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Original operating manual for ABUS single-girder overhead travelling crane ELK
order: 16735993 / 1 EOT crane
serial number type wheel diameter number of wheels
110-034551 ELK 8 t x 7000mm 160.3 4
hoist
serial number size type reeving wheel diameter
250-068733 3000 E 4/1 160 mm
Push button pendant
611 S
documentation: Spare parts catalogue ABUETK, A120250_001 Product Manual Operating the Crane, A120192GB_001 Product Manual General information, A120197GB_001 Product Manual crane EL, A120139GB_006 mounting instructions for drive gear AZP, A120009GB_001 Technical Data for End carriage 160, A120069GB_002 installation, operating and maintenance instructions for ABUS wire rope hoist, A120055GB_002 Operating instructions for lifting gear drive, A120056GB_001 Operating instructions for emergency limit switch, A120064GB_003 Operating instructions for rope guide GM800-GM6000, A120057GB_002 Technical data for wire rope hoist GM3000, A120061GB_004 installation, operating and maintenance instructions for push button pendant, A120028GB_003 installation, operating and maintenance instructions for ABUS LIS-SV, A120077GB_000 Operation instructions Cross-type limit switch KHS, A120216GB_000 Electric parts list wiring diagram, no. 500000GB_004; 600167GB_000
ABUS Kransysteme GmbH D-51647 Gummersbach, 03.02.2017
© ABUS Kransysteme GmbH, DruckDoku Version 5.11w101
Kransysteme
Product Manual for Operating the ABUS Crane
ABUS Kransysteme GmbH Sonnenweg 1 51647 Gummersbach Germany Tel. 0049 – 2261 – 37-0 Fax. 0049 – 2261 – 37-247 [email protected]
110-034551
Serial number
250-068733 Distribution or reproduction of this document, or the utilisation and disclosure of its contents without explicit approval is prohibited. Violations will incur liability for damage compensation. All rights are reserved in regard to patent issuance or registered designs.
Instructions regarding safety
(page 3)
Instructions regarding safety when slinging a load
(page 8)
Emergency stop
(page 10)
Check before beginning work and switching on
(page 11)
Operating the crane with the pendant control
(page 16)
Switching off the crane
(page 23)
AN 120192EN001
2014-02-28
Translation of the original operating instructions
Contents
Contents 1.
Instructions regarding safety .................... 3
2.
Instructions regarding safety when slinging a load .......................................... 8
3.
Preventing damage to the crane............... 9
4.
Emergency stop...................................... 10
5.
Check before beginning work and switching on ............................................ 11
6.
Operating the crane with the pendant control..................................................... 16
7.
Lifting and lowering................................. 16
8.
Crane travel, trolley travel and slewing ... 17
9.
Overload protection ................................ 18
10. Inching counter ....................................... 19 11. Observe the specified duty cycles .......... 19 12. Working in the range of the travel limit switch ..................................................... 20 13. Load display and tare ............................. 22 14. Securing the crane in a power failure ..... 22 15. Switching off the crane ........................... 23
Page 2
Instructions regarding safety
Operating the ABUS crane
Operating the ABUS crane This section applies to anyone who lifts loads using the crane or works nearby.
Be sure to read and observe the product manual of the entire crane! The instructions given here apply in addition to the other product manuals.
1. Instructions regarding safety
Only with cranes with one trolley Observe the maximum load capacity!
Observe these instructions for safe handling of the crane. Special hazard notices are located in the corresponding sections in which the danger arises.
Observe the product manuals! In addition to the points described here, all information in the section “Instructions regarding safety” in the other supplied product manuals also applies.
If the maximum load capacity is exceeded, the crane and the supporting structure could be damaged.
Only trained and authorised personnel may operate the crane! Special technical expertise is required to correctly sling and safely lift and move loads.
This could cause the load to fall, killing or injuring people.
Otherwise, accidents could occur.
The maximum load capacity is specified on the trolley and on the bottom block or hook assembly. The maximum load capacity of the crane is also given:
Personnel working with the crane (e.g. crane operators and load handlers) must first have received instruction regarding operation and be assigned this work by the end user.
Always work safely! Suspended loads always pose a hazard when working with the crane.
Observe the maximum load capacity of the trolley and the crane and do not exceed it!
─
For overhead travelling cranes: on the main girder
─
For jib cranes: on the jib arm
─
For HB cranes: on the crane girder
─
For single-rail trolley tracks: on the trolley track
Always keep your own safety as well as the safety of others in mind when working with the crane. The technical knowledge gained from the instruction and the supplied ABUS product manuals will be aid you in working safely with the crane.
Page 3
Instructions regarding safety
Operating the ABUS crane
Only with cranes with multiple trolleys
─
Observe the maximum load capacity!
If the maximum load capacity of the crane cannot be accurately added together from several trolleys, first the maximum load capacity of the crane is given, then the maximum load capacity of the trolleys, specified in brackets with a “/”. Maximum load capacity of crane
16 t trolley
If the maximum load capacity is exceeded, the crane and the supporting structure could be damaged.
10 t trolley
Additional rules:
This could cause the load to fall, killing or injuring people.
If the maximum load capacity of the crane corresponds exactly to that of the largest trolley, the maximum load capacity of the crane and the brackets are omitted.
Observe the maximum load capacity of the trolleys and the crane and do not exceed it!
