2790 120 4,60 4,90 5,10 4,15 0,77
20357144.indd/191213

1) Imax = maximum current for lowering motion.

2) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.
15
 Chain hoist size Motor size No. of PN CDF nN Starts/h Min./max. currents and start-up current
poles IN min. IN max. Imax. 1) IA/IN max. cos N
DC-Com [kW] [%] [rpm] [A] [A] [A]
220-240 V, 60 Hz, 3 ~ (CE / CCSAUS) 2)
8 0,06 20 870 240 2,10 2,50 2,50 1,45 0,47
1 ZNK 71 B 8/2
2 0,22 40 3525 120 2,50 3,35 3,35 2,75 0,45
8 0,11 20 825 240 2,10 2,50 2,80 1,45 0,55
2 ZNK 71 B 8/2
2 0,44 40 3425 120 2,90 3,30 3,85 2,75 0,62
8 0,22 20 815 240 2,90 3,30 3,50 1,45 0,50
5 ZNK 80 A 8/2
2 0,86 40 3345 120 4,60 5,00 5,60 3,00 0,76
8 0,32 20 840 240 3,55 3,90 4,60 1,80 0,53
ZNK 100 A 8/2
2 1,30 40 3345 120 6,50 6,40 7,30 3,60 0,80
10
8 0,68 20 825 240
ZNK 100 B 8/2 -
2 2,80 40 3390 120
380-400 V, 60 Hz, 3 ~ (CE) 2)

8 0,06 20 870 240 1,35 1,60 1,60 1,45 0,47

1 ZNK 71 B 8/2
2 0,22 40 3525 120 1,70 2,00 2,00 2,75 0,45
8 0,11 20 825 240 1,50 1,60 1,80 1,45 0,55
2 ZNK 71 B 8/2
2 0,44 40 3425 120 1,80 2,00 2,30 2,75 0,62
8 0,22 20 815 240 1,80 1,95 2,00 1,45 0,50
5 ZNK 80 A 8/2
2 0,86 40 3345 120 1,75 2,90 3,20 3,00 0,76
8 0,32 20 840 240 2,40 2,70 2,90 1,80 0,53
ZNK 100 A 8/2
2 1,30 40 3345 120 3,80 4,00 4,60 3,60 0,80
10
8 0,68 20 825 240 3,90 4,30 4,90 1,85 0,57
ZNK 100 B 8/2
2 2,80 40 3390 120 7,20 7,70 8,00 4,15 0,76
440-480 V, 60 Hz, 3 ~ (CE / CCSAUS) 2)
8 0,06 20 870 240 1,05 1,25 1,25 1,45 0,47
1 ZNK 71 B 8/2
2 0,22 40 3525 120 1,25 1,65 1,65 2,75 0,45
8 0,11 20 825 240 1,05 1,25 1,40 1,45 0,55
2 ZNK 71 B 8/2
2 0,44 40 3425 120 1,45 1,65 1,95 2,75 0,62
8 0,22 20 815 240 1,50 1,70 1,80 1,45 0,50
5 ZNK 80 A 8/2
2 0,86 40 3345 120 2,30 2,50 2,80 3,00 0,76
8 0,32 20 840 240 1,80 1,95 2,30 1,80 0,53
ZNK 100 A 8/2
2 1,30 40 3345 120 3,25 3,20 3,70 3,60 0,80
10
8 0,68 20 825 240 3,10 3,50 4,00 1,85 0,57
ZNK 100 B 8/2
2 2,80 40 3390 120 5,70 6,40 6,60 4,15 0,76
575 V, 60 Hz, 3 ~ (CE / CCSAUS) 2)
8 0,06 20 870 240 0,85 0,85 1,45 0,48
1 ZNK 71 B 8/2
2 0,22 40 3525 120 0,90 0,90 2,75 0,46
8 0,11 20 825 240 0,90 1,00 1,45 0,65
2 ZNK 71 B 8/2
2 0,44 40 3425 120 1,00 1,15 2,75 0,63
8 0,22 20 815 240 1,10 1,35 1,45 0,54
5 ZNK 80 A 8/2
2 0,86 40 3345 120 1,75 2,10 3,00 0,88
8 0,32 20 840 240 1,35 1,55 2,10 0,58
ZNK 100 A 8/2
2 1,30 40 3345 120 2,40 2,70 3,80 0,87
10
8 0,68 20 825 240 2,40 2,70 1,85 0,62
ZNK 100 B 8/2
2 2,80 40 3390 120 4,40 4,50 4,15 0,83
20357144.indd/191213

1) Imax = maximum current for lowering motion.

2) Temporary voltage tolerances of ± 10% and temporary frequency tolerances of ± 2% are possible. Motors are rated to insulation class F.
16
 Mains connection delay fuse links
Voltage 220-240V 380-415V 500-525V 220-240V 380-400V 440-480V 575V
Frequency 50Hz 60Hz
Size Motor size [A] [A] [A] [A] [A] [A] [A]
DC-Com 1 ZNK 71 B 8/2
6 6
DC-Com 2 ZNK 71 B 8/2
6 6 6 6
DC-Com 5 ZNK 80 A 8/2 6
10 10
ZNK 100 A 8/2
DC-Com 10
ZNK 100 B 8/2 - 10 10 - 16 10

Danger – live components.

Danger to life and limb.

