Technical data

D-Balancers D-BP 55 and D-BP 110

42104744.eps

291102 EN/PDF 120503 203 359 44 714 IS 862

 Part nos. Demag rope balancer D-BP 55
Part no.
922 020 46 Basic unit with U-type seal
922 021 46 Basic unit with T-type seal
922 011 46 with up/down control
922 012 46 with up/down control and D-BGR
922 013 46 with 1-load balancer control
922 014 46 with 2-load balancer control
922 015 46 with manual force control

Demag rope balancer D-BP 110

Part no.
922 022 46 Basic unit with U-type seal
922 023 46 Basic unit with T-type seal
922 001 46 with up/down control
922 002 46 with up/down control and D-BGR
922 003 46 with 1-load balancer control
922 004 46 with 2-load balancer control
922 005 46 with manual force control

Selection of the basic unit depending
on the application and type of seal
The Demag rope balancer is available with two different piston seals. If the devices
are ordered with Demag controls, the type of control determines the type of seal.
Depending on the application, the basic units differ in the type of piston seal.
Available are:
1. Low-friction type with T-type seal.
For applications in which the load is to be moved with low manual force without
control pendant.
Used e.g. in connection with a 1-, 2-, n-load balancer control, as well as with the
electro-pneumatic manual force control.
Due to physical reasons, this seal lets escape a small quantity of air.
This type is less suitable for applications in which the load is to be held over a
longer period of time, even if the compressed air supply of the cylinder is inter-
rupted (e.g. up/down operation).

2. Optimized seal tightness type with U-type seal.

For applications in which loads are to be moved by means of the control pen-
dant and are to be moved by hand only in a small range. If the compressed
air supply of the cylinder is interrupted, the load is held in position over a long
period of time.
Used e.g. in connection with an up/down control, which allows manual move-
ment of the load only within the air cushion range, i.e. it springs back into its
original position.

Note: The rope balancer should not be used in connection with a busbar line
integrated in the KBK rail, since the manual force required for the rope
balancer is lower than the force required for displacing the current collector.
20335944.p65/120503

2
 Dimensions
Length x Width x Height (C- dim.) 1)
Up/down control 1-load balancer control 2-load balancer control Manual force control
D-BP 55 425 x 308 x 445 425 x 308 x 410 425 x 308 x 410 425 x 308 x 758
D-BP 110 508 x 335 x 477 508 x 335 x 429 508 x 335 x 429 508 x 335 x 813

42541244.eps 42541344.eps 42541544.eps 42541744.eps

Up/down control 1-load balancer control 2-load balancer control Basic unit 2)
with speed governor D-BGR incl. swivel unit incl. swivel unit
D-BP 55 425 x 308 x 445 425 x 308 x 527 425 x 308 x 527 425 x 308 x 223
D-BP 110 508 x 335 x 477 508 x 335 x 546 508 x 335 x 546 508 x 335 x 250

42541244.eps 42541444.eps 42541644.eps 42541844.eps

1) Height dimensions from centre of suspension eye bore hole
2) Design dimensions of basic unit see page 4

SWL SW L at

3 b ar 4 b ar 5 b ar 6 b ar 7 b ar 8 b ar 9 b ar 10 b ar

D-BP 55 2 5 kg 3 5 kg 4 5 kg 5 5 kg 6 5 kg 7 5 kg 8 5 kg 9 5 kg
D-BP 110 5 0 kg 7 0 kg 9 0 kg 1 1 0 kg 1 3 0 kg 1 5 0 kg 1 7 0 kg 1 9 0 kg

Rope balancers are used with a supply pressure of 6 bar (max. permissible pressure
10 bar, with limited service life of the mechanical components).
The SWL specified is based on a pressure loss of the control of 0.5 bar.
Pneumatic and electro-pneumatic controls require a pressure difference between
the system pressure and the internal pressure in the cylinder of 0.5 bar, in order to
be able to move loads with lower manual forces and at higher speeds.
20335944.p65/120503