Maximum load capacity of the crane and, at the same time, of the largest trolley
The maximum load capacity is specified on the trolley and on the bottom block or hook assembly. The maximum load capacity of the entire crane is also given on the crane itself: ─
For overhead travelling cranes: on the main girder
─
For jib cranes: on the jib arm
─
For HB cranes: on the crane girder
─
For single-rail trolley tracks: on the trolley track
Maximum load capacity of the smaller trolley
Maximum load capacity of the crane and, at the same time, of the largest trolley
Maximum load capacity of the smaller trolleys ─
If the maximum load capacity of the crane can be added together exactly from several trolleys, the load capacities of the respective trolleys are given with a “+”. The total is the maximum load capacity of the crane. First 5 t trolley
Second 5 t trolley
─
In this case as well, the maximum load capacity of the crane can be added together from several trolleys. 20 t trolley
5 t trolley
10 t trolley
Total 10 t, maximum load capacity of crane Total 25 t, maximum load capacity of crane 20 t trolley
10 t trolley
5 t trolley
Total 35 t, maximum load capacity of crane
Page 4
Operating the ABUS crane
Only with cranes with partial load ranges
Instructions regarding safety
Note the weight of the load lifting attachment!
This section only applies if the main girder (for overhead travelling cranes), the jib arm (for jib cranes), the crane girder (for HB cranes) or the trolley track (for single-rail trolley tracks) are divided into different areas with different maximum load capacities.
Observe the differing maximum load capacities of the crane!
The weight of the load lifting attachments (e.g. crossheads) can be very heavy and thus reduce the maximum load capacity of the crane. If this weight is not factored in, the maximum load capacity of the crane could be exceeded.
If the maximum load capacity is exceeded, the crane and the supporting structure could be damaged. This could cause the load to fall, killing or injuring people. Depending on the position of the trolley, the crane will have different maximum load capacities. Observe the maximum load capacity of the partial load range in which the trolley is currently located. Do not exceed the maximum load capacity!
The weight of the load lifting attachment must be taken into account in the crane operator's decision of whether a load can be lifted with the crane.
Only with cranes with warning devices This section only applies if the crane has a warning device (e.g. horn or bell).
Sound alarm in the event of danger!
The maximum load capacities of the individual areas on the main girder (for overhead travelling cranes), the jib arm (for jib cranes), the crane girder (for HB cranes) or on the trolley track (for single-rail trolley tracks) are separated from each other by vertical lines. The respective maximum load capacity of the partial load range is given within the lines.
Especially when the crane operator is not standing directly at the crane (e.g. if using radio remote control), personnel nearby may not necessarily be aware that the crane is in use. This could result in dangerous situations where people can be killed or injured. Use the warning device (e.g. horn or bell) to warn persons nearby of suspended loads.
Page 5
Instructions regarding safety
Do not pull loads at an angle!
If an attached load is pulled or towed at a slant (e.g. over the floor), the trolley can tip due to the lateral forces and fall. The trolley can also be damaged by wire ropes or chains running askew. This in turn means the load or crane itself could fall and kill or injure people. Always only lift the load vertically! Do not pull any vehicles or carriages!
Do not jerk the load free!
Operating the ABUS crane
Do not attempt to catch loads!
If a load in the load hook, the lifting tackle or the load lifting attachment is dropped and then caught with the crane (e.g. a component is only loosely suspended and then detached), the strong jolt could cause the trolley to fall. As a result of this people can be killed or injured. Do not attempt to catch loads!
Do not turn loads!
If an immobile or jammed load (e.g. due to rusted together or bolted together parts) is jerked free, the trolley could fall due to the strong jolt from the sudden release of the load. As a result of this people can be killed or injured. Do not jerk the load free with the crane.
If a load in the lifting tackle or load lifting attachment is rotated or turned, it can suddenly tilt. The strong jolt could cause the trolley to fall. As a result of this people can be killed or injured. Only turn the load if the crane is installed with a load lifting attachment specially designed for turning loads.
Page 6
Operating the ABUS crane
Instructions regarding safety
Do not attempt to transport any persons!
Do not cause loads to swing!
The crane is not equipped with the necessary safety devices to safely transport people.
A load that swings too heavily from side to side can no longer be safely controlled.
This means that persons could fall during the transport and be killed or injured.
As a result of this people can be struck by the load and killed or injured.
Do not lift persons either together with a load or without one. If any persons step onto the load or the load lifting attachment (e.g. climbing into a pallet cage or sitting on the crosshead), do not lift the load.
During crane travel and trolley travel, avoid swinging the load too much from side to side.
Do not transport loads above anyone!
Do not intentionally run the load to the emergency limit switch!
The emergency limit switch (in wire rope hoists) and the friction clutch (in chain hoists) can be damaged if subjected to regular use, and will therefore no longer function if the load hook is run too high or too low. If the load is not slung correctly or the lifting tackle snaps, the load can fall. As a result of this people can be killed or injured. Do not transport a suspended load above anyone.
This could damage the crane and cause the load to fall. Do not intentionally or under normal operating conditions run the load so as to engage the emergency limit switch or the friction clutch. If work needs to be performed near the highest or lowest hook position during normal operation, an additional operating limit switch must be employed to avoid damaging the emergency limit switch.
Page 7
Instructions regarding safety when slinging a load
Do not allow the pendant control to swing about!
Uncontrolled swinging of the pendant control can cause it to strike something and become damaged. This could expose voltageconducting parts. This poses the risk of electrical shocks. Do not allow the pendant control to swing back and forth!
2. Instructions regarding safety when slinging a load
Operating the ABUS crane
Do not sling the chain or wire rope of the hoist around the load!