Electric energy may cause very severe injuries. Danger of death caused by electric current if the insulation or individual
components are damaged.
For safety reasons, we recommend the use of 3-pole automatic circuit breakers/circuit breakers (to DIN EN 60898-1,
tripping characteristic B or C) instead of separate fuse links. This arrangement ensures that all phases are disconnected
from the power supply in the event of a short circuit.

Supply lines 1) for 5% voltage drop ∆U and starting current IA

Voltage 220-240V 380-415V 500-525V 220-240V 380-400V 440-480V 575V
Frequency 50Hz 60Hz
Size Motor size [mm2] [m] [mm2] [m] [mm2] [m] [mm2] [m] [mm2] [m] [mm2] [m] [mm2] [m]
DC-Com 1 ZNK 71 B 8/2
89 100 76 100
DC-Com 2 ZNK 71 B 8/2
1,5 100 1,5 1,5 100 100
DC-Com 5 ZNK 80 A 8/2 31 1,5 1,5 26 75 1,5 1,5
94
ZNK 100 A 8/2 34 29 78
DC-Com 10
ZNK 100 B 8/2 - - 38 61 - - 2,5 45 43 78
20357144.indd/191213

1) The lengths of the supply lines are calculated on the basis of an earth-loop impedance of 200 mΩ. 17
 1.10 Dimensions

Load capacity ≤ 1000 kg, 1/1 reeving, with long suspension bracket

42064548.eps

Load capacity ≤ 1000 kg, 1/1 reeving, with short suspension bracket (optional)

42064449.eps
The following dimensions change due to larger cut-off springs for higher speeds:
1) H8 chain collector boxes are used for H5 hook paths and speed v2.

Chain hoist Motor Suspension bracket Suspension

size bracket
short long short long short long
Chain collector
box size
H4 H4
20357144.indd/191213

H8 H8
H5 H5
C C 1 1) b b1 l l1 l2 l3 l4 l5 b4 b6 d d1 d2 h1 h2 h1 h2 h4 h5
DC-Com 1/2 ZNK 71 B 8/2 326 364 335 365 373 403 268 138 422 237 170 183 100 124 22 263 300 163 50
19 92 8 40 78
DC-Com 5 ZNK 80 A 8/2 378 416 395 425 435 465 280 141 468 265 175 60 195 107 151 24 293 323 201
60
18 DC-Com 10 ZNK 100 A 8/2 472 505 493 582 526 615 349 184 528 289 183 227 135 23 124 187 18 33 350 65 383 98 233
 Load capacity > 1000 kg, 2/1 reeving, with long suspension bracket

Bottom block with external cut-off

springs, 2/1 reeving
Dimension C is increased by 60 mm
when this bottom block is used.

DC-Com 10 units
with 2/1 reeving and
a hook path of 8 m
are supplied with a
flexible chain collector
bag (pay attention to
dimensions).
42666144.jpg 42666051.eps

Size Motor Suspension bracket Suspension

bracket
short long short long short long
20357144.indd/191213

Chain collector box size

ZNK 100 B 8/2
DC-Com 10

H4 H4 H4 H4 H4 H4
H8 H8 H8 H8 H8 H8
H5 H5 H5 H5 H5 H5
C C1 b b1 l4 l5 l l1 l2 l3 b4 b6 d d1 d2 h1 h2 h1 h2 h4 h5
564 597 582 632 615 665 349 409 184 244 227 340 170 225 578 304 149 60 23 124 187 18 42 350 65 383 98 233 60 19
 1.11 Suspension
Standard suspensions

Item Designation Scope of delivery Chain hoist

size
1 Long suspension bracket Standard
DC 1-5
2 Short suspension bracket Optional
3 Long suspension bracket Standard
DC 10
4 Short suspension bracket Optional
5 Suspension bracket Standard DC 15 / 16-25

The suspension bracket facilitates installation, since the chain hoist can be directly
suspended from the trolley. It is not necessary to dismantle existing trolleys.

Optional suspensions

Item Designation Chain hoist Order no. Dimensions [mm]

size L B H h D d
1 DC 1 - 5 718 278 45 92 18 62,5 19,5 31 8,4
Suspension ring, for suspension parallel to the
2 DC 10 715 278 45 124 22 117 27 53 18,4
track girder
20357144.indd/191213

3 DC 16 - 25 721 278 45 170 35 147 38 84 20,5

DC 1 - 5 718 910 45 92 22 104 - 25 -
4 Suspension hook, folding DC 10 715 910 45 124 36 152 - 36 -
DC 16 - 25 721 910 45 170 44,5 193 - 40 -

20 Not shown Suspension bracket for KBK III up to 3200 kg DC 15 - 16 721 870 45 Contour as for item 5 in “Standard suspension”
 Standard suspension assignment

Chain hoist load capacity [kg] 80- 80- 160- 315- 1250- 1000- 2000- 1250- 2500- 2000- 4000-
125 250 500 1250 2500 1600 3200 1600 3200 2500 5000
Reeving 1/1 2/1 1/1 2/1 1/1 2/1 1/1 2/1
Trolley size Trolley Flange Flange Crossbar DC 1 DC 2 DC 5 DC 10 DC 15 DC 16 DC 25
load width thickness diameter
capacity
[kg] [mm] [mm] [mm] See “Standard suspension” for diagram
1+2 1+2 1+2
RU 3 450 60-90 12 21 11) 11) 1) 11)

