Beruflich Dokumente
Kultur Dokumente
Page
Contents
1 Safety instructions 3
1.1 Symbols 3
2.2 Direct control, assembling the limit switch for the upper hook position 4
2.2.1 Mounting the spring buffer 5
2.3 Contactor control, assembling the limit switch for upper hook position 6
2.3.1 Mounting the spring buffer 7
3.2 Direct control, assembling the limit switch for the upper hook position 12
3.2.1 Mounting the spring buffers 13
3.3 Contactor control, assembling the limit switch for upper hook position 14
3.3.1 Mounting the spring buffers 15
4 Wiring diagram 20
4.1 Direct control
Upper limit switch 20
Upper and lower limit switches 21
4.2 Contactor control
Upper limit switch 22
Upper and lower limit switches 23
2
Foreword
You have purchased a Mannesmann Dematic product. This chain hoist was manu-
factured in accordance with German and European standards and regulations
e.g. EC Machinery Directive 89/392/EEC, and state-of-the-art engineering principles.
For safety instructions applying to electrical equipment, see 206 978 44, 720 IS 900.
These safety instructions are designed to provide the operator with appropriate in-
structions for safe and correct operation.
Every individual given the task of transporting, mounting, commissioning, operating,
maintaining and repairing our product and additional equipment must have read and
understood
• the operating instructions
• the safety regulations
• safety instructions in the individual chapters and sections.
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.
1 Safety instructions
1.1 Symbols These symbols are used throughout the operating instructions in order to visually
indicate hazard warnings or to give you assistance.
3
2 Limit switches, 1/1 reeving
2.1 Preparation for assem- Before assembling a supplied set of limit switches, disassemble the following compo-
nent parts of the chain hoist in accordance with the Operating instructions,
bly of limit switch set 206 867 44:
• chain collector box
• limit stop
• load hook assembly
• chain (run out with motor)
• hook assembly buffer cap
(not required for the upper limit switch)
• for limit stop, see section 2.1.1 below.
2.1.1 Removing the upper limit stop The limit stop is not required for the limit switch set
1 2
3 3 6
6
1 2 5
Insert angular clamping spring (1) behind the sup- 5 Fit insert together with switching element (6).
porting rail (2). Then secure the supporting rail (2) Press cap (5) into the insert (4). Insert limit switch (6)
using 2 Torx screws (3). into the cap (5).
12 13 17
14 18
Screw stud bolt (11) into the assigned tapped hole Fit rocker (17).
underneath the electrical housing with Loctite. Insert spacer sleeve (18) into the rocker (17) and
Continue as follows: fasten to the chain guide using set pin (16).
Assemble spring (12), operating lever (13) and
locknut (14) as shown above.
Using the locknut (14), tighten the operating
lever (13) to a dimension of 12,5 mm.
28
27
28 31
29
30
Fig. 4 41908244.eps
5
2.3 Contactor control
Assembling the limit switch for the upper hook position
1
1
1
2
2
3 3 5
3 ca. 12,5 mm
2 4
2
6
7
Push the switch rod (1) upwards into the assigned Press the two washers (3) apart. To secure the Screw stud bolt (5) into the assigned tapped hole
bore hole in the electrical housing. Then insert the switch rod (1), fit the snap ring (4) into the groove underneath the electrical housing with Loctite.
two springs (2) and the two washers (3). provided. Continue as follows:
Assemble spring (6), operating lever (7) and
locknut (8) as shown above.
Using the locknut (8), tighten the operating
lever (7) to a dimension of 12,5 mm.
Fig. 5 41165644.eps 41165744.eps 41492644.eps
35
7
10
13
12
9
11
Fit rocker (9). Insert insulating strip (12). Insert momentary-contact limit switch (13) into its
Insert spacer sleeve (11) into the rocker (9) and locating position. Press connection cable into the
fasten to the chain guide using set pin (10). holding clips (35).
15
14
Fix momentary-contact switch in position with Fit the terminal strip (14) into the housing and
plastic cover and secure using 2 Torx screws. secure using 2 Torx screws (15).
28
27
31
28
30
29
41907844.eps
Fig. 8
7
2.4 Direct control
Assembling the limit switch for the upper and lower hook positions
6
3 3
6
1 2 5
10
9 10
7
11 ca. 12,5 mm
8
13 15
6 12
14 Screw in
threaded insert
Insert the switching element (7) into the location Screw stud bolt (11) into the assigned tapped hole Push the switch rod (15) upwards into the as-
provided in the electrical housing. underneath the electrical housing with Loctite. signed bore hole in the electrical housing.