The chain of the chain hoist and the wire rope of the wire rope hoist are not lifting tackle. They must always run in a straight line. If twisted or laid around sharp edges, they will be damaged. The chain or wire rope could thereby break, causing the load to fall. Do not sling the chain of the chain hoist or the wire rope of the wire rope hoist around the load and use them for lifting. Instead, use suitable lifting tackle or load lifting attachments.
Close the hook safety latch!
Observe the product manuals! In addition to the points described here, all information in the section “Instructions regarding safety” in the other supplied product manuals also applies.
If the hook safety latch is not closed, the lifting tackle or load lifting attachment can inadvertently slip from the load hook. This could cause the load to fall. Hang the lifting tackle or the load lifting attachment fully in the load hook and allow the hook safety latch to spring back to secure it.
Page 8
Preventing damage to the crane
Operating the ABUS crane
Observe the maximum angle of spread and maximum load capacity of lifting tackle!
3. Preventing damage to the crane Follow these instructions to ensure a long service life of the crane.
No inching operation! To position a load precisely, do not use inching operation (button pressed repeatedly in quick succession).
If the maximum angle of spread or the maximum load capacity of the lifting tackle is exceeded, it can break. This could cause the load to fall. Always observe the maximum angle of spread and maximum load capacity of the lifting tackle.
Lift the load at slow lifting speed and with lifting tackle under tension!
Due to the jolt when lifting from the ground with a fast lifting speed, the crane is heavily strained and can be overloaded. This jolt is amplified if the lifting tackle is slack while switching directly to fast lifting speed. The jolt could break the lifting tackle or the crane could be damaged, causing the load to fall. Lift the load from the ground at slow lifting speed until the lifting tackle is tensioned and the load hangs freely. Only then continue lifting, if necessary, with fast lifting speed.
Instead, use low speed or the slow lifting speed (button pressed halfway).
Do not run against the safety buffer! The safety buffers are designed to absorb the total energy of movements. Nevertheless, an impact on the safety buffer is an extreme situation and places strain on the crane and the entire supporting structure. ─
For overhead travelling cranes: Do not run the crane with the safety buffer against the end of the crane track.
─
For overhead travelling cranes: Do not run the trolley against the end of the main girder.
─
For overhead travelling cranes: Do not allow the crane to run against another crane.
─
For jib cranes: Do not run the jib arm against the safety buffer at the end of the slewing range.
─
For jib cranes: Do not run the trolley against the safety buffer on the jib arm.
─
For HB cranes: Do not run the HB crane against the end of the crane track.
─
For HB cranes: Do not run the trolley against the end of the crane girder.
Report any unusual noises and abnormal behaviour! Be watchful for any unusual noises or abnormal behaviour of the crane during operation. Unusual noises and abnormal crane behaviour can indicate defects and signs of wear. If there is any damage or problems arise, do not work with the crane; inform coworkers and supervisors. If necessary, stop the crane. In the early stages, such damage can usually be simply and inexpensively rectified.
Page 9
Emergency stop
Operating the ABUS crane
Use electrically isolated lifting tackle for welding!
4. Emergency stop
Electrically isolated lifting tackle
Observe the product manuals! In addition to the points described here, all information in the section “Emergency stop” in the other supplied product manuals also applies.
In dangerous situations with the crane: Emergency stop switch
Component to be welded If the crane is used to hold components on which welding work is performed, be sure to use electrically isolated lifting tackle (e.g. insulated swivel, round sling made of non-conductive material). Otherwise, the welding current can flow through the crane and damage the electrical controls, the wire rope and the bearing.
Press the emergency stop switch. The crane brakes immediately; the load hook halts.
When the danger has been eliminated: Emergency stop switch
Page 10
Turn the emergency stop switch a quarterturn clockwise. The crane is ready for use.
Operating the ABUS crane
5. Check before beginning work and switching on Check the following points before beginning work with the crane. If there is any damage or problems arise, do not work with the crane; inform coworkers and supervisors.
Observe the product manuals! In addition to the points described here, all information in the section “Check before beginning work and switching on” in the other supplied product manuals also applies.
External check of crane
Check before beginning work and switching on
Only with wire rope hoists
Inspect the entire wire rope for damage. The damage shown here or any similar damage should not be detectable on the wire rope. Examples of damage:
The joining of the wire rope has opened. The inner strands of the wire rope are visible.
Loops have formed in the wire rope.
In all supplied product manuals, check whether additional points need to be checked before switching on.
─
Can any damage be detected on the crane or its accessories (e.g. rust, loose parts, leaking oil, missing screws,...)?
─
Is the load hook turnable and otherwise OK?
There is a kink in the wire rope. This results from violent external forces being applied to the wire rope.
The wire rope is flattened at one point. This results from the wire rope being pinched.
A bird cage has formed in the wire rope. This results from violent untwisting of the wire rope. Load hook
The wire rope has a corkscrew-type deformation.
Page 11
Check before beginning work and switching on
Operating the ABUS crane
Switching on
Check the wire rope for detectable broken wires. If broken wires are found in the wire rope, do not work with the crane. Have a comprehensive wire rope test performed. See “General Product Manual for ABUS Cranes”.
In all supplied product manuals, check whether additional points need to be checked for switching on.
Only with chain hoists
─
Is the chain lubricated with oil?
Inspect the entire chain for damage. The damage shown here or any similar damage should not be detectable on the chain. Examples of damage:
The chain link is heavily worn.
