Operating instructions

Double-load balance control system (pneumatic)

020502 EN 214 627 44 720 IS 853

 Manufacturer: Demag Cranes & Components GmbH
P.O. Box 67, D-58286 Wetter
Telephone (+49 2335) 92-0, Telefax (+49 2335) 927676
Internet http://www.demagcranes.de

1 Safety instructions 3
Contents
1.1 Symbols 3
1.2 Appropriate use 3
1.3 Inappropriate use 3
1.4 General safety information 4
1.5 Safety instructions for using pneumatic equipment 5
1.6 Safety instructions for assembly and disassembly 5
1.7 Safety instructions when first putting the unit into service
after completing installation 5
1.8 Safety instructions for operation 5

2 Technical data 6
2.1 Double-load balance control system scope of delivery 6
2.2 Operating principle 6
2.3 Weight 6

3 General 7
3.1 Inspection regulations 7
3.2 Noise emission measurement according to DIN 45653 7
3.3 Operating site 7
3.4 Storage and shipping 7
3.5 Operating conditions 7

4 Description 8
4.1 Double-load balance control system 8
4.2 Pneumatic connection interface 9
4.3 Putting into operation 9
4.4 Operation 9
4.4.1 End of shift 9
4.4.2 Switch-over delay 9
4.4.3 Sudden compressed air pressure drop 10
4.5 Taking the unit out of service and transportation 10
4.6 Changing the load 10
4.7 Signals 10
4.8 Pressure switch 10
4.9 Feeding in the switch-over signal 11

5 Inspections/maintenance 12
5.1 Inspection before starting work and during operation 12
5.2 Inspections and maintenance 12
5.3 Hoses and valves 12

6 Fault list 13
6.1 Double-load balance control system 13

7 Double-load balance control system component parts 14

These operating instructions only describe the components of the double-load

21462744K1.p65/020502

balance control system. The components for generating the switch-over

signals vary according to the installation and are not included in these
operating instructions.

2
 1 Safety instructions

1.1 Symbols The following symbols and recommendations indicate potential safety hazards or
causes of damage or provide useful information.

Hazard warning
This symbol appears in the operating instructions next to all instructions relating to
safety at work wherever a potential danger to life and limb exists.
Follow these instructions at all times and be particularly careful and cautious.
Pass on safety instructions to all persons entrusted with working on the product in-
cluding the power supply.
In addition, observe all general safety regulations at all times.

Operating hazard for the installation

This symbol in the operating instructions indicates all warnings which, if not complied
with, may result in damage to the product.

1.2 Appropriate use The product may only be operated when in perfect working order by trained person-
nel in accordance with the relevant safety and accident prevention regulations. This
also includes compliance with operating and maintenance conditions specified in the
operating instructions.
Double-load balance control systems are used with a system pressure of 6 bar (max.
permissible pressure 10 bar, with limited service life of the mechanical components).
For maintenance work on the double-load balance control system, the supply of
energy must be interrupted and it must be ensured that all pressurised components
are free of pressure.
During operation or when the energy supply is not switched off, pneumatic compo-
nents are pressurised. In the event of inappropriate operation and non-compliance
with the existing regulations, this may result in fatal situations.
Serious personal injury or damage to property may occur in the event of:
• unauthorized removal of covers,
• inappropriate use of the product,
• incorrect operation,
• insufficient maintenance,
• working on pressurised parts.

When using the double-load control system with the D-BP rope balancer, the follow-
ing items must be observed:
• The suspension height and the possible working range must be rated so that the
load can always be deposited at the lowest point without approaching the lower
end positions of the basic unit.
• The lower end position of the basic unit must not be approached in normal opera-
tion.

1.3 Inappropriate use Certain work and practices are prohibited when using the product as they may in-
volve danger to life and limb and result in lasting damage to the product, e.g.:
• Manipulating pneumatic equipment
• Supplying energy other than the compressed air specified on the type plate and in
these operating instructions.
• Non-compliance with specified mounting positions
• Non-compliance with the min./max. permissible operating temperature
When using the double-load control system with the D-BP rope balancer, the follow-
ing must be observed:
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• Loads must not drop when the rope is in a slack condition (see also operating
instructions 214 421 44).

