Technical data

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

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290702 EN 203 359 44 714 IS 862 1

 Part numbers Demag D-BP 55 rope balancer
Part no.
922 020 46 Basic unit with U-seal
922 021 46 Basic unit with T-seal
922 011 46 with up/down control system
922 012 46 with up/down control system and D-BGR
922 013 46 with single-load balance control system
922 014 46 with double-load balance control system
922 015 46 with manual force control system

Demag D-BP 110 rope balancer

Part no.
922 022 46 Basic unit with U-seal
922 023 46 Basic unit with T-seal
922 001 46 with up/down control system
922 002 46 with up/down control system and D-BGR
922 003 46 with single-load balance control system
922 004 46 with double-load balance control system
922 005 46 with manual force control system

Selection of the basic unit based on The Demag rope balancer is available with two different types of piston seals. If the
application and type of seal units are ordered in conjunction with Demag control systems, the type of control
determines the type of seal.
Depending on the application, the basic units feature different types of piston seals.
Available are:
1. A low friction variant with T-seal.
For applications in which the load is to be moved without control pendant – with
low manual force.
Operation, for example, in conjunction with single, double or multiple balance
control and the electro-pneumatic manual force control.
Owing to its physical characteristics, the seal only allows small quantities of air to
escape.
For applications in which the load must be held for a long time also in the event of
the compressed air supply of the cylinder being interrupted (e.g. up/down opera-
tion), this variant is less suitable.

2. A variant with optimised sealing characteristics U-seal.

Suitable for applications in which loads are to be moved by means of the control
pendant only over a small range by hand. If the compressed air supply to the
cylinder is cut off, the load is held in the same position for a long time.
Application, for example, in conjunction with an up/down control system which
only enables load movements guided by hand in the air cushion – i.e. with return-
ing into the initial position.

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Dimensions
Length x width x height (C dimension) 1)
Up/down control Single-load balance control Double-load balance control Manual force control
D-BP 55 420 x 305 x 458 420 x 305 x 410 420 x 305 x 410 420 x 305 x 794
D-BP 110 508 x 336 x 477 508 x 336 x 429 508 x 336 x 429 508 x 336 x 813

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Up/down control with Single-load balance control Double-load balance control Basic unit 2)
D-BGR speed controller incl. swivel incl. swivel
D-BP 55 420 x 305 x 458 420 x 305 x 527 420 x 305 x 527 420 x 305 x 279
D-BP 110 508 x 336 x 477 508 x 336 x 546 508 x 336 x 546 508 x 336 x 298

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

Load capacities Load capacity at

3 bar 4 bar 5 bar 6 bar 7 bar 8 bar 9 bar 10 bar

D-BP 55 25 kg 35 kg 45 kg 55 kg 65 kg 75 kg 85 kg 95 kg

D-BP 110 50 kg 70 kg 90 kg 110 kg 130 kg 150 kg 170 kg 190 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 load capacities specified take into account a pressure loss of the control sys-
tem of 0,5 bar.
For pneumatic and electro-pneumatic control systems, a difference between the
supply pressure and the internal pressure of the cylinder of min. 0,5 bar is required
to be able to move the load with low manual force and at higher speeds.

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 Suspension heights, rope The standard rope length of the D-BP Demag rope balancer is 6 m including the
safety windings on the drum. They are assigned to 1,25 m safety windings which
always remain on the drum, 2 m max. hook path and 2,75 m dead rope. This re-
sults in a max. suspension height of approx. 4,75 m – from the lower edge of the
rope balancer. If the balancer is to be suspended at larger heights, a longer rope
can be ordered specifically (please specify in the order).
The following special ropes are also available
• stainless steel rope (shorter maintenance cycles are required in this case)
• a 6-strand rope, in particular for the American market
part-no.: 826 621 44
All ropes have a diameter of 5 mm.
For the up/down control system, the DSK control pendant is provided with a 3,5 m
long supply line as standard. The control pendant should be suspended at a height
of approx. 1 – 1,5 m above the ground. In the event of larger suspension heights
(> 4,5 m) of the rope balancer, take into account that a longer supply line to the
DSK control pendant is required.
The manual force control system is supplied with a helical cable for transmission of
the electrical signals of the D grip (standard extended length = 2,8 m). Thus the
suspension height is limited to max. 3,8 m from the lower edge of the rope balanc-
er.
In the case of larger suspension heights, a special helical cable is required which
must be specified in addition in the order (suspension height must be specified).
If the helical cable is shortened, this does not result in a smaller C dimension.

Interface for load handling device

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

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

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D Grip with swivel unit and rope socket D Grip, solo

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Hook assembly
Part no. 826 640 44 Part no. 826 641 44
mainly for the US market

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 Dimensions

Detail A
Bore hole for M8 thread “grooved”

Connecting plate not

included in the scope
of supply

Thread cutting screw, DIN 7500 EE M8 x 30

Part no. 324 737 99 (4 off)

Detail X

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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-BP 55 425 206 219 194 27 199 197 27 6 308 92 104 65

31 50 68 75 16,5 10 14 150 150
D-BP 110 508 240 268 216 22 219 218 29 21 338 105 116 60

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Mounting The rope balancer can either be suspended by means of the suspension eyes of the
housing or using the bore hole pattern provided at the lower side of the housing
(see dimension l4 / b5), using thread cutting screws, DIN 7500 EE M8 x 30
part no. 324 737 99 (4 off).
For connection to KBK, use load bar (part no. 984 685 44).
Dimension h4 in the dimensions table does not include the clamp section and buffer
on the rope. In both cases, dimension h4 may be increased by 19 mm.