Mains switch of the crane installation Only if the crane installation has a mains switch: Turn on the entire crane installation using the mains switch.
Emergency stop switch
The chain link is mechanically damaged.
Page 12
Turn the emergency stop switch a quarterturn clockwise. The crane is switched on.
Operating the ABUS crane
Only with radio remote control Logging in
Switch on the transmitter of the radio remote control and log in to the receiver. See the radio remote control product manual.
Check before beginning work and switching on
Checking the emergency stop switch, hoist drive and brakes on the hoist drive Test the following before beginning work:
Red signal lamp
The red signal lamp lights up when the transmitter has been logged in and enabled.
Press the ‘Lift’ button completely. The load hook moves up. Press the emergency stop switch. The load hook halts. The brake makes a clicking noise and the load hook immediately comes to a stop. The functional checks of the emergency stop switch, hoist drive and brakes on the hoist drive are now completed. Switch the crane back on using the pendant control.
Only with trolleys with electrically powered trolley travel and cranes with electrically powered crane travel
The radio remote control can now be used.
Checking the drive and the brakes of the drive Test the following before beginning work:
Fully push the trolley travel and crane travel buttons. The trolley and crane run in the corresponding direction. Press the emergency stop switch. The trolley and crane stop running. The brakes engage with an audible click and the trolley and crane immediately come to stop. The functional test of the drive and the drive brakes is now completed. Switch the crane back on using the pendant control.
Page 13
Check before beginning work and switching on
Operating the ABUS crane
Only with jib cranes with electrically powered slewing
Only with chain hoists with an electronic hoist limit switch
Testing the slewing drive
Checking the switching points
Test the following before beginning work:
Test the following before beginning work:
Press the ‘Slewing’ button completely.
The crane pivots in the corresponding direction.
Press the emergency stop switch. The crane stops pivoting and slowly comes to a stop. The slewing drive has no brake, therefore the crane slowly swings out. The functional check of the slewing drive is now completed. Switch the crane back on using the pendant control.
Move the load hook until it reaches the set switching points. The chain hoist no longer travels in the respective direction.
Only with chain hoists without a hoist limit switch The chain hoist has a friction clutch. It prevents damage to the chain hoist if the load hook in the highest hook position knocks against the housing from below.
Danger from falling suspended load! Never run the load hook so far up that the friction clutch engages.
Only with wire rope hoists and for chain rope hoists with a mechanical hoist limit switch
This would damage the friction clutch long-term and the load could fall, killing or injuring people.
Testing the hoist limit switches Test the following before beginning work:
Press the 'Lift' button halfway and move the load hook completely up with slow lifting speed. At the highest hook position, the load hook halts. For hoists without operating limit switches: The functioning of the top emergency limit switch has now been tested. For hoists with operating limit switches: The functioning of the top operating limit switch has now been tested.
Page 14
Therefore, also refrain from testing the friction clutch before performing work.
Operating the ABUS crane
Check before beginning work and switching on
Only with travel limit switches with braking function
Only with travel limit switches with braking and shut-down functions
Test the travel limit switch
Test the travel limit switch
Test the following before beginning work:
Test the following before beginning work:
─
Testing the braking function:
For overhead travelling cranes: Run the crane at high speed until it reaches the end of the crane track.
Check the braking function as previously described.
Check the shut-down function:
─
For overhead travelling cranes: Run the trolley at high speed until it reaches the end of the main girder.
─
For jib cranes: Pivot the jib arm with fast slewing speed until it reaches the end of the slewing range.
─
For jib cranes: Run the trolley at high speed until it reaches the end of the jib arm.
─
For HB cranes: Run the HB crane at high speed until it reaches the end of the crane track.
─
For HB cranes: Run the trolley at high speed until it reaches the end of the crane girder.
─
For single-rail trolley tracks: Run the trolley at high speed until it reaches the end of the trolley track.
Shortly before the end, the crane/trolley brakes and continues running at low speed.
─
For overhead travelling cranes: Run the crane until it reaches the end of the crane track.
─
For overhead travelling cranes: Run the trolley until it reaches the end of the main girder.
─
For jib cranes: Pivot the jib arm until it reaches the end of the slewing range.
─
For jib cranes: Run the trolley until it reaches the end of the jib arm.
─
For HB cranes: Run the HB crane until it reaches the end of the crane track.
─
For HB cranes: Run the trolley until it reaches the end of the crane girder.
─
For single-rail trolley tracks: Run the trolley until it reaches the end of the trolley track.
At the end, the crane/trolley brakes to a standstill. The crane/trolley comes to a stop just before the end.
Testing additional warning and safety devices If the crane has additional warning and safety devices:
Test the warning devices. Test the safety devices.
Page 15
Operating the crane with the pendant control
6. Operating the crane with the pendant control
Operating the ABUS crane
7. Lifting and lowering
Observe the product manuals! In addition to the points described here, all information in the section “Lifting and lowering” in the other supplied product manuals also applies.
Buttons for lifting/lowering
Line of vision Take the pendant control in your hand.
Lifting or lowering with slow lifting speed
With the pendant control in hand, turn so that the crane is in your line of vision. This is the optimum position for operating the crane. In this position, the directions of the operating direction signs (arrows) on the pendant control match the actual direction of travel of the crane and the trolley.
Operating direction signs on the crane
Independent of their respective position, the colours of the operating direction signs (yellow and black arrows) always point the correct running direction of the crane and the trolley. Observe the operating direction signs.
Page 16
The hoist lifts or lowers with slow lifting speed.