3
 1.4 General safety informa- Persons under the influence of drugs, alcohol or medicines which affect reactions
must not install, put into service, operate, maintain, repair or disassemble the prod-
tion uct. Any conversions and modifications to the installation must comply with the tech-
nical safety requirements. Work on pneumatic equipment may only be carried out by
specialists in accordance with technical regulations. The product must be taken out
of service immediately and the relevant energy supplies must be disconnected in the
event of any malfunctions.
Malfunctions must be eliminated immediately.
National accident prevention regulations and codes of practice and general safety
regulations must be observed when operating our products. Important information
and instructions are marked by corresponding symbols. Follow these operating and
safety instructions to avoid personal injury and damage to machinery.
The operating instructions must be kept available at the place where the product is in
use at all times.
They include significant aspects and appropriate excerpts from the relevant guide-
lines, standards and regulations. The owner must instruct his personnel appropriately.
If the safety instructions given are not observed in any way, personal injury or even
death can result. Observe general statutory and other obligatory regulations relating
to accident prevention and environmental protection and basic health and safety
requirements in addition to those included in these operating instructions.
Such requirements may also relate, for example, to the handling of hazardous materi-
als or the provision/wearing of personal protection equipment.
Comply with these regulations and general accident regulations relevant for the place
at which the product is used and follow the instructions therein when working with
the product.
The product may still constitute a danger to life and limb if it is not installed, operated,
maintained or used appropriately by personnel which have not been trained or spe-
cially instructed.
The safety instructions must, if required, be supplemented by the owner with instruc-
tions and information (e.g. factory regulations) relating to organization of work, work-
ing procedures, operating personnel, etc. Supervising and reporting obligations as
well as special operating conditions must also be taken into consideration.
Personnel assigned to working with the product must have read the operating in-
structions and the safety instructions.
All activities relating to the product which are not described in the operating instruc-
tions may only be carried out by specifically trained specialist personnel. The owner
must ensure that personnel work in a safety and hazard-conscious manner in compli-
ance with the operating instructions. The owner must ensure that the product is only
operated when in proper working order and that all relevant safety requirements and
regulations are complied with.
The product must be taken out of service immediately if functional defects or irregu-
larities are detected.
In the event of a stoppage (e.g. if defects regarding safe and reliable operation are
detected, in emergency situations, in the event of operating malfunctions, for mainte-
nance purposes, if damage is detected or after finishing work), the operator/experi-
enced technician must carry out all prescribed safety measures or observe that they
are automatically carried out. Personal protective clothing must be worn as necessary
or as required by regulations. Personnel must not wear loose clothing, jewellery in-
cluding rings or long hair loose. Injury may occur, for example, by being caught or
drawn into the mechanism.
All safety and hazard warnings on the product, its access routes and energy supply
must be preserved completely and in legible condition.
Modifications, additions to and conversions of the product which may impair safety in
any way must not be carried out without the approval of Demag. Safety devices must
not be rendered inoperative. Only genuine Demag spare parts may be used. Observe
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prescribed deadlines or those specified in the operating instructions for routine

checks/inspections.

4
 1.5 Safety instructions for For handling pneumatically operated components, note that:
using pneumatic • potential hazards may be caused by stored compressed air.

equipment • dynamic movements may be caused as a consequence of the compressibility of

compressed air.

1.6 Safety instructions for • Installation and disassembly work may only be performed by experienced techni-
cians.
assembly and disas-
• Installation and disassembly work must be co-ordinated by the person carrying out
sembly the work and the owner within the scope of their responsibility.
• The assembly zone must be made safe.
• The installation must be isolated in accordance with the relevant technical regula-
tions (pneumatic equipment).
• Customer-specific regulations must be observed.
• Only appropriate, tested and calibrated tools may be used.