When using the universal pin set (fitting outside) for connection to the D Lift, the
connection plates may be applied to the suspension eyes from the outside (max.
plate thickness 6 mm).

Universal pin set for mounting on the outside, part. no. 610 381 45

Universal pin set for mounting on the inside, part no. 826 548 44. For fitting on the
inner side of the suspension eyes. Max. width of suspension 31 mm.

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Mounting turned through 180° If the electro-pneumatic manual force control system is used for D-BP 55 and
D-BP 110 rope balancers, take into account that mounting the unit turned throught
180° (compressed air supply on the lower side and rope outlet to the top) is not
permissible. Any other mounting positions are possible.
The other control systems may be fitted in any position.

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 Weights D-BP 55 [kg]
Basic unit (without control system) 18,0
Up/down (incl. DSK and hose) 2,9
Up/down (incl.speed controller, DSK and hose) 5,3
Single-load balance control 3,0
Double-load balance control 7,2
Manual force control (incl. handle and helical cable 2800 mm) 8,7
Set rope wedge with swivel 0,7

D-BP 110 [kg]

Basic unit (without control system) 27,0
Up/down (incl. DSK and hose) 3,3
Up/down (incl.speed controller, DSK and hose) 5,7
Single-load balance control 3,3
Double-load balance control 7,7
Manual force control (incl. handle and helical cable 2800 mm) 13,5
Set rope wedge with swivel 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 NW 7,2 mm plug-in connector or NPT 3/8" thread
(for US only)

Voltage (for manual force control only)

100 - 240 V AC, 1 phase, 47 – 63 Hz

Accessories

RUN ERROR

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An operating terminal with extension cable is required for programming the parame-
ters of the manual force control system (part no.: 650 090 45).
The terminal must always be operated together with the extension cable since
otherwise signal transmission errors occur.
The handle of the electro-pneumatic manual force control system is provided with a
quick-release coupling at the lower end.
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For the D grip, a protection plate (part no. 773 235 44) is available which protects
the right-angle plug from damage. This cover is galvanized.

Protection plate
(option)

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For applications in which the load is turned about the vertical axis, a swivel unit (part
no. 773 260 44) consisting of rope wedge connection and swivel mounted on a ball
bearing is available for protection of the rope.

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 D brake system (on request) This device only avoids slow lowering of the load in the event of a complete com-
pressed air supply failure.
The system is not suitable to act as an active brake for braking operating
motions.
If the compressed air supply of the rope balancer is switched off or there is loss of
compressed air resulting in reduction of the pressure to 0 bar, the load lowers after
a certain period of time.
For the D-BP 110, it is possible to avoid this creeping motion of the load by means
of the optional D brake system.
The D brake system is separately supplied via an internal compressed air supply at
a pressure of 2 bar. This pressure acts against a spring force which, in the event of
a compressed air loss, actuates a pin mechanically that latches the rope drum and
thus prevents the load from lowering. The D brake system becomes active, if the
pressure in the supply line drops to 0 bar. Therefore, we recommend that the lock-
ing unit with vent valve be selected so that active venting of the supply line to the
rope balancer is possible.
If the pressure is reduced to > 0 bar, the D brake system does not become active.
For the D-BP 55, this optional device is not available.

D brake

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Interface to the load handling Load hook 1) Hook assembly Rope socket Swivel unit
attachment slewing type bent
- 826 640 44 (DK)
Up/down control 826 557 44 2) 773 260 44 2)
- 826 641 44 (B)

Single-load balance - 826 640 44 (DK)

control - 826 641 44 (B)
826 557 44 773 260 44
Double-load balance - 826 640 44 (DK)
control - 826 641 44 (B)

Manual force control 835 665 44 - 3)

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

1) Only for quick-release coupling

2) Fitting only permissible if
1. the load handling attachment is fitted permanently and
2. has a weight of min. 3,5 kg.
3) Swivel unit and rope socket integrated in the operating part (D grip) of the manual force control system

For the manual force control system, the load handling attachments from the
DK product range
• Load hook
• C hook
• Parallel gripper system etc.
are available for the quick-release coupling.
The elements can be connected at the bottom of the handle.
For further load handling attachments suitable for the quick-release coupling, see
also DKUN technical data.

Accompanying documents Ident. no.

D-BP pneumatic rope balancer (colour brochure) 213 055 44
Operating instructions Demag rope balancer 214 421 44
Operating instructions Up/down control system 214 587 44
Operating instructions Single-load balance control system 214 654 44
Operating instructions Double-load balance control system 214 627 44
Operating instructions Manual force control system 214 611 44
Data sheet Demag rope balancer load bar 214 196 44
Data sheet Power supply system in preparation
Technical data DKUN 202 846 44

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 Printed in Germany H/290702/50St

Demag Cranes & Components

P.O. box 67 · D-58286 Wetter
Telephone (+49) 2335 92-0 · Telefax (+49) 2335 927676
www.demagcranes.de

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