Lifting or lowering with fast lifting speed
Operating direction signs on the pendant control
Half-press the button (stage 1).
Press the button completely (stage 2). The hoist lifts or lowers with fast lifting speed.
Crane travel, trolley travel and slewing
Operating the ABUS crane
Braking 8. Crane travel, trolley travel and slewing
Release the button halfway (back to stage 1).
Observe the product manuals! In addition to the points described here, all information in the section “Crane travel, trolley travel and slewing” in the other supplied product manuals also applies.
The hoist brakes and then lifts or lowers again with slow lifting speed.
Standstill
Release the button. The hoist brakes and comes to a stop.
Only with electrically powered trolley travel, crane travel and slewing
Button for crane travel
Button for trolley travel
At low speed
Half-press the button (stage 1). For cranes: The crane runs at low speed. For trolleys: The trolley runs at low speed. For jib cranes: The crane pivots with slow slewing speed.
At high speed
Press the button completely (stage 2). For cranes: The crane runs at high speed. For trolleys: The trolley runs at high speed. For jib cranes: The crane pivots with fast slewing speed.
Page 17
Overload protection
Braking
Operating the ABUS crane
9. Overload protection
Only with wire rope hoists
Release the button halfway (back to stage 1). For cranes: The crane brakes and runs again at low speed.
The wire rope hoist has an LIS-SE or LIS-SV load indicator system. It measures the suspended load and ensures that the wire rope hoist cannot lift any load which exceeds the maximum load capacity.
For trolleys: The trolley brakes and runs again at low speed.
Nevertheless, do not exceed the maximum load capacity of the wire rope hoist!
For jib cranes: The crane brakes and pivots again with slow slewing speed.
Danger from falling suspended load! Despite this overload protection, the crane could be damaged by a load that is too heavy, causing the load to fall.
Standstill
Do not exceed the maximum load capacity of the crane! Release the button. For cranes: The crane brakes and comes to a stop. For trolleys: The trolley brakes and comes to a stop. For jib cranes: The crane brakes and comes to a stop.
Only with crane travel, trolley travel, slewing by hand
Pull or push on the load, the bottom block, the hook assembly, the lifting tackle or load lifting attachment to move the load. Do not pull on the pendant control in order to move the load or the empty load hook.
Only pivot or move the load if it can be easily and safely stopped by hand.
If the wire rope hoist no longer lifts with the button pressed:
With load display: The load display flashes. Release the ‘Lift’ button. Press the ‘Lower’ button and set down the load.
In addition, the load indicator system has a protective device to prevent lifting the load with a sudden jolt (sudden load increase).
If the wire rope hoist briefly halts when lifting a load:
Page 18
The load indicator system has triggered.
The load indicator system has detected lifting with a sudden jolt (sudden load increase). The wire rope hoist briefly lifts only at slow lifting speed. Continue to hold the 'Lift' button completely pressed (stage 2). Once the sudden load increase is over, the wire rope hoist accelerates again to the fast lifting speed.
Inching counter
Operating the ABUS crane
Only with chain hoists The chain hoist has a special overload protection (friction clutch). This ensures that the chain hoist cannot be used to lift loads that could cause direct mechanical damage to the chain hoist. It also prevents damage to the chain hoist if the load hook in the highest hook position knocks against the housing from below. Nevertheless, do not exceed the maximum load capacity of the chain hoist!
If the load hook no longer moves, but the chain hoist is still running:
The friction clutch has engaged. Release the ‘Lift’ button. Press the ‘Lower’ button and set down the load.
Danger from falling suspended load! Never run the load hook so far up that the friction clutch engages.
The motors on the crane are not designed for continuous operation. They must have break intervals for cooling down.
Intermittent duty Normally, an individual motor on a crane (e.g. the motor on the trolley drive) is not operated continually over a lengthier period, but rather only briefly with corresponding break intervals (in which then, for example, the crane travel drive is operated). This operating mode is called intermittent duty. How long an individual motor should be operated and how long the breaks for cooling down must be is determined by the duty cycle. The duty cycle of the hoist drive and travel drive can be found in the test log book of the crane or in the section “Technical data” in the production manual of the respective hoist drive or travel drive. The values can also be taken from this table.
10. Inching counter
Duty cycle at high speed
Observe the maximum permissible duty cycle and the maximum switching rate of the hoist and the travel drives.
Duty cycle at low speed
Total duty cycle
This would damage the friction clutch long-term and the load could fall, killing or injuring people.
11. Observe the specified duty cycles
Only with wire rope hoists with LISSE
25 % 2.5 min
0.8 min
1.7 min
30 % 3 min
1 min
2 min
40 % 4 min
1.3 min
2.7 min
50 % 5 min
1.7 min
3.3 min
The LIS-SE has an inching counter. It ensures that the wire rope hoist is not used too long in inching operation (button pressed repeatedly in quick succession).
If the wire rope hoist no longer lifts after repeated brief presses of the button:
The inching counter has triggered. The wire rope hoist has been raised 16 times in inching operation. Lower the load hook for two seconds. The inching counter is reset. The wire rope hoist can be normally operated again.
60 % 6 min 2 min 4 min Table: The specified values (percentage and minutes) refer to a duration of ten minutes. Example: a duty cycle of 40% means that the motor may run for a maximum of four minutes and must remain stationary for six minutes within any 10minute period. Furthermore, the total duty cycle is divided into 1/3 of the duty cycle at low speed and 2/3 of the duty cycle at high speed.