1.7 Safety instructions • The working area must be made safe.

when first putting the • First check that the rated pressure specified on the type plate of the handling
equipment matches and does not exceed the owner’s supply system.
unit into service after
• In the course of putting the product into service, it may be necessary to render
completing installation safety devices or features inoperative when carrying out adjustments or function
checks.
• When putting the unit into service, it may be necessary to perform work in the
danger zone, therefore, it must be ensured that only appropriately trained person-
nel are employed for this work.

1.8 Safety instructions for All instructions and measures described in the operating instructions with regard to
safe operation and items concerning general safety and accident prevention which
operation have to be observed before, during and after putting into service must be strictly
complied with. Any failure to comply can lead to accidents resulting in fatalities.
The product must be taken out of service immediately or not put into operation if any
defects relating to operating safety and reliability are detected.
Safety devices must not be rendered inoperative or modified in contradiction to their
intended use.
Only operate the product when all protective devices and safety-relevant equipment,
e.g. movable protective devices and emergency-stop devices, are fitted and fully
functioning.
In the event of damage to pneumatic devices and lines, immediately switch off the
handling equipment.
Ensure that nobody is endangered by operation of the product before switching it on
or putting it into operation.
If the operator notices persons who may be exposed to a risk to health or personal
safety by operation of the equipment, he must suspend operation immediately and
may not resume operation again until the persons are outside the danger zone.
Before putting the product into operation, the operator must be satisfied that the
product is in safe and correct operating condition.
Work on the product may only be carried out when instructions to this effect have
been issued, when operation and function of the equipment have been explained and
when the working and danger zone has been made safe.
Cooling devices, such as ventilation openings, may not be rendered permanently
21462744K1.p65/020502

inoperative (e.g. covered or closed). Special local conditions or special applications

can lead to situations which were not known when this chapter was written. In such
cases, special safety measures must be implemented by the owner.

5
 2 Technical data

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1
7
3

2
6

8
11

9
12
5

4 10

Note:
The scope of delivery for the D Lift and the D Arm differs
from the scope illustrated in the figure.
42533344.eps

2.1 Double-load balance These operating instructions only describe the components of the double-load
balance control system. The components for generating the switch-over
control system scope signals vary according to the installation and are not included in these
of delivery operating instructions.
The control system comprises:
1. Block for connecting the compressed air supply with one additional outlet for
special functions (not assigned in the basic version).
2. Pressure switch
3. Volume flow booster 1/2” (setting load 1)
4. Pilot control valve 1/8” (setting load 2)
5. Emergency lowering device
6. Bi-stable pulse valve 1/8” (load switch-over)
7. Safety valve
8. Supply tube dia. 14 x 2 mm
9. Screw-in connection G 1/2”
10. Mounting plate
11. Return valve
12. Distribution block
13. Signal delay

2.2 Operating principle The double-load balance control system is suitable for operation with pneumatically
operated handling equipment (manipulators, rope balancers, etc).
For operation of a pneumatic double-load balance control system, the handling
equipment to be controlled must be provided with a compressed air cylinder with
single function that acts against the suspended load.
The standard variant of the pneumatic double-load balance control system is de-
signed for D-BP rope balancers, D Lift lifting axes and D Arm parallelogram arms with
a working pressure of max. 10 bar.
The double-load balance control system makes it possible to change between two
pre-set loads e.g. for assembly processes (Load 1: Deadweight of the load handling
attachment; Load 2: sum of load handling attachment weight plus payload).
The air pressure required for load 1 and load 2 must be set accordingly (see sec-
tion 4.3).
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Switch-over between the two load stages is effected via pneumatic signals which are
sent from the load handling attachment to the double-load balance control system.
These signals ensure simultaneous change of the internal cylinder pressure for at-
taching and detaching the load.
2.3 Weight Weight of the complete control system approx. 8,0 kg
6
 3 General

3.1 Inspection regulations Routine inspections

Double-load balance control systems must be inspected by an experienced techni-

cian at least once a year.
Routine inspections mainly consist of a visual inspection and a function check which
should include a check to determine the condition of components and equipment
regarding damage, wear, corrosion or other alterations and a check to determine the
integrity and efficiency of safety devices. It may be necessary to dismantle the unit in
order to inspect wearing parts.