58-143 20 30
450 1 1 1 1)
144-300 18 35
RU 6
58-143 20 30
700
144-300 18 38
850 58-300 1 1 1
34
RU / EU 11 DK 58-143 16
1350
144-300 45
RU / EU 22 DK 2600 82-300 22 51 3 13) 3 13) 5 4) 5 4) 7) 5 4)
RU / EU 36 DK 10) 3600 106-300 56 5 5
5 5
106-186 30 70 5
RU / EU 55 DK 10) 5500
187-300 82,5
CF 5 550 50-91 15 16
58-200 1+2 1+2 1+2
U / EU11 1100 22 30 3+4 5)
201-310
U / EU22 2200 82-200
3+4 3+4 5 9)
2200 201-310 30 2) 40 1 1 1 5) 12) 6) 12)
U / EU34
3400 82-310 5 5
98-200 5 5 5
RU / EU56 5600 30 55 3 8) 3 8) 5
201-310
KBK
100 100
I 300 2 2 2
Trolley
II 600 3+4 3)
III 1300 3
I 400 1 1 1
Load bar
II 1200
(double trolley) 3
III 2600 3 3 14)
100 200
I 600
Load bar
II 1400-2200
3
III 2600 3 3 14)
1 1 1
100 200
I 600
Crab frame
II 1200/2400
3 3
III 3300 3 14)

1) up to 400 kg
2) max. 28 mm for DC16/25
3) up to 500 kg
4) max. flange thickness 15 mm
5) DC 10 - 1250 1/1 with U / EU22
6) DC 10 - 2500 2/1 with U / EU34
7) up to 2500 kg
8) DC 10 with RU / EU56 on request
9) up to 2200 kg
20357144.indd/191213

10) discontinued, no longer available

11) short suspension bracket = from flange width 75 mm
12) short suspension bracket = from flange width 170 mm
13) from flange width 120 mm
14) Suspension bracket for KBK III up to 3200 kg = contour
as for item 5 in “Standard suspension” 21
 2 Trolleys

2.1 Track girder Pay attention to the following when our trolleys are employed:
characteristics
Tolerance designation Crane runways
Tolerance C of straightness with reference to Tolerance class 1 C = ± 5 mm c = 1 mm
the height of the crane rail centre and crane Tolerance class 2 C = ± 10 mm c = 2 mm
rail length.
Tolerance c of straightness with reference to
2000 mm measured length (sample measure- Tolerance class 3 C = ± 20 mm c = 4 mm
ment) at any point of the crane runway.
Source: VDI 3576, recommendation: minimum tolerance class 2
Position of a rail seen in elevation (longitudinal
slope)

● I beams with parallel or sloping flanges to DIN 1025 can be used as tracks.
The track must satisfy at least tolerance class 2 for manufacturer tolerance C.
Displacement between the rails and gaps at the joint must be avoided. Any
displacement between the rails should be ground flat, if required.
● The trolleys must not be obstructed by protruding suspension pins, bolt heads,
clamping plates and joint flanges, etc., on the track.
● The running surface of the track girder must only be given a primer coat of
40 μm in the area engaged by the trolley wheels.
● In unclean environments, the running surface of the track should be cleaned
regularly and should be free of oil and grease.
● Resilient buffers should be mounted at the level of the travel wheel axle at the
ends of tracks to prevent the trolley from derailing.
● Supporting rollers must be fitted to the trolleys if U11/U22/U34/EU56 trolleys are
used with ZBF motors in combination with small flange widths.
● Metal or similar hard stops must not be approached as this may result in
damage to the electronic equipment. Resilient buffers should be mounted at
the level of the travel wheel axle at the ends of tracks to prevent the trolley from
derailing.

2.2 General information

on standard trolleys
Properties The trolleys have the following product features:
● Infinitely variable adjustment of the flange width by means of adjusting rings,
● U11 travel wheels made of plastic (optional steel rollers),
● U22/U34/RU56 travel wheels made of spheroidal-graphite cast iron,
● Universal travel wheels for parallel and sloping running surfaces,
● Travel wheels without flanges, additional lateral steel guide rollers,
● Integrated drop stops in the individual die-cast aluminium halves,
● The side cheek surfaces are powder-coated.
U11 - U34 travel on curved track The minimum permissible curve radius for push-travel trolleys is 1000 mm for U11
and 2000 mm for U22/34 trolleys. However, to ensure good travel characteristics
and a longer trolley service life, we recommend that much larger curve radii be
used, e.g. 1500 mm or 3000 mm, respectively.
The minimum permissible curve radius for electric-travel trolleys is 2000 mm (U11)
and 3000 mm (U22/U34).
Wear of the travel wheels is highly dependent on the curve radius. I beam tracks
should be bent with the utmost care to obtain a clean, regular curve. The forces
required to move the load may strongly increase in the case of small curve radii in
connection with high loads.
Trolleys with steel and spheroidal- We recommend that steel travel wheels be used for:
graphite cast iron travel wheels
20357144.indd/191213

● frequent travel on curved tracks,

● extreme ambient conditions (dirt accumulation, hot atmospheres, etc.),
● heavily worn girders,
● very heavy dead loads.
22
 Articulated trolleys The travel wheels and guide rollers of four-wheel trolleys may display increased
wear in installations featuring intensive operation, we recommend the use of
double-wheel articulated trolleys for:
● frequent travel on curved tracks that have small curve radii (1000 mm) and high
load capacities,
● automatic operation in connection with travel on curved tracks, small curve radii
(1000 mm) and high load capacities.

2.3 Curve radii for The specified curve radii apply for normal applications.
standard trolleys Contact the manufacturer or his representative for frequent curve travel
operation (e.g. automatic installations).
Trolley size Load capacity Push travel Electric travel Travel wheel
Push-travel Travel drive/ Girder flange width 1) Rmin Girder flange width 1) Rmin material
trolley travel motor [kg] [mm] [mm] [mm] [mm]
CF 5 550 50-91 800 - - Plastic
U11 E11 1100 58-310 1000 58-310 2000 Plastic 2)
Spheroidal-
U22 E22-C 2200 82-200 82-200 graphite cast
2000 3000 iron 3)
2200 201-310 201-310
U34 E34 Spheroidal-
3400 82-310 82-310
graphite cast iron
RU56 EU56 5600 98-310 2000 4) 98-310 2500 4)

2.4 Cross and long-travel speeds

Load capacity Chain hoist size Reeving Possible speeds Trolley 5) Travel drive/travel motor
[kg] DC-Com 6) in approx. ... m/min

125 1 1/1 20/5 U11 ZBF 63 A 8/2

250 2 1/1 24/6 U11 E11
500 5 1/1 40/10 U11 ZBF 63 A 8/2
12/4 EU56 ZBF 80 A 12/4
20/5 U11 ZBF 63 A 8/2
U11 E11
1000 10 1/1 24/6
EU56 ZBF 71 A 8/2
U11 ZBF 63 A 8/2
40/10
EU56 ZBF 80 A 8/2
12/4 EU56 ZBF 80 A 12/4
20/5 U22 ZBF 63 A 8/2
U22 E22-C
1250 10 1/1
24/6 U34 E22-C
2000 10 2/1
EU56 ZBF 71 A 8/2
U22 ZBF 71 A 8/2
40/10
EU56 ZBF 80 A 8/2
20357144.indd/191213

1) Max. flange width 500 mm (except CF 5) 3) Plastic travel wheels on request 5) U11 - U34 trolleys can only be used together
2) Steel travel wheels optional 4) From flange width 106 mm with ZBF motors in combination with a
VGZ11-34 dual-output gearbox.
6) A special crossbar is needed when DC 10 units
are combined with EU56 trolleys 23
 2.5 CF 5 trolley Suitable for
Demag chain hoist:
Max. load capacity 550 kg
DC-Com 1 - 80 to 125,
for girders to DIN 1025, part 1 + 5 DC-Com 2 - 80 to 250,
DC-Com 5 - 80 to 500

For further information, see “CF5-DC/DCM trolley technical data”, refer to the table on page 11.

tmax.=15

Designation Max. flange thickness Flange width Order no. Weight

t [mm] [mm] [kg]
CF 5 15 50 - 91 840 007 44 2,6

CF 5 universal bracket
Order no. 840 045 44

Chain hoist parallel to the track

girder
Girder connections by means of fish plates are not permitted in the The long suspension bracket of the
area of the guide rollers DC chain hoist must be used.
41777948.eps
20357144.indd/191213

24
 2.6 U11 trolley For use with Demag chain hoists
Max. load capacity 1100 kg ≤ 1000 kg load capacity:
DC 1, DC 2, DC 5
for girders to DIN 1025, part 1 + 5
DC 10 up to 1000 kg
DCM 1, DCM 2, DCM 5
DKUN 1, DKUN 2, DKUN 5, DKUN 10

For further information, see “U11-U34/DC/DCM/DK trolley technical data”, refer to the table on page 11.

Adjusting ring with grub screw

Tightening torque 18 Nm Supporting Detail “X” Wheel contact
washers Retaining point
arrangement
complete

42781345.eps

Pay attention to clearance dimension for girder connection by means of fish plates.
Total play between adjusting rings and suspension bracket: U11 = 4 - 8 mm.
Travel wheel material: plastic, steel travel wheels optional
Designation Load ca- Order no. Flange Max. flange Load bar Sloping flange Parallel flange Weight Track girder curve
pacity width thickness radii
t l i s i s Push Electric
travel travel
[kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] Rmin [mm] Rmin [mm]
U11 - 200 716 502 45 7,3
58 - 200 320
U11 S - 200 716 507 45 min. 3 min. 4 9,0
1100 22 13 7,8 1000 2000
U11 - 310 716 503 45 201 - 310 430 to 6 to 7 7,7
U11 - 500 On request 311 - 500 620 9,9

Number of supporting washers Flange width [mm]

58 66 74 82 90 98 - 310
20357144.indd/191213

Screws for Tightening Thread depth DC 1-5, DCM 1-5 10

fittings torque min. max. DKUN 1-2
[Nm] [mm] [mm] DKUN 5 10 Adjusting rings
M6 9 12 17 DC 10 1/1 8
M8 18 16 21 DKUN 10 8
25
 2.7 U22/U34 trolley For use with Demag chain hoists
≤ 2000 kg load capacity:
Max. load capacity 2200 kg/3400 kg
DC 1 - 10, DCM 1 - 5, DKUN 5 - 10
for girders to DIN 1025, part 1 + 5 ≤ 3400 kg load capacity:
1/1 reeving: DC 16 - 25
2/1 reeving: DC 10 - 16
DKUN 16 - 20

For further information, see “U11-U34/DC/DCM/DK trolley technical data”, refer to the table on page 11.

Adjusting ring with grub screw

Tightening torque 36 Nm Supporting washers Detail “X” Wheel contact
Retaining point
arrangement
complete

42781445.eps

Pay attention to clearance dimension for girder connection by means of fish plates.
Total play between adjusting rings and suspension bracket: U22/U34 = 6 - 12 mm.
Travel wheel material: spheroidal-graphite cast iron, plastic travel wheels on request
Designation Load Order no. Flange Max. flange Load bar Sloping flange Parallel flange Weight Track girder curve
capacity width thickness radii
t 1) l i s i s Push Electric
travel travel
[kg] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] Rmin [mm] Rmin [mm]
U22 - 200 716 602 45 74 - 200 350 14,5
2200
U22 - 500 On request 311 - 500 625 19,8
min. 2 min. 1
2200 201 - 310 30 17 9,5 2000 3000
U34 - 310 716 703 45 460 up to 6 up to 5 15,5
3400 82 - 310
U34 - 500 3400 On request 311 - 500 600 20,8
1) max. 28 mm for DC 16 - 25
Number of supporting washers Flange width [mm]
82 90 100 - 310
20357144.indd/191213

Screws for Tightening Thread depth DC 1-5, DCM 1-5, DKUN 5

fittings torque min. max. DC 10 14
[Nm] [mm] [mm] DC 16 - 25 8 12 Adjusting rings
M6 9 12 17 DKUN 10 / 16 14
M8 18 16 21 DKUN 20 12
26
 2.8 E11/E22-C/E34 travel drive Suitable for
220-480 V, 50 / 60 Hz, 3 ~ Trolleys:
U11 - U34
KBK RF 125

For further information, see “E11-E34 DC travel drive assembly instructions (I)+(II)”,
refer to the table on page 11.

Design overview
1 Housing lower part
2 DC worm geared motor
3 Rotary encoder (E22-C)
4 Housing cover safety retainer
5 Plug-in module with unions
6 Window for 7-segment display
(E22-C)
7 Cover plate of control board
8 Control board
9 Housing cover

Selection table

Max. displaceable Travel Travel speed for 50/60 Hz 1) Possible Order no. Max.
weight drive Steps Stepless trolleys weight
incl. dead loadt 2)
vmax at partial
vrated at full load 3) v at full load 3) v at partial load 3)
load 3)
[kg] Type [m/min] [m/min] [m/min] [m/min] [kg]
1100 E11 24/6 30/7,5 1,92 - 24 2,40 - 30 U11 716 570 45 4
24/3 30/3,7 1,2 - 24 1,5 - 30 U22 / U34
2200 E22-C 716 950 45
27/3,5 33/4 1,4 - 27 4 - 33 RF 125 5
3400 E34 14/3,5 - 1,12 - 14 - U34 716 740 45

Electric key data Size Motor Min./max. currents and start-up current
size 220-480 V, 50 / 60 Hz, 3 ~ (CE/CSA) 4)
PN CDF nN Starts/h IN 220 IN 480 Imax
1) In connection with DCS (stepless) from [kW] [%] [rpm] [A] [A] [A]
0,5 m/min to vmax 0,025 20 862 240 0,30 0,15 1,30
20357144.indd/191213

2) Max. gradient 1%, > 1% on request E11 MP 56 M

0,1 40 3450 120 1,10 0,55 0,65
3) Travel speed values = default. They can be
changed by programming the parameters. 0,05 20 630 240 0,50 0,24 1,16
E22-C MP 56 L
4) Temporary voltage tolerances of +5% and -10% 0,2 40 2525 120 1,80 0,90 4,30
are possible. Motors are rated to insulation 0,04 20 478 240 0,50 0,24 1,16
class F. E34 MP 56 XL
0,15 40 1914 120 1,60 0,80 3,80 27
 Properties ● IP 55 enclosure,
● Ambient temperature -20 °C to + +40 °C,
● Temperature monitoring,
● 7-segment display for operating status, error messages, parameter
programming,
● All electrical connections are of plug-in design,
● Inputs for limit switches and fast-to-slow limit switches are integrated into the
control board,
● Smooth starting via ramps,
● For voltages from 480 V - 575 V, a single-phase isolating transformer with the
following technical data be integrated into the line power supply:
Type: TTT 0,25
Voltage, primary: 575 V
Voltage, secondary: 230 V
Output: 250 VA
● E11 - E34 is fitted to the relevant U11 - U34 trolley,
● E22 can also be fitted to the new RF 125 friction wheel travel drive,
● The travel drive is designed to match the electric concept of the DC chain hoist,
● Line voltage relayed from the travel drive to the chain hoist,
● Signal transmission in steps with 24 V tri-state signals for controlled
DC chain hoists (half-wave evaluation),
● Stepless signal transmission with 0–24 V PWM (pulse width modulation) signals
in connection with stepless DCS chain hoists.
E11 - E34 units are shipped ready for operation.
The following settings are also possible:
● Travel speed, acceleration and braking parameters can be programmed via
DSE-10C/CS control pendants.
42670747.jpg
● Infinitely variable cross-travel speed only in connection with DCS-Pro and
DSE-10CS.
The new E22-C travel drive offers the following advantages compared to E22 units:
● Improved long-travel characteristics, since there is less potential for skewing of
the crane bridge thanks to master/slave operation.
● Variable long-travel speeds.
● The 7-segment display is visible from the outside.
● The parameters can be programmed without opening the cover. The master unit
transfers the parameters to the salve unit.
● The master unit receives the speed command (from the control pendant) and
communicates the speed reference value to the slave drives (maximum of 2
possible).
● Motor speed detection by means of a separate encoder, which eliminates the
need to synchronise the long-travel drives; the influence of the load is also
reduced.
● E22 and E22-C travel drives cannot be combined with each other within one
travel axis.
The following are provided for the electric connection between the chain hoist and
the trolley travel drive:

DC 1-10
Control cable set (part no. 720 070 45) and
Power supply cable (part no. 720 072 45).
20357144.indd/191213

28 42670746.jpg
 E11 - E34 travel drive on U11 - U34 trolley

Trolley A1 B H X1 X2 X3 T1
[mm] [mm] [mm] [mm] [mm] [mm] [mm]
EU11 58 273 98 50 68 115 41
EU22
60 288 112 68 44 117 49
EU34

The following must also be considered:

20357144.indd/191213

● Application as a long-travel drive on bottom flanges is not recommended because of the single-wheel drive.
● E11 to E34 travel drives cannot be used in combination with a dual-output gearbox in a vertical mounting
arrangement.
● We recommend horizontal mounting of the travel drive for outdoor operation.
29
 E22-C travel drive on KBK RF 125

Spring length with washer when pretensioned

47 mm. 42670544.jpg

For further information, see “KBK classic (steel, powder-coated) technical data”, refer to the table on
page 11.

2.9 Dual-output gearbox Trolley Dual-output gearbox

for E11 - E34 travel Size Flange width Order no. Weight Order no. Weight
[mm] [kg] [kg]
drive U11 - 200 716 502 45 7,3
58 - 200
U11 S - 200 716 507 45 9,0
U11 - 310 201 - 310 716 503 45 7,7 716 680 45 2,2
U22 - 200 82 - 200 716 621 45 13,6
U34 - 310 82 - 310 716 731 45 14,6

When U11-34 trolleys are fitted with E11-34 travel drives, 1 travel wheel is driven.
Under certain ambient conditions, e.g. travel track contaminated with oil, it may
be necessary to drive more than one travel wheel. The VG dual-output gearbox is
used for driving both travel wheels on the driven side cheek.

Older trolley designs cannot be combined with the dual-output gearbox, as they
partly have only one travel wheel that can be driven per trolley (U22-34) or different
axle centre distances (U11). If all 4 travel wheels are to be driven, 2 separately
driven side cheeks, 1 crossbar and 2 drives and 2 dual-output gearboxes must be
ordered.
42764544.eps
If a dual-output gearbox is installed between the trolley and the travel drive, the
travel drive protrudes a further 51 mm beyond the girder.
20357144.indd/191213

For further information, see “VG11-34 EU11-34 dual-output gearbox assembly instructions”, refer to the
table on page 11.
30
 2.10 EU11 - EU34 trolley with ZBF three-phase motor

42734945.eps
Trolley size Motor a1 a2 m1 m2 k1 L1 L2 L3 L4 Weight for flange width
≤ 200 mm > 200 - 310 mm
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] [kg]
EU11 3,44 134 22,6 1) 23,0 1)
ZBF 63
140 70 124 218 335 29,8 30,8
40,53 153
EU22 / EU34 ZBF 71 18,44 142 32,0 33,0
ZBF 80 157 80 134 231 391 39,3 40,3

Trolley size EU11 EU22 EU34 Motor type Order no. Weight
Load capacity [kg] 1100 2200 3400
Designation Travel speed [m/min] [kg]
16/4
20/5 ZBF 63 A 8/2 716 750 45
20/5
20/5
ZBF 63 A 8/2
28/7 716 751 45
1 VG11-34 ZBF travel drive cpl.
28/7 ZBF 71 A 8/2 5,3
without trolley and motor
30/7,5 ZBF 63 A 8/2
40/10 ZBF 71 A 8/2 716 752 45
40/10 ZBF 80 A 8/2
40/10 ZBF 63 A 8/2
716 753 45
50/12,5 ZBF 71 A 8/2

Example for ordering

EU11 cpl. up to flange width 310 mm
Consisting of:
1 U11 - 310 trolley complete
1 Travel motor with specification of voltage and type of enclosure
1 Travel gearbox according to speed and load capacity assignment

Supporting roller fittings

Supporting rollers need to be fitted to trolleys for smaller flange widths in combination with the larger motors. Supporting
rollers are required for trolleys in the following cases:
● with ZBF 80 motors up to flange width 130,
● with ZBF 90 motors up to flange width 200.

Cross-travel unit control

The Polu-Box (DC 1-10) contains the brake controls. GF brake modules are used and motors are supplied with a star point for
voltages higher than 500 V.

Long-travel unit control

An additional GF brake module must be included.
20357144.indd/191213

1) for steel travel wheels +1,7 kg 31

 2.11 Hook dimension C with trolleys

DC-Com 1-10 chain hoist

with CF 5 trolley, U11 - U34

Chain hoist Reeving Motor size Trolley (A), (C) trolley at right angles to the girder (B), (D) trolley parallel to the girder
size 1) C C1 with chain collector C C1 with chain collector
(hook path) (hook path)
H4/H5 H8 H4/H5 H8
U11 416 425 455 410 419 449
DC-Com 1/2 ZNK 71 …
CF 5 406 415 445 401 410 440
U11 468 487 517 462 481 511
DC-Com 5 1/1 ZNK 80 …
CF 5 458 477 507 453 472 502
U11 557 578 667 581 602 691
ZNK 100 A 8/2
DC-Com 10 U22 569 590 679 593 614 703
2/1 ZNK 100 B 8/2 U22 / U34 661 679 729 685 703 753

20357144.indd/191213

1) Dimensions C and C1 decrease when the short

suspension bracket is used:
by 38 mm for DC-Com 1-5 units,
32 by 33 mm for DC-Com 10 units.
 3 Accessories
3.1 Mechanical options

3.1.1 Buffer stop

Use We recommend that track ends be provided with elastic buffers and that our KP-A
and KP-T clamp-fitted buffers are used:

Properties ● simple installation;

● for sloping and parallel flanges;
● for various trolleys, from CF 5 Click-fit trolleys to U11 and RU56 trolleys;
● tightening torques for assembly cast into clamp-type buffer;
● buffers can be easily replaced;
● operating temperature range: from -20°C to +70°C;
● sufficient resistance to ageing, ozone and weather;
● resistant to acids and lyes;
● not suitable for chain hoists with suspension and support roller for chain
collector box;
● not suitable for articulated trolleys.

General operating conditions Buffer size KP-A10 KP-T16

Flange thickness max. 21 mm max. 31 mm
Flange width 50 mm to 314 mm 82 mm to 305 mm
Smallest DIN girder profile INP IPE IPB IPBL INP IPE IPB IPBL
section 100 100 120 120 180 180 180 180
Largest DIN girder profile INP IPE IPB IPBL INP IPE IPB IPBL
section 300 600 320 450 500 600 650 1000
Travel wheel diameter 56 mm to 80 mm 80 mm to 125 mm

KP-A10 (KP-T16) clamp-fitted buffer

t max. = 21 (31)

Hazard Hazard
Shorten any overhang Shorten any overhang

42508146.jpg

1) Two of the part no. parts given are required for providing limit stops at both ends of the runway.

Clamp-fitted
KP-A10 KP-T16
buffer 1)
Designation KP-A10/150 KP-A10/250 KP-A10/360 KP-T16/250 KP-T16/360 KP-T16/420
Order no. 826 924 44 826 926 44 826 928 44 826 982 44 826 984 44 826 986 44
Flange width [mm] 50 - 104 105 - 204 205 - 314 82 - 195 196 - 305 306 - 420
20357144.indd/191213

For further information, see “Clamp-fitted buffer technical data”, refer to the table on page 11.

33
 3.2 Electric options

3.2.1 Long and cross-travel limit switches

For further information, see “E11-E34 DC travel drive assembly instructions (I)+(II)” and
“KBK classic technical data”, refer to the table on page 11.

Cross-type limit switches for single or double-stage cut-off of the travel motion

Dimensions

Examples for mounting U11 U22 / U34

RU56 KBK II

Designation Order no. Weight

20357144.indd/191213

[kg]
EU11 to EU56 716 663 45 1,60
Limit switch
KBK II-L, KBK II, KBK II-H 858 351 44 0,85
KBK II-L, KBK II 851 352 44 0,60
Switching vane
34 42700152.eps KBK II-H 858 352 44 0,66
 Maintained contact magnet switch Switching vane on profile sections

43428744.eps 43428844.eps

Designation Order no. Weight

[kg]
Installation parts for maintained contact magnet switch 748 671 46 7,5
Switching vane on profile sections 748 032 46 2,6

The travel motion can be cut off mechanically by means of a travel limit switch at a
switching vane/limit switch fitting or electrically by means of a maintained contact
magnet switch.
20357144.indd/191213

35
 3.2.2 Power supply lines

The following must also be considered:

● Only use M8x30 bolts on DC trolleys U11 to RU56.
● A maximum torque of 100 Nm may be applied to towing arm
tube (1).

Item Designation Trolley Order no.

A) Current collector CF 5 Click-fit 840 085 44
Current collector consisting of: U11 - U34
B) 716 560 45
Towing arm tube (1), current collector tube (2), tube clip (3) RU / EU56

Example: KBK 25
KBK 25 trailing cable power supply
line for straight track sections up to
30 m in length, comprising:
1 KBK 25 rail section (galvanised)
2 Towing trolley
3 Flange clamp
4 C-rail 800 mm
5 Steel girder (by the customer)
6 Clamp-fitted buffer
7 Control pendant
8 Chain hoist
9 C-rail bracket
10 Cable trolleys
11 Trailing cable
12 Rail end cable clamp
13 Adjustable limit stop
14 Terminal box
15 Mains connection switch
16 Rising line (by the customer)

42531645.jpg
20357144.indd/191213

For further information, see “KBK trailing cable technical data”, refer to the table on page 11.

36
 DCL-Pro with end powerfeed or line The DCL-Pro system (Demag Compact Line) can be used as an alternative to a
powerfeed trailing cable power supply arrangement.
It can be installed quickly and easily thanks to patented connectors. The rail
elements are supplied pre-assembled and do not have any loose parts. It can
be connected to its supporting superstructure either by threaded pins or by
suspensions for C-rails.
DCL-Pro can be supplied as an enclosed conductor line system that has 4 to 7
poles with IP23 protection (IP24 optional). Thanks to its modular design, it can be
easily adapted to your superstructure.

42735545.eps

A) Suspension with M8 threaded pin 3) Sliding suspension 7) Towing arm

B) Suspension from C-rail 4) Connector caps 8) Entry/transfer section
1) Clamp section 5) Connector end cap (with powerfeed) 9) Straight section (standard length 4000 mm)
2) Attachment bracket 6) Current-collector trolley
20357144.indd/191213

For further information, see “DCL-Pro conductor line technical data”, refer to the table on page 11.

37
 DC chain hoist Please configure your DC chain hoist and send the project engineering sheet to your next Demag Cranes
& Components sales office or to your relevant agent, authorised reseller or head office in Wetter.

project engineering
sheet
Customer: Project no.:
Customer no.:
Visit/ Tel./ Fax dated:
Contact: Quotation submission date:
Telephone/mobile: Filled in by (name)/dept.:
Fax: Date:
Email:

O Consultation by telephone O With acceptance O Customer has forklift O With installation

O Customer requests visit O Test weight available O Customer has platform O In normal working hours
O At the weekend
Delivery
Delivery date
location

Please enter model code:

Oper. voltage/
Trolley type Chain hoist type Load capacity Reeving Hook path Hoist speed Travel speed Flange width
frequency

Trolley size Chain hoist size [kg] [m] [v/min] [V/Hz] [m/min] [mm]

Number of chain hoists:

Type: O Stationary
O Travelling
O Low headroom O Low headroom in extended KLDC design Grid dimension
O DC Wind
O Double chain hoist O LDC-D (with connecting shaft) O KLDC-D (low-headroom
design)
Type O 2/4 O 3/4 O 4/5
Hook distance L1 L2 (only for 3/4)

Ambient conditions: O Electroplating, pickling, galvanising plant O Clean room, class

O Foundry O Foodstuffs sector
O Special ambient temperature < -20 °C / > +45 °C:
Other ambient conditions:

Special chain: O Corrud chain O HS 7 chain O RS 6 stainless steel V4A chain

Paint finish: O Special colour in RAL
Suspension: O Standard O ZMS O Short suspension bracket (only for DC-Com)
O Suspension ring turned 90° O Susp. bracket for KBK III (only for DC 15/16)
O Suspension hook
Trolley: O Click-fit push-travel trolley O EU electric-travel trolley Travel speed
O U push-travel trolley
O EUD articulated trolley Curve radius Girder type/size:
O Suitable for KBK size O straight O articulated
Trolley options: O U11 steel travel wheels O Supporting roller fittings O Current collector
O Trolley buffer O Mechanically coupled at distance of
O Clamp-fitted buffer O Thoraxol paint finish for EU56 travel motor/articulated trolley
Motor: O CSA design O Microtherm

LAM load handling attachment O LAM to ident. no. O LAM w/o ident. no.
for Manulift/rocker switch: Ident. no.: Container/load:

Control units: O None O Standard O DSK O DST Radio control O DRC-DC O DRC-MP
Control cable: O None O Standard O DC support sleeve O 2TY O Mobile
Control cable length: O for H 5 (0,8-3,8 m) O for H 8 (3,9-6,8 m) O for H11 (6,9-9,8 m)
20357144.indd/191213

Cable length longer than H11:

Additional plug connection: O Harting main power supply O Harting control cable

38
 Limit
switches: O Lifting/lowering (DC-Com 1/1 only)
O Cross-travel limit switches
Geared limit switch O 3 contacts O 4 contacts (for external use)
O 8 contacts (for external use)
Additional electric equipment: O Control of the DC unit via floating contacts with 24 V AC (DC terminal box/diode)
O DC control by means of conventional control signals/contacts 42-230V AC, 50/60Hz (KT3/DT3 signal converter)
O Control of an AC travel motor (Polubox)
O Generation of conventional control signals/contacts of 42-230V AC, 50/60Hz (3TK signal converter)
O 2 chain hoists in tandem operation
O Overload cut-off with ZMS and electric evaluation device
O Rotary encoder fitting type
O Double brake

Power supply: O KBK 25 trailing cable power O DCL-Pro conductor line

supply

Chain hoist supplied with

trolley: O Chain hoist completed with trolley

Further special features, e.g.: O Canopy O Chain hoist rated to BGV-D8+

O Heat deflection shield O IP65 enclosure (DC 1 - 15 only)
O Oil drip tray O Control pendant jib length
20357144.indd/191213

39
The current addresses of our sales offi ces, subsidiaries and agencies worldwide can
be found on the Tri-State Overhead Crane website at
www.tsoverheadcrane.com/contact-us

Distributed by Tri-State Equipment Company Inc.

Email: [email protected]
Web: www.tsoverheadcrane.com
PH: 314-869-7200 | FAX: 314-869-7226

Demag Cranes & Components GmbH

PO Box 67 · 58286 Wetter (Germany)
Phone +49 (0 )2335 92-0
Fax +49 (0 )2335 92-7676
Printed in Germany

Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, 58286 Wetter (Germany)

Subject to change. Not liable for errors or omissions.