Secure using the 2 Torx screws (10) through the Continue as follows:
terminal strip (8) and earth terminal (9). Assemble spring (12), operating lever (13) and
locknut (14) as shown above.
Using the locknut (14), tighten the operating
lever (13) to a dimension of 12,5 mm.
Fig. 10 41164744.eps 41901844.eps 41902044.eps
24
20
ca. 11,5 mm
21 22 25
26
23
Screw stud bolt (20) into the assigned tapped hole Fit rocker (9).
underneath the electrical housing with Loctite. Insert spacer sleeve (26) into the rocker (25) and
Continue as follows: fasten to the chain guide using set pin (24).
Assemble spring (21), operating lever (22) and
locknut (23) as shown above.
Using the locknut (23), tighten the operating
lever (22) to a dimension of 11,5 mm.
28
33
27 32
31
28
33
29
30
Fig. 12 41908044.eps
9
2.5 Contactor control
Assembling the limit switch for the upper and lower hook positions
1
1
1
2 2
3
3 3 5
ca. 12,5 mm
4
2 2
6
7
Push the switch rod (1) upwards into the assigned Press the two washers (3) apart. To secure the Screw stud bolt (5) into the assigned tapped hole
bore hole in the electrical housing. Then insert the switch rod (1), fit the snap ring (4) into the groove underneath the electrical housing with Loctite.
two springs (2) and the two washers (3). provided. Continue as follows:
Assemble spring (6), operating lever (7) and
locknut (8) as shown above.
Using the locknut (8), tighten the operating lever (7)
to a dimension of 12,5 mm.
35
13
10
13
12
11
Fit rocker (9). Insert insulating strip (12). Insert the two momentary-contact limit
Insert spacer sleeve (11) into the rocker (9) and switches (13) into their locating positions.
fasten to the chain guide using set pin (10). Press connection cables into the holding
clips (35).
15
14
Fix momentary-contact switches in position with Fit the terminal strip (14) into the housing and
plastic cover and secure using 2 Torx screws. secure using 2 Torx screws (15).
The following assembly points are described in the relevant sections of the
DKUN 1 Operating instructions, 206 867 44.
28
1. Run in chain with motor (section 5.8) 33
2. Slide the spring buffers (27/28) onto the chain
27 32
3. Fit the hook assembly (section 5.8) without buffer cap (29)
31
4. Slide the spring buffers (32/33) onto the chain
5. Fix limit stop (30) to the 10th link of the chain (section 5.8) 28
33
6. Fit the chain collector box (31) (section 5.11) 29
30
Fig. 16 41910644.eps
3.1 Preparation for assem- Before assembling a supplied set of limit switches, disassemble the following compo-
nent parts of the chain hoist in accordance with the Operating instructions,
bly of limit switch set 206 867 44:
• chain collector box
• bottom block
• buffer plug from the bottom block assembly
not required for the upper limit switch
• limit stop (at the dead end of the chain)
• chain (run out with motor)
• for limit stop, see section 3.1.1 below
3.1.1 Removing the upper limit stop
The limit stop is not required for the limit switch set
1
2
Remove the two bolts (1). Remove limit stop (2) with chain.
Fig. 17 41892944.eps 41893044.eps 11
For further procedure, see sections: 3.2 Direct control
Assembling the limit switch for upper hook position.
3.3 Contactor control
Assembling the limit switch for upper hook position.
3.4 Direct control
Assembling the limit switch for upper and lower hook positions.
3.5 Contactor control
Assembling the limit switch for upper and lower hook positions.
3 3 6
6
1 2 5
Insert angular clamping spring (1) behind the sup- 5 Fit insert together with switching element (6).
porting rail (2). Then secure the supporting rail (2)
Press cap (5) into the insert (4). Insert limit switch (6)
using 2 Torx screws (3).
into the cap (5).
Fig. 18 41165144.eps 41901344.eps 41492444.eps
11 ca. 12,5 mm 16
12 13 17
14 18
Screw stud bolt (11) into the assigned tapped hole Fit rocker (17).
underneath the electrical housing with Loctite. Insert spacer sleeve (18) into the rocker (17) and
Continue as follows: fasten to the chain guide using set pin (16).
Assemble spring (12), operating lever (13) and
locknut (14) as shown above.
Using the locknut (14), tighten the operating
lever (13) to a dimension of 12,5 mm.
3.2.1 Mounting the spring buffers The following assembly points are described in the relevant sections of the
DKUN 1 Operating instructions, 206 867 44.
2
Push chain with 2/1 chain anchor (2) into stop (1) Place chain sprocket into chain loop. The chain is
from below. correctly aligned when the links are not twisted.
Push stop (1) sideways into the chain guide slot, Tightening torque of the bolt (3) 4 Nm
chain anchor (2) clicks into the round section provid-
ed in the chain guide.
28 33
27
4. Fit the bottom block without buffer plug (29) (section 5.9) 32
5. Fix limit stop (30) to the 10th link of the chain (section 5.8)
6. Fit the chain collector box (31) (section 5.11) 28 31
33
29
30
Fig. 22 41907744.eps
13
3.3 Contactor control
Assembling the limit switch for the upper hook position
1
1
1
2 2
3 5
3 3 ca. 12,5 mm
4
2 2
6
7
Push the switch rod (1) upwards into the assigned Press the two washers (3) apart. To secure the Screw stud bolt (5) into the assigned tapped hole
bore hole in the electrical housing. Then insert the switch rod (1), fit the snap ring (4) into the groove underneath the electrical housing with Loctite.
two springs (2) and the two washers (3). provided. Continue as follows:
Assemble spring (6), operating lever (7) and
locknut (8) as shown above.
Using the locknut (8), tighten the operating lever (7)
to a dimension of 12,5 mm.
35
7
10
13
12
9
11
Fit rocker (9).
Insert spacer sleeve (11) into the rocker (9) and Insert insulating strip (12). Insert momentary-contact limit switch (13) into its
fasten to the chain guide using set pin (10). locating points. Press connection cable into the
holding clips (35).
Fig. 24 41901444.eps 41166144.eps 41166344.eps
15
14
Fix momentary-contact switch in position with Fit the terminal strip (14) into the housing and
plastic cover and secure using 2 Torx screws. secure using 2 Torx screws (15).
3.3.1 Mounting the spring buffers The following assembly points are described in the relevant sections of the
DKUN 1 Operating instructions, 206 867 44.
2
Push chain with 2/1 chain anchor (2) into stop (1) Place chain sprocket into chain loop. The chain is
from below. correctly aligned when the links are not twisted.
Push stop (1) sideways into the chain guide slot, Tightening torque of the bolt (3) 4 Nm
chain anchor (2) clicks into the round section provid-
ed in the chain guide.
28
33
4. Fit the bottom block without buffer plug (29) (section 5.9)
5. Fix limit stop (30) to the 10th link of the chain (section 5.8) 27 32
6. Fit the chain collector box (31) (section 5.11)
31
28 33
29 30
Fig. 28 41907944.eps
15
3.4 Direct control
Assembling the limit switch for the upper and lower hook positions
3 3 6
6
1 2 5
4
5
Insert angular clamping spring (1) behind the sup- Fit insert together with switching element (6).
porting rail (2). Then secure the supporting rail (2) Press cap (5) into the insert (4). Insert limit switch (6)
using 2 Torx screws (3). into the cap (5).
Fig. 29 41165144.eps 41901344.eps 41901744.eps
10
9 10
7
11 ca. 12,5 mm
8
15
12 13
6
Screw in
14
threaded insert
Insert the switching element (7) into the location Screw stud bolt (11) into the assigned tapped hole Push the switch rod (15) upwards into the as-
provided in the electrical housing. underneath the electrical housing with Loctite. signed bore hole in the electrical housing.
Secure using the 2 Torx screws (10) through the Continue as follows:
terminal strip (8) and earth terminal (9). Assemble spring (12), operating lever (13) and
locknut (14) as shown above.
Using the locknut (14), tighten the operating
lever (13) to a dimension of 12,5 mm.
24
20
ca. 11,5 mm
21 22 25
23 26
Screw stud bolt (20) into the assigned tapped hole Fit rocker (9).
underneath the electrical housing with Loctite. Insert spacer sleeve (26) into the rocker (25) and
Continue as follows: fasten to the chain guide using set pin (24).
Assemble spring (21), operating lever (22) and
locknut (23) as shown above.
Using the locknut (23), tighten the operating
lever (22) to a dimension of 11,5 mm.
2
Push chain with 2/1 chain anchor (2) into stop (1) Place chain sprocket into chain loop. The chain is
from below. correctly aligned when the links are not twisted.
Push stop (1) sideways into the chain guide slot, Tightening torque of the bolt (3) 4 Nm
chain anchor (2) clicks into the round section provid-
ed in the chain guide.
4. Fit the bottom block without buffer plug (29) (section 5.9)
5. Slide spring buffers (32/33) onto the chain 28
6. Fix limit stop (30) to the 10th link of the chain (section 5.8) 33
7. Fit the chain collector box (31) (section 5.11) 27
32
31
28
29 33
30
Fig. 34 41908144.eps
17
3.5 Contactor control
Assembling the limit switch for the upper hook position
1
1
1
2
2
3 3 5
3 ca. 12,5 mm
2 4
2
6
7
8
Push the switch rod (1) upwards into the assigned Press the two washers (3) apart. To secure the Screw stud bolt (5) into the assigned tapped hole
bore hole in the electrical housing. Then insert the switch rod (1), fit the snap ring (4) into the groove underneath the electrical housing with Loctite.
two springs (2) and the two washers (3). provided. Continue as follows:
Assemble spring (6), operating lever (7) and
locknut (8) as shown above.
Using the locknut (8), tighten the operating lever (7)
to a dimension of 12,5 mm.
35
7
10 13
13
12
9
11
Fit rocker (9).
Insert spacer sleeve (11) into the rocker (9) and Insert insulating strip (12). Insert both momentary-contact limit switches (13)
fasten to the chain guide using set pin (10). into their locating position. Press connection
Fig. 36 41901444.eps 41166144.eps cables into the holding clips (35). 41166444.eps
15
14
Fix momentary-contact switches in position with Fit the terminal strip (14) into the housing and
plastic cover and secure using 2 Torx screws. secure using 2 Torx screws (15).
3.5.1 Mounting the spring buffers The following assembly points are described in the relevant sections of the
DKUN 1 Operating instructions, 206 867 44.
2
Push chain with 2/1 chain anchor (2) into stop (1) Place chain sprocket into chain loop. The chain is
from below. correctly aligned when the links are not twisted.
Push stop (1) sideways into the chain guide slot, Tightening torque of the bolt (3) 4 Nm
chain anchor (2) clicks into the round section provid-
ed in the chain guide.
28
4. Fit the bottom block without buffer plug (29) (section 5.9) 33
5. Slide spring buffers (32/33) onto the chain 27
32
6. Fix limit stop (30) to the 10th link of the chain (section 5.8)
7. Fit the chain collector box (31) (section 5.11) 31
28
29 33
30
Fig. 40 41908344.eps
19
4 Wiring diagram
Hoist unit
Lift Lower
Limit switch Lift
For required supply cable conductor
Crane switch cross sections and mains connection
fuses:
See Operating instructions!
PE PE
+
L3 2
+
L2 2
+
L1 1
+ -X1
-SO11A1
11 21 31 1 2
- W1
3 4
12 22 32 -S1
PE
4
-X1 -M013 -X1 PE 1 2 3 4 5 6 7 8 9 17 18 19 20
-S1
10
11
12
13
1 3
9
2 4
-X1 19 20
1 11
2 21
-S011A2 13 23 53 63
3 31
4 12 -S011A1
14 24 54 64
10 22
11 32
22 32
33 34 6 12 53 63
43 44 5 22
11 12 7 34
21 22 8 44
-S011A2
12 13
13 23
9 64
-M013
9
1W1 2W1
1V1 M 2V1
3
1U1 2U1
PE
Important
Remove bridges -S011A2 13 - -
S011A2 53 and -S011A2 23 - -
S011A2 63 in the control pendant!
List of equipment
-M013 = Hoist motor
-X1 = Terminal strip
-S015 = Emergency stop
-S011A1 = Crane switch
-S011A2 = Lift/Lower button
-S1 = Limit switch Lift
Cable list
-W1 = for cable, see operating instructions
-W12 = YMHYKT-0 14 x 1,5
19847346.eps
20 Fig. 41
Upper and lower limit switches
Hoist unit
Lift Lower
Limit switch Lift
For required supply cable conductor
Crane switch Limit switch Lower cross sections and mains connection
fuses:
See Operating instructions!
PE PE
+
L3 2
+
L2 2
4 3
+
L1 1
2 1
+ -X1 -S2
-SO11A1
11 21 31 4 3
- W1
2 1
12 22 32 -S1
16
PE
-X1
5
15
-S1 2 4 -S2 4 2 -M013 -X1 PE 1 2 3 4 5 6 7 8 9 15 16 17 18 19 20
10
11
12
13
14
15
1
9
1 3 3 1
17 18 20 19
-X1 -X1
1 11
-W12
2 21
-S011A2 13 23 53 63
3 31
4 12 -S011A1
14 24 54 64
10 22
11 32
33 34 6 12
43 44 5 22
11 12 7 34
21 22 8 44
12 13
-S011A2
13 23
15 64
14 63
-X1 4 -X1 5 6 4 -X1 9 8 7 9 54
-M013
9
DSK3DP2S
1W1 2W1
1V1 M 2V1
3
1U1 2U1
PE
Important
Remove bridges-S011A2 13 - -
S011A2 53 and -S011A2 23 - -
S011A2 63 in the control pendant!
List of equipment
-M013 = Hoist motor
-X1 = Terminal strip
-S015 = Emergency stop
-S011A1 = Crane switch
-S011A2 = Lift/Lower button
-S1 = Limit switch Lift
-S2 = Limit switch Lower
Cable list
-W1 = for cable, see operating instructions
-W12 = YMHYKT-0 18 x 1,5
19848546.eps
Fig. 42 21
4.2 Contactor control
Upper limit switch
Hoist unit
Control power transformer Lift Fast
Thermal release Emergency stop Lower
1L1
1L2
1L3
PE
Limit switch
-W12 1
-X2 10 -S015 12 22 32 Lift
-W1 1 2 3 GNYE
-X2 L1 L2 L3 -X2 PE 11 21 31
7 9
105°C
1 13 24 43 54
-S0168
-T013
-X2 PE 23 53
44
-X901 PE -X901 PE
-X2 15
5 3 1 5 3 1 1
-S0160
-K016 -K017
6 4 2 6 4 2 2
R8 R6 4 2
-K018
R7 R5 3 1
2 1 2 1 2 1
01.1 01.2 01.2
4 3 4 3 4 3
01.1 01.2 01.2
6 5 6 5 R6 R5
1W1 2V1 01.1 01.2 01.2
22 21 22 21 R8 R7
1V1 M 2W1 01.2
3AC
1U1 2U1
PE
-M012
PE
For required supply cable conductor
cross sections and mains connection
fuses:
See Operating instructions!
List of equipment
-K016 = Contactor Lift
2 - S016D 1
-K017 = Contactor Lower - W1
-K018 = Pole-changing contactor for hoist unit
PE
- M012 - X2
-S016B = Lift/Lower button
-S016D = Limit switch Lift
1
3
4
2
22 Fig. 43 36850846.eps
Upper and lower limit switches
Hoist unit
Control power transformer Lift Fast
Thermal release Emergency stop Lower
1L1
1L2
1L3
PE
-X901 PE -X901 PE
-X2 15 -X2 16
15
5 3 1 5 3 1 1 1
-S0160 -S0170
-K016 -K017
6 4 2 6 4 2 2 2
R8 R6 4 2
-K018
R7 R5 3 1
2 1 2 1 2 1
01.1 01.2 01.2
4 3 4 3 4 3
01.1 01.2 01.2
6 5 6 5 R6 R5
1W1 2V1 01.1 01.2 01.2
22 21 22 21 R8 R7
1V1 M 2W1 01.2
3AC
1U1 2U1
PE
-M012
PE
For required supply cable conductor
cross sections and mains connection
fuses:
See Operating instructions!
List of equipment
-K016 = Contactor Lift
-K017 = Contactor Lower
2 - S016D 1 3 - S017D 4
-K018 = Pole-changing contactor for hoist unit
-M012 = Hoist motor
-S015 = Emergency stop
-S016B = Lift/Lower button
PE
L1
L2
L3
10
12
13
14
15
16
- M012 - X2
-S016D = Limit switch Lift
-S017D = Limit switch Lower
PE
1
2
3
1
1
2
3
Fig. 44 36852646.eps 23
Reproduction in whole or in part only with prior consent of Mannesmann Dematic AG, D-58286 Wetter Subject to alteration
Mannesmann Dematic AG
P.O. 67, D-58286 Wetter
Telephone (+2335) 92-0, Telefax (+2335) 927676
Internet http://www.dematic.com
Printed in Germany MBR/0299/1T