3.2 Noise emission meas- The noise emission level (LpAF) is:
urement according to less than
+2
70 dB (A)
DIN 45635
at a distance of 1 m from the control system.
These noise emission levels were measured under maximum load.
Structural influences such as
• transmission of noise via steel structures
• reflection of noise from walls, etc.
• Outgoing air noise of the control systems
were not allowed for in the above measurements.

3.3 Operating site The double-load balance control system may only be used in buildings and enclosed
areas.

3.4 Storage and shipping The air inlet openings are closed to prevent dirt from entering the system.
The air inlet openings may only be opened immediately before the unit is put into
operation.

Status as delivered/for transportation

The high-precision pressure controllers (3) and (4) of the double-load balance control
system are adjusted to a set pressure of 0 bar in the factory. Therefore, no hazardous
situation can occur when putting the unit into service.
For transportation of the double-load balance control system and the handling equip-
ment to be operated at a later stage, the high-precision pressure controllers (3)
and (4) must be adjusted to a set pressure of 0 bar again.

3.5 Operating conditions Double-load balance control systems can be operated at an ambient temperature of
+5° to +50°C.
Other operating conditions are also possible.
Please refer to the manufacturer for information on any modifications that may be
necessary. See page 2 for the address.
Compressed air specifications in accordance with ISO 8573-1:
• Solid particles Class 3 (< 5 µm)
• Water Class 4 (dew point < +3°C)
• Oil Class 4 (< 5 mg/m³)
The quality of the compressed air supply must be ensured by means of an upstream
maintenance unit.
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7
 4 Description

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1
7
3

2
6

8
11

9
12
5

4 10

Note:
The scope of delivery for the D Lift and the D Arm differs
from the scope illustrated in the figure.
42533344.eps

4.1 Double-load balance The double-load balance control system is used to balance two different loads pre-
set on high-precision pressure controllers (3) and (4), e.g. for assembly and
control system placement processes in which a payload is moved in a special fixture (load handling
attachment) and then deposited.
Load 1 is only the weight of the load handling attachment “Idle load”.
Load 2 is the total weight resulting from the load handling attachment plus payload
“Full load”.
The double-load balance control system can be used for
- Demag D-BP rope balancers,
- Demag D Arm parallelogram arms,
- Demag D Lift lifting axes.
Operation of the double-load balance control system is only ensured in combination
with a maintenance unit that guarantees the required compressed air specification
(see D-BP rope balancer operating instructions 214 421 44).

To ensure switch-over between the two pre-set loads and thus safe operation of the
double-load balance control system, a load handling attachment must be used which
either
a) provides pneumatic signals for the operating statuses ”Idle load” (load 1) and ”Full
load” (load 2) or
b) provides a pneumatic signal only for ”Full load” (load 2). Pay attention to the con-
trol of the bi-stable pulse valve (see section 4.9).
Switch-over of the double-load balance control system between load 1 and load 2 is
effected by means of the bi-stable pulse valve (6) with the effect of a pneumatic signal
on bi-stable pulse valve (6). To ensure safe operation of the double-load balance
control system, the signal must be provided by the load handling attachment (installa-
tion-specific) in line with the load status:
- payload applied
- no payload applied
The bi-stable pulse valve (6) is designed as difference plunger pulse valve and is sup-
plied with pressure at the signal connection (gate 10 / 12). Therefore, the switching
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Gate condition is also maintained in the event of a compressed air supply failure so that
safe restarting of the handling equipment is ensured with unchanged load status. See
42533744.eps also section 4.9

8
 4.2 Pneumatic connection
interface The interface to the compressed air supply is a dia. 7,2 mm coupling section.

4.3 Putting into operation The high-precision pressure controllers (3) and (4) of the double-load balance control
system are adjusted to a set pressure of 0 bar in the factory. The bi-stable pulse valve
(6) is in the ”Idle load” position.
After attaching the load handling attachment (load 1), the set pressure on volume flow
booster (3) is increased until the load handling attachment is held in balance. Make
the adjustment so that the manual force required for moving the load handling attach-
ment is equal for the lifting and the lowering movement. Then move the load handling
attachment into the load pick-up position and pick up the payload with the load han-
dling attachment. The load handling attachment must transmit a pneumatic signal
(installation-specific) when the load has been safely picked up to triggers switch-over
to load 2 ”Full load”. The overall system must be brought to a balanced condition by
means of pilot control valve (4) so that the force required for moving the load is equal
for lifting and for lowering.
Dangerous movements of the load are caused if the loads which the settings of high-
precision pressure controllers (3) and (4) are based on are not complied with.
It is recommended that pressure switch (2) be set to a value approx. 0,5 bar below
the available system pressure. Otherwise there is the risk that the switch may be
triggered by system pressure variations caused by compressed air consumption and
bring the installation to a standstill. See also section 4.8
Pressure switch (2) is set by its adjusting screw.
There are two methods of reading the switching pressure. Via the manometer of the
maintenance unit or by connecting a manometer in the air supply line to the double-
load balance control system.
Measure the pressure in the supply line for setting and then reduce it by the required
amount (for example by closing the controller of the maintenance unit). When setting
pressure switch (2), switch-over is indicated by a sound.
The normal pressure can then be restored in the supply line.
After setting the air pressure for load 2, it is recommended that it be moved up and
down three to four times and the adjustment be checked.

4.4 Operation Dangerous load movements might occur as a result of uncontrolled switching over
between the two load stages without feedback regarding an applied payload and
without a check for the correct payload. A corresponding check must be taken into
account for the design of the installation-specific load handling attachment.

4.4.1 End of shift At the end of the shift, the load must not remain in suspended balanced condition. It
must be lowered and moved to a safe parking position. During lifting or lowering
operation, the load must not be detached or the load weight be changed since this
may result in hazardous movement of the load.

4.4.2 Switch-over delay The adjustable throttle for signal delay (13) provides the option of implementing a time
delay for switching over from load 1 to load 2. The time delay can be varied by open-
ing or closing the throttle.
This makes it possible, for example for operation of a vacuum suction device, to eval-
uate the signals of the load handling attachment and to correct the load stage (load 1
/ load 2), if required, before the balancing pressure is built up. This setting should be
made once when the installation is put into operation.
For vacuum suction devices, in particular, there is the danger of the load being de-
tached from the load handling attachment in the event of a compressed air supply
failure. When the unit is switched on again, the control system is still in “Load 2”
mode. Therefore, there is no balancing condition and unwanted movements of the
load handling attachment may occur. The correct load stage “Load 1” is restored
21462744K1.p65/020502

again by setting signal delay (13).

9
 4.4.3 Sudden compressed air In the event of a failure of the compressed air supply or the pressure falling below the
pressure drop minimum value, the working cylinder is locked. Lifting is then no longer possible.
An emergency lowering device (5) is provided by means of which the load can be
lowered in a controlled manner.
There are two procedures:
1. Releasing the compressed air by carefully opening the emergency lowering screw-
type connection (5) by the operator.
2. Lowering the load via the pre-setting of the emergency lowering device (5). The
load is lowered at a pre-set speed as soon as safety valve (7) closes (e.g. for oper-
ation of a vacuum system as a load handling attachment). This setting can be
made when the installation is put into operation. To do this, set the lowering speed
on emergency lowering device (5) by screwing out the screw-type connection and
secure it with the counter nut.
After an emergency lowering process, do not change load 1 or load 2. The load han-
dling attachment should remain attached and any payload should remain in the load
handling attachment to avoid dangerous movements when the unit is switched on
again.

4.5 Taking the unit out of To take the unit out of operation, move the payload with the load handling attach-
ment into the depositing position. Do not remove it from the handling equipment to
service and transporta- be controlled.
tion Then select the idle load pressure stage. Set both pressure controllers to 0 bar pres-
sure. The load is slowly lowered down to the ground. As soon as the compressed air
is released from the handling equipment to be controlled, you may remove the load.
Adjust the pressure controller with special care since otherwise rapid load move-
ments and therefore hazardous situations may occur.
For transportation of the handling equipment, make sure both pressure controllers
are set to 0 bar to avoid hazardous movements of the load while putting the unit into
service.

4.6 Changing the load Increasing or reducing the load in balanced condition results in unwanted movements
of the load. If the load to be handled is to be increased/reduced, counterbalance the
new load again on the pressure controller. To do this, take the handling equipment
out of service (see section 4.5).
Put it into service again with the new load weight (see section 4.3).

4.7 Signals Switch-over between the two load stages is effected by means of a bi-stable pulse
valve (6) with difference plunger. This makes it possible to:
1. Switch-over by means of a signal for idle load and for full load
2. Switch-over by compressed air being supplied either to one or to both sides of the
switch-over valve. If both sides are supplied with compressed air, the valve moves
to a default position (see switch symbol in figure).
In the event of an installation failure, the last selected pressure stage remains set.
The signals are fed in via two 1/8” screw-type connections on the front sides of the
valve.

4.8 Pressure switch Pressure switch (2) is used to monitor the system pressure and to trigger cut-out of
the installation in the event of the pressure dropping below the min. pressure value. In
the factory, pressure switch (2) is set to 5,0 bar. It is finally adjusted by specialist
personnel when the unit is put into operation for the first time. The system pressure
available at the site of operation is then determined and the switch-on threshold of
pressure switch (2) is set to a lower value. It is recommended that pressure switch (2)
be set to a value approx. 0,5 bar below the available system pressure. Otherwise
there is the risk that the switch may be triggered by system pressure variations
21462744K1.p65/020502

caused by compressed air consumption and bring the installation to a standstill.

10
 4.9 Feeding in the The signals for switching over between load 1 and load 2 are generated on the load
handling attachment (installation-specific).
switch-over signal
Incorrect switch-over between the load stages might result in hazardous
movements on the handling equipment.
We recommend that the following be checked when starting work:
• whether a load is in the load handling attachment,
• it is the correct load,
• the load is safely picked up.
The signals are fed in via gates 10 and 12 (threaded connection G 1/8”). If an equally
strong signal is applied on both sides, the signal at gate 12 prevails and the valve
moves to the corresponding switch position. A corresponding check must be taken
into account for the design of the installation-specific load handling attachment.

Gate

42533744.eps
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 5 Inspections/maintenance

The handling equipment must be disconnected from the compressed air supply be-
fore carrying out any maintenance or repair work.
Double-load balance control systems require little maintenance. Despite this, continu-
ous function checks and visual inspections must be regularly carried out by qualified
personnel (safety officers, engineers). The owner should have the handling equipment
checked by an experienced technician at least once a year. He should check the
correct functioning and condition of components regarding damage, wear, corrosion
or any other changes. The safety devices must be particularly checked to ensure that
they are complete and effective.
If defects are detected, the handling equipment must not be returned to service be-
fore the cause has been determined and the defect eliminated.
The power supply must be disconnected and secured against restoration before
maintenance and repair work is carried out. In addition, measures must be taken to
prevent unwanted lowering of the load. All inspections, maintenance and repair work
must be documented.
Refer to the relevant operating instructions of the handling equipment and their con-
trol systems for fault analysis purposes.
Typical faults might be:
• The handling equipment does not balance the load.
• The handling equipment jolts or does not lift and lower loads smoothly.
• The handling equipment sways when at rest.

5.1 Inspection before The operator must check all functions before starting work.
starting work and Check for unwanted lifting motions and/or unusual noise when switching on the com-
pressed air supply. The double-load balance control system must be taken out of
during operation service immediately if its functions are not guaranteed or any defects are detected.

5.2 Inspections and If routine maintenance reveals that the intervals are too long, they should be adapted
to the specific operating conditions.
maintenance
Only use genuine Demag parts for repairs.
The use of spare parts not approved by Demag renders any liability and guarantee
claims void.

5.3 Hoses and valves Hoses, valves and unions must be visually inspected before starting work.
The unit must be switched off immediately and the parts specified must be replaced if
any of the following situations occur:
• damage or surface wear,
• hard, stiff, charred hoses or cracks resulting from the effects of heat,
• badly corroded valves,
• leaks in hoses and valves,
• blistered, soft or loose outer layer.
It must be ensured that the entire handling device (hoses, valves, etc) is not under
pressure before defective parts are removed.
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12
 6 Fault list

6.1 Double-load balance

control system
Problem Cause Remedies

Deposit load by means of emergency pressure

release. Any payload attached must not be removed
Safety valve is tripped from the load handling attachment. This would
possibly result in dangerous load reactions when
putting the unit into operation
Return valve prevents the load from dropping in
Load can no longer be moved Leak in compressed air supply spite of a compressed air failure
The load can be lowered manually by reducing the
set pressure on the high-precision pressure
Compressed air supply is switched off
controller
See Taking out of operation note
Leak in hose line between compressed air Proceed as for putting into operation when the
connection of control system and return valve compressed air supply has been restored
Idle load moves at creep speed
Volume flow booster setting incorrect See Putting into operation

Full load moves Pilot valve or volume flow booster setting incorrect See Putting into operation

Load cannot be lifted after putting unit into

Safety valve has not opened Check system pressure
operation

Manual force for lifting/lowering motion is unequal Pre-setting of pressure imprecise Correct setting of high-precision pressure controller

Manual force for lifting/lowering motion strongly Sealing on handling equipment worn Replace sealing, relubricate (see operating
increases Insufficient lubrication instructions of the relevant handling equipment)
Compressed air connection between double-load
Move double-load balance control system closer to
Unit sways when at rest balance control system and compressed air cylinder
compressed air cylinder
is too long
See also notes in fault list, inspection and maintenance work for the relevant handling equipment
(e.g. D-BP 55 and D-BP 110 rope balancer operating instructions, 214 421 44)
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 7 Double-load balance control system component parts

42532544.eps 21462744K1.p65/020502

14
 7 Double-load balance control system component parts

Item no. Part no. Quantity Designation Material Standard

1 82656144 1 Mounting plate D-BP 55

1 82666144 1 Mounting plate D-BP110
2 82665844 1 Securing plate
3 82665744 1 Spacer
4 82655244 1 Connecting block 2-Last-St.
5 82655344 1 Pad D-BP 55/110
6 34367344 1 Reduction
7 34367144 1 Pressure governor G1/8
8 34367044 2 Check valve R1/8
9 34366844 1 Valve G 3/8
10 34366744 1 Amplifier G 1/2
11 34366544 4 Hose 6 x 4 blau
12 34366244 1 Angle union G1/8
13 34366144 4 Plug connection 1/8"
14 34366044 2 Seal G1/2" DR12EL
15 34365944 2 Connection angle G1/2
16 34365844 2 Connection angle G3/8
17 34365744 3 Connection angle G1/8
18 34365544 1 Sound absorber G3/8
19 34365444 1 Reducing nipple L=53
20 34365344 1 Screw-in union
21 34365244 2 Screw plug MS
22 34365144 1 Reducing nipple R3/8
23 34364944 1 Directional ctrl valve 3/2 Impuls
24 34363844 1 Seal G3/8" DR38EL
25 34327644 2 Screw plug G3/8X 9
26 34327544 1 Check valve G1/2-G1/2
27 31953599 2 Hex.socket cylind.screw M 4 X 30 10.9 DIN 912
28 31922099 1 Hex.socket cylind.screw M 5 X 40 10.9 A2F DIN 912
29 31921399 3 Hex.socket cylind.screw M 5 X 10 10.9 A2F DIN 912
30 30766799 1 Hexagonal screw M 4 X 8 8.8 A2F ISO 4017
31 15189399 2 Hex.socket cylind.screw M 4 X 55 8.8 A2F DIN- 912
32 15069099 4 Hexagonal nut M 5 8 A2F ISO 4032
33 34374644 1 Pressure switch
34 34374444 1 Screw-in union
35 34374544 1 Tube 14x2 schw.
36 34365044 1 Extension thread D-BP110
37 34363744 1 Plug coupling 3/8"
38 34366644 1 Hose 4,3x 3 blau

21462601.tbl
21462744K2.p65/020502

15
 Printed in Germany MBR/280502/5H

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