Page 19
Working in the range of the travel limit switch
Operating the ABUS crane
Total switching rate
Switching rate at low speed
Switching rate at high speed
150 c/h
100 c/h
50 c/h
180 c/h
120 c/h
60 c/h
Duty cycle of hoist drive in intermittent duty (see previous table)
Corresponding duty cycle in short term duty for low speed
Corresponding duty cycle in short term duty for high speed
Short term duty cycle for hoist drives:
240 c/h
160 c/h
80 c/h
25 %
3 min
15 min
300 c/h
200 c/h
100 c/h
30 %
3.5 min
30 min
40 %
4 min
30 min
50 %
5 min
60 min
360 c/h 240 c/h 120 c/h Table: The values are given in switches per hour. Example: 240 switches per hour means that the motor may switch up to a maximum of 240 times within one hour. Furthermore, the total maximum switching rate is divided into 2/3 of the switches at low speed and 1/3 of the switches at high speed.
60 % 6 min Over 60 min Table: Duty cycle in intermittent duty and the corresponding duty cycle if the hoist drive is operated in short term duty. Likewise in short term duty, the total duty cycle is divided into 1/3 of the duty cycle at low speed and 2/3 of the duty cycle at high speed.
Short term duty In special situations, a motor may need to run continuously for a longer period than allowed in intermittent duty (e.g. for a long crane run or if a longer hook path must be travelled). In these cases, the motor can be run in short term duty. The motor may only be run up to the maximum period given in the table. The motor must then be allowed to cool down.
Duty cycle of drive in intermittent duty (see previous table)
Corresponding duty cycle in short term duty for low speed
Corresponding duty cycle in short term duty for high speed
Short term duty cycle for drives:
25 %
2.5 min
15 min
30 %
3 min
15 min
40 %
3.5 min
30 min
50 %
4 min
30 min
60 % 5 min 60 min Table: Duty cycle in intermittent duty and the corresponding duty cycle if the drive is operated in short term duty. Likewise in short term duty, the total duty cycle is divided into 1/3 of the duty cycle at low speed and 2/3 of the duty cycle at high speed.
Page 20
Operating the drive in short term duty:
If the crane was previously just used: Wait until the motor has cooled down to the ambient temperature.
Only run the motor at low and high speed maximally as specified in the table. In short term duty, the motor may not be switched on more than 10 times.
Wait until the motor has cooled down to the ambient temperature.
Then run the motor again in either short term duty or intermittent duty.
12. Working in the range of the travel limit switch
Observe the product manuals! In addition to the points described here, all information in the section “Working in the range of the travel limit switch” in the other supplied product manuals also applies.
Operating the ABUS crane
Working in the range of the travel limit switch
Only with travel limit switches with braking function
Only with travel limit switches with braking and shut-down functions
The crane (or the trolley) has a travel limit switch with a braking function. The braking function prevents the crane (or the trolley) from impacting the safety buffer at high speed.
The crane (or the trolley) has a travel limit switch with braking and shut-down functions. The braking function prevents the crane (or the trolley) from impacting the safety buffer at high speed. The shutdown function additionally prevents the crane (or the trolley) from impacting the safety buffer at low speed.
If the crane (or the trolley) runs at high speed:
The crane (or the trolley) brakes at the switching point for the braking function:
─
For overhead travelling cranes: The crane brakes a small distance before the end of the crane track.
─
For overhead travelling cranes: The trolley brakes a small distance before the end of the main girder.
─
For jib cranes: The jib arm brakes a small distance before the end of the slewing range.
─
For jib cranes: The trolley brakes a small distance before the end of the jib arm.
─
For HB cranes: The HB crane brakes a small distance before the end of the crane track.
─ ─
If the crane (or the trolley) runs into the limit switch range of the braking function:
The crane (or the trolley) brakes at the switching point for the shut-down function:
─
For overhead travelling cranes: The crane brakes just before the end of the crane track.
─
For overhead travelling cranes: The trolley brakes just before the end of the main girder.
─
For jib cranes: The jib arm brakes just before the end of the slewing range.
─
For jib cranes: The trolley brakes just before the end of the jib arm.
─
For HB cranes: The trolley brakes a small distance before the end of the crane girder.
For HB cranes: The HB crane brakes just before the end of the crane track.
─
For single-rail trolley tracks: The trolley brakes a small distance before the end of the trolley track.
For HB cranes: The trolley brakes just before the end of the crane girder.
─
The crane (or the trolley) continues running at low speed.
For single-rail trolley tracks: The trolley brakes just before the end of the trolley track.
Continue running the crane (or the trolley), if necessary, at low speed.
Run the crane (or the trolley), if necessary, in the opposite direction out of the limit switch range.
The crane (or the trolley) is at the outermost limit of the traversing range and cannot go any further. Run the crane (or the trolley), if necessary, in the opposite direction out of the limit switch range.
Page 21
Load display and tare
13. Load display and tare
Operating the ABUS crane
14. Securing the crane in a power failure
Only with cranes with load display In the event of a power failure: Emergency stop switch
Load display
The load display shows the weight of the load currently suspended in the load hook.
Only with cranes with load display and tare
Tare
The load display of the crane can be reset to zero using “Tare”. This enables a differential measurement, e.g. in order not to include the weight of a load lifting attachment (such as a crosshead).
The display of the suspended load is set to zero.
Page 22
The travel motors and the hoist motors are immediately and reliably braked even without electricity. The entire crane halts. The load cannot sag or fall. Due to the abrupt braking, the load can swing more than usual. Release all buttons on the pendant control and press the emergency stop button. This ensures that the crane cannot be inadvertently operated once the power is restored.
Press the 'Tare' button.
Travel drive and hoist drive remain stationary due to the power failure.
If necessary: Secure the area under the suspended load.
Switching off the crane
Operating the ABUS crane
15. Switching off the crane
Observe the product manuals! In addition to the points described here, all information in the section “Switching off the crane” in the other supplied product manuals also applies.
Only with cranes with a rail clamp type wind anchor This section only applies if the crane is operated completely outdoors and if it can be secured from wind by means of a rail clamp.
Switch on the rail clamp. Make sure the crane is secured.
Emergency stop switch
Load hook
Press the emergency stop switch.
Lifting tackle
If possible, set down or remove lifting tackle (wire ropes, chains, ...) and load lifting attachments (crossheads, ...).
For lengthier interruptions:
After the end of work, run the load hook to just below the highest hook position.
Only with cranes which are partially operated outdoors This section is only applicable if the crane can be operated either in a building or outdoors (if the crane track leads out of the building).
Move the crane to the resting position in the building.
Only with cranes with a wind anchor secured by a falling latch This section only applies if the crane is operated completely outdoors and if it can be secured from wind by means of a falling latch.
Move the crane to the resting position at the end of the crane track.
Run the crane until the falling latch closes.
Mains switch Switch off the crane at the mains switch.
Make sure the crane is secured.
Page 23
AN 120192EN001
2014-02-28
Kransysteme
General Product Manual for ABUS Cranes ABUS single and double girder travelling crane, underslung travelling crane, wall travelling crane and semi-goliath crane ABUS pillar slewing jib crane and wall jib crane ABUS HB crane ABUS single-rail trolly track ABUS mobile gantry crane ABUS chain hoist and wire rope hoist First read the product manual! The various product manuals for this crane supplement each other. Read this product manual first. It contains important information and references to other manuals.
Order No.
ABUS Kransysteme GmbH Sonnenweg 1 51647 Gummersbach Germany Tel. 0049 – 2261 – 37-0 Fax. 0049 – 2261 – 37-247 [email protected]
16735993 / 1
Distribution or reproduction of this document, or the utilisation and disclosure of its contents without explicit approval is prohibited. Violations will incur liability for damage compensation. All rights are reserved in regard to patent issuance or registered designs.
General instructions regarding safety
(page 9)
Machine description
(page 15)
Instructions regarding safety - Putting into operation
(page 24)
Connecting the crane to the mains supply
(page 28)
Test before initial commissioning
(page 33)
Regular inspection
(page 36)
Basics for determining the remaining service life
(page 43)
Instructions regarding safety - Performing maintenance work
(page 51)
Lubricants
(page 54)
AN 120197EN001
2014-02-28
Translation of the original operating instructions
Crane: various types, versions and options This product manual applies to cranes of various types, versions and options. The work steps described and the technical data will vary according to the type, version and options of the crane. The areas of this product manual which do not apply to all cranes, but are applicable only under certain conditions, are enclosed in a dashed box. At the start of the box, the types, versions and options to which the section is applicable are specified.
Crane (type) Single-girder travelling crane
Double-girder travelling crane
Underslung travelling crane
Pillar slewing jib crane HB crane
Chain hoist
Wall travelling crane
Semi-goliath crane
Wall jib crane Single-rail trolley track
Single rail trolley
Side-mounted trolley
Mobile gantry crane
Double-rail trolley
Cranes with overlapping operating range
Two cranes (overhead travelling crane and wall travelling crane shown here) whose operating ranges overlap (here for example, two overlapping crane levels)
Crane on a crane track
Two cranes on a shared crane track
Tandem operation (optional)
Two cranes in tandem operation
Two trolleys on one crane (optional)
Crane with two trolleys
Crane and trolley with walkway Trolley with walkway
Crane with walkway
Crane travel limit switch with braking function and/or shut-down function (optional)
In the test log book of the crane, check whether the crane has a crane travel limit switch. In the test log book of the crane, check whether the crane travel limit switch can be used for braking or shut-down.
Trolley travel limit switch with braking function and/or shut-down function (optional)
In the test log book of the crane, check whether the crane has a trolley travel limit switch. In the test log book of the crane, check whether the trolley travel limit switch can be used for braking or shut-down.
ABULiner Lifting/Lowering
In the test log book of the crane, check whether the hoist is equipped with the ABULiner frequency converter.
Contents
Contents 1. GENERAL INFORMATION..................... 6 1.1 At the start ................................................ 6
3.6 Inspecting the chain................................ 42 3.7 Basics for determining the remaining service life .............................................. 43
1.2 Instructions regarding safety: For anyone who performs work with or on the crane, or works nearby ....................... 9
3.8 Checking the remaining service life ........ 44
1.3 Instructions regarding safety: For the end user of the crane.............................. 11
3.10 Documenting the test.............................. 45
1.4 The crane ............................................... 15
3.11 Acceptance test after substantial changes .................................................. 45
1.5 Storage of the crane ............................... 23
2. INSTALLING AND CONNECTING .......... 24 2.1 Instructions regarding safety: Before putting into operation .............................. 24 2.2 Instructions regarding safety: When putting into operation .............................. 25 2.3 Instructions regarding safety: After putting into operation .............................. 26
3.9 Checking the test log book ..................... 45
3.12 Testing of components subject to especially high stress ............................. 46 3.13 Test plan and maintenance schedule ..... 47
4. MAINTENANCE ............................... 49 4.1 Switching off the crane ........................... 49 4.2 Instructions regarding safety: Prior to maintenance ........................................... 51
2.4 Installation overview ............................... 26
4.3 Instructions regarding safety: During maintenance ........................................... 52
2.5 Equipping the crane for operation in unprotected environments ...................... 27
4.4 Instructions regarding safety: After maintenance ........................................... 52
2.6 Connecting the crane to the mains supply ..................................................... 28
4.5 Releasing the crane................................ 53
2.7 Ensuring electromagnetic compatibility (EMC) ..................................................... 32 2.8 Test before initial commissioning............ 33 2.9 Shutting down the crane ......................... 34 2.10 Disassembly ........................................... 35 2.11 Reassembling the crane ......................... 35
4.6 Modifying the crane ................................ 53 4.7 ABUS Service ......................................... 54 4.8 Lubricants ............................................... 54 4.9 Wiring diagrams...................................... 68 4.10 Declaration of Conformity, Declaration of Incorporation....................................... 69
3. INSPECTION .................................... 36 3.1 At the start .............................................. 36 3.2 Scope of the test..................................... 37 3.3 Checking the load hook .......................... 39 3.4 Inspecting the conductor system ............ 40 3.5 Inspecting the wire rope ......................... 41
Page 5
At the start
General information
1. General information This section applies to anyone who lifts loads using the crane, performs work on the crane, or works nearby.
1.1 At the start
Instructions for the product manual
Using this product manual
Read the product manual through carefully before beginning work. Also be sure to observe additional product manuals for accessories and components.
The following symbols are used in this product manual:
Afterwards, keep the product manual available in the vicinity of the crane. It must be accessible to all who work with or on the crane.
Danger to persons! This warning notice indicates hazards for persons and provides instructions for avoiding these hazards.
Danger from electric shock! This warning notice indicates hazards for persons due to incorrect handling of the electrical system and electricity.
Danger from falling suspended load! This warning notice describes hazardous situations that can lead to the suspended load falling.
─
This is an instruction regarding an action and prompts you to perform a work step. This is the result of an action and describes what happens on the device. This is a list.
Only with... A section enclosed in a dashed box is only applicable for certain types, versions or options. Which type, version or option this is can be seen in the first line. You can find out whether or not the section is applicable for your crane by referring to the section “Various types, sizes, versions and options” at the beginning of this manual.
Page 6
In the case of reselling or hiring out, always provide the product manual together with the crane.
Observe the safety instructions and warnings! The safety instructions (general) and the warnings (before the respective operative instruction) in this product manual warn against dangers that cannot be eliminated through design. Failure to heed these safety instructions or warnings can result in people being killed or injured. Carefully read and follow the safety instructions and warnings and the entire product manual!
Observe the technical documentation of third-party manufacturers! The technical documentation for additional components (e.g. radio remote control, lifting tackle,...) contains important information on operation as well as additional safety instructions. Carefully read and observe all documentation!
At the start
General information Note regarding the designation “crane”
Proper use
The term “crane” as used in all product manuals refers to every ABUS product with which a load can be lifted and/or transported.
The crane is designed for the lifting and lowering of correctly attached loads and, depending on design, moving them as well.
The term “crane” also refers to all overhead travelling cranes, jib cranes, HB cranes and other cranes including trolley (with wire rope hoist or chain hoist). Solo wire rope hoists and solo chain hoists are also referred to as “crane”.
Printing out product manuals or making them available per computer The product manuals belonging to this crane are available on the enclosed CD as files in PDF format. Some of these product manuals may also be enclosed in printed format in the documentation folder of the crane. All supplied product manuals (on CD or printed) must be made continually available to all persons working with or on the crane.
Print out all product manuals supplied on the CD and store them near the crane. Keep the product manuals in a place accessible to all persons who work with or on the crane. Alternatively, make all product manuals supplied on the CD available per computer. In doing so, make sure the computer is able to display the PDF files and is always operational, and that all persons who work with or on the crane can access this computer. Keep the product manual “Operating the ABUS crane” available in the vicinity of the crane. This product manual contains important information for the crane operator and should be within easy reach at all times.
Observe the product manuals! In addition to the points described here, all information in the section “Proper use” in the other supplied product manuals also applies.
ABUS cranes are designed for these applications: ─
Overhead travelling crane for all-round moving of loads.
─
Jib crane for moving loads in a circular direction.
─
HB crane for all-round moving of lightweight loads.
─
Single-rail trolley track for moving loads in a linear direction.
─
Mobile gantry crane for location-independent all-round moving of lightweight loads.
─
Solo chain hoist and solo wire rope hoist for the stationary lifting and lowering of loads.
─
During operation, observe the classification according to FEM, duty cycle and switching rate. See the product manual “Operating the ABUS crane”.
─
Only operate the hoist if the actual hours of use are fewer than the number of hours representing the theoretical service life.
─
Only use the crane in chemically nonaggressive environments that pose no risk of explosion.
─
Long-term usage of the crane only in weatherproof areas. Temporary use in unprotected environments (outdoors in rain, snow or cold weather) is permitted. For longer operation in unprotected environments, modifications must be made to the crane. See “Equipping the crane for operation in unprotected environments” page 27. In windy environments, even short-term use is prohibited. If the crane is to be used in windy conditions, modifications must be made to the crane. See “Equipping the crane for operation in unprotected environments”. page 27.
Page 7
At the start
Regulations The installation has been built and tested according to European standards, rules and regