Technical Data

203 359 44 714 IS 862291102 EN/PDF 120503

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Technical dataD-Balancers D-BP 55 and D-BP 110

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Part nos.

The Demag rope balancer is available with two different piston seals. If the devicesare 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 withoutcontrol pendant.

Used e.g. in connection with a 1-, 2-, n-load balancer control, as well as with theelectro-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 alonger 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 compressedair supply of the cylinder is interrupted, the load is held in position over a longperiod 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 itsoriginal position.

The rope balancer should not be used in connection with a busbar lineintegrated in the KBK rail, since the manual force required for the ropebalancer is lower than the force required for displacing the current collector.

Selection of the basic unit dependingon the application and type of seal

Note:

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Dimensions

SWL

Rope balancers are used with a supply pressure of 6 bar (max. permissible pressure10 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 betweenthe system pressure and the internal pressure in the cylinder of 0.5 bar, in order tobe able to move loads with lower manual forces and at higher speeds.

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Suspension heights, rope The standard rope length of the Demag D-BP rope balancer is 6 m including thesafety windings on the rope drum. The length is divided into 1.25 m safety windingsalways remaining on the drum, 2 m max. hook path and 2.75 m dead rope. Thisresults in a max. suspension height of 4.75 m – from the lower edge of the ropebalancer. If the rope balancer is to be fitted at larger suspension heights, a longerrope 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 longsupply cable as standard. The control pendant should be suspended at a height ofapprox. 1 -1.5 m above floor level. If the rope balancer is fitted at larger suspensionheights (> 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 of2.8 m (extended) for transmitting the electric signals from the D Grip. This limits thesuspension 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 statedadditionally when ordering (please state suspension height).

Shortening the helical cable will not result in a reduction of the C dimension.

Interface for load handling deviceSee load handling devices for fitting to quick-release coupling, e.g. hook forquick-release coupling, PGS etc.

Swivel unit incl. rope socket (part no.: 773 260 44)

Rope socket

Part no.: 151 837 99

Rope socket, cranked

Part no.: 826 557 44

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Hook assembly

Part no. 826 640 44

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D Grip with swivel unit and rope socket

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Part no. 826 641 44primarily for the US market

D Grip solo

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h6

R25

b4

b3

A

A

B

B

X

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b1 b2

b

h5

l3

l5

b5

R

A

B

d1

l4

h7

l

h4h3

l2l1

d2

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Dimensions

Bore hole for M8 thread “screw-cut”

Thread cutting screw, DIN 7500 EE M8 x 30Part no. 324 737 99 (4 off)

Connecting plate notincluded in the scopeof supply

Detail X

Detail A

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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 therope. 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 connectingplates may be fitted on the suspension eyes from the outside (max. plate thickness6 mm).

If the electro-pneumatic manual force control is used for D-BP 55 and D-BP 110rope 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. Anyother mounting position is possible.

All other control types may be mounted in any position.

Overhead mounting

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

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Weights

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

For setting the parameters of the manual force control an operator terminal withextension cable is required (part no.: 650 090 45)

The terminal must always be operated together with the extension cable, otherwisefaults 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.

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A protective plate is available for the D Grip system (part no. 773 235 44), whichprotects the right-angle plug against damage. The protective plate is galvanized.

Protective plate (option)

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

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D brake system (on request)

D brake

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 periodof 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 airsupply. 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 inthe case of a loss off compressed air. The D brake system becomes active, whenthe 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 lineto the rope balancer is possible.

In the case of a pressure reduction >0 bar , the D brake system does not becomeactive.

This option is not available for D-BP 55.

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Interface to the load handling device

(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 and2. 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 ofDKUN.

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

Accompanying documents

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Demag Cranes & Components GmbH

P.O. Box 67, D-58286 Wetter

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

www.demagcranes.com

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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.