3
 Suspension heights, rope The standard rope length of the Demag D-BP rope balancer is 6 m including the
safety windings on the rope drum. The length is divided into 1.25 m safety windings
always remaining on the drum, 2 m max. hook path and 2.75 m dead rope. This
results in a max. suspension height of 4.75 m – from the lower edge of the rope
balancer. If the rope balancer is to be fitted at larger suspension heights, a longer
rope can be ordered for this specific case (please state when ordering).
Available as special ropes are
• special steel ropes (require shorter maintenance intervals))
• 6-strand ropes, especially for the American market, part no.: 826 621 44
• easily bending ropes, particularly suitable, if the rope is to be lead through addi-
tional rope sheaves. Part no.: 826 777 44
All ropes have a diameter of 5 mm.
For the up/down control the DSK control pendant is equipped with a 3.5 m long
supply cable as standard. The control pendant should be suspended at a height of
approx. 1 -1.5 m above floor level. If the rope balancer is fitted at larger suspension
heights (> 4.5 m), a longer supply cable is required for the DSK control pendant.
The manual force control is equipped with a helical cable with a standard length of
2.8 m (extended) for transmitting the electric signals from the D Grip. This limits the
suspension height to max. 3.8 m from the lower edge of the rope balancer.
Larger suspension heights require a special helical cable which must be stated
additionally when ordering (please state suspension height).
Shortening the helical cable will not result in a reduction of the C dimension.

Interface for load handling device

See load handling devices for fitting to quick-release coupling, e.g. hook for
quick-release coupling, PGS etc.
Rope socket, cranked Rope socket
Part no.: 826 557 44 Part no.: 151 837 99

42541944.eps

Swivel unit incl. rope socket (part no.: 773 260 44)
20335944.p65/120503

4 42540944.eps
 D Grip with swivel unit and rope socket D Grip solo

42543644.eps

Hook assembly
Part no. 826 640 44 Part no. 826 641 44
primarily for the US market
20335944.p65/120503

42541144.eps 5
 Dimensions

Detail A
Bore hole for M8 thread “screw-cut”
l3
l5

Connecting plate not

included in the scope
of supply
h6

Thread cutting screw, DIN 7500 EE M8 x 30

Part no. 324 737 99 (4 off)

b5
Detail X
b4
b3

R2
5

l2
l1
B d2
X B
R
h2

h5

h7

B
h1

h4
h3

A A l4

b1 b2 d1
b l

42104544.eps

Size b b1 b2 b3 b4 b5 d1 d2 h1 h2 h3 h4 h5 h6 h7 l l1 l2 l3 l4 l5
min. max.

D- B P 5 5 425 206 219 194 24 199 197 24 6 308 92 104 65

32 50 68 75 16,5 10 14 150 150
D- B P 1 1 0 508 240 268 216 27 219 218 22 21 335 105 116 53
20335944.p65/120503

6
 Mounting The rope balancer may either be suspended from the suspension eyes of the hous-
ing or from the thread cutting screw DIN 7500 EE M8 x 30, part no. 324 737 99
(4 off) according to the bore hole pattern on the lower side of the housing (see di-
mension l4 / b5).
For connecting the rope balancer to KBK, the load bar must be used
(part no. 984 685 44).
Dimension h4 in the dimension table is without clamp section and buffer on the
rope. If required, dimension h4 is increased by 19 mm in both cases.

If the universal pin set (external fitting) is used for fitting to the D Lift, the connecting
plates may be fitted on the suspension eyes from the outside (max. plate thickness
6 mm).

Universal pin set for fitting to the inside of the suspension eyes,
part no.: 826 548 44. Maximum width of the suspension 31 mm.

42540744.eps

Overhead mounting If the electro-pneumatic manual force control is used for D-BP 55 and D-BP 110
rope balancers, attention must be paid to the fact that overhead mounting (com-
pressed air supply on the lower side or rope outlet on the top) is not allowed. Any
other mounting position is possible.
All other control types may be mounted in any position.
20335944.p65/120503

7
 Weights D-BP 55 [kg]
Basic unit (without control) 18,0
Up/down (incl. DSK and hose) 2,9
Up/down (inkl. speed governenor DSK and hose) 5,3
1-load balancer control 3,0
2-load balancer control 7,2
Manual force control (incl. handle and helical cable 2800 mm) 8,7
Rope wedge set with swivel unit 0,7

D-BP 110 [kg]

Basic unit (without control) 27,0
Up/down (incl. DSK and hose) 3,3
Up/down (inkl. speed governenor DSK and hose) 5,7
1-load balancer control 3,3
2-load balancer control 7,7
Manual force control (incl. handle and helical cable 2800 mm) 13,5
Rope wedge set with swivel unit 0,7

Power supply Compressed air quality

acc. to ISO 8573-1

Solid particles class 3 (< 5 mm)

Water class 4 (dew point < +3°C)
Oil class 4 (< 5 mg/m³)

Compressed air connection

Connection of the supply line via plug-in connector NW 7.2 mm or NPT 3/8" thread
(for USA only)

Voltage (only for manual force control)

100 - 240 V AC single-phase, 47 - 63 Hz

Accessories

RUN ERROR

42520944.eps

For setting the parameters of the manual force control an operator terminal with
20335944.p65/120503

extension cable is required (part no.: 650 090 45)

The terminal must always be operated together with the extension cable, otherwise
faults may occur in signal transmission.
The handle of the electro-pneumatic manual force control is equipped with a quick-
release coupling at its lower end.
8
 A protective plate is available for the D Grip system (part no. 773 235 44), which
protects the right-angle plug against damage. The protective plate is galvanized.

Protective plate (option)

42540844.eps

For applications in which the load is turned around a vertical axis, a swivel unit is
available (part no. 773 260 44) which protects the rope and consists of a rope
wedge connection and a swivel unit mounted on ball bearings.

42540944.eps
20335944.p65/120503

9
 D brake system (on request) This system is exclusively used to prevent that the load slowly sinks, if the com-
pressed air supply fails completely.
The system is not suitable for actively braking from the working motion.
If the compressed air supply of the rope balancer is switched off or a loss of com-
pressed air reduces pressure down to 0 bar, the load will sink after a certain period
of time.
It is possible to prevent this creeping movement of the load by means of the option-
al D brake for the D-BP 110.
The D brake system is supplied with 2 bar from an internal separate compressed air
supply. This pressure works against a spring force which is required to mechanical-
ly operate a pin engaging with the rope drum, thus preventing that the load sinks in
the case of a loss off compressed air. The D brake system becomes active, when
the pressure in the supply line decreases down to 0 bar. Therefore it is recom-
mended to select the shutoff unit with valve so that active venting of the supply line
to the rope balancer is possible.
In the case of a pressure reduction >0 bar , the D brake system does not become
active.
This option is not available for D-BP 55.

D brake

42541044.eps
20335944.p65/120503

10
 Interface to the load handling device Load hook 1) Hook assembly Rope socket Swivel unit
swivelling cranked
- 826 640 44 (DK)
Up/down control 826 557 44 2) 773 260 44 2)
- 826 641 44 ( B )

1-load balancer - 826 640 44 (DK)

control - 826 641 44 ( B )
826 557 44 773 260 44
2-load balancer - 826 640 44 (DK)
control - 826 641 44 ( B )
Manual force control 835 665 44 - 3)

(DK) = DK hook assembly, (B) = Bullard hook assembly (primarily for the US market)

1) only for the quick-release coupling of the DKM-5 control handle of the DKM 1 Manulift.
2) Fitting only allowed, if
1. the load handling device is permanently attached and
2. has a min. weight of 3.5 kg.
3) Swivel unit and rope socket integrated in the D Grip operating element of the manual force control.

The load handling devices known from the DK range, such as

• load hook
• C hook
• parallel gripper system etc.
are available for the manual force control for connection to the quick-release cou-
pling.
The devices can be engaged on the lower side of the handle.
Further load handling devices for the quick-release coupling see technical data of
DKUN.

Accompanying documents Ident. no.:

D-BP pneumatic rope balancer (brochure) 213 055 44
Operating instructions Demag rope balancer 214 421 44
Operating instructions Up/down control 214 587 44
Operating instructions 1 load balance control 214 654 44
Operating instructions 2 load balance control 214 627 44
Operating instructions manual force control 214 611 44
Operating instructions DKM 1 214 087 44
Data sheet Load bar for rope balancer 214 196 44
Data sheet Power supply in preparation
Technical data DKUN 202 846 44
20335944.p65/120503

11
Demag Cranes & Components GmbH
P.O. Box 67, D-58286 Wetter
Printed in Germany

Telephone (+49 2335) 92-0, Telefax (+49 2335) 927676

www.demagcranes.com

Reproduction in whole or in part only with prior consent of Demag Cranes & Components GmbH, D-58286 Wetter Subject to change. Not liable for errors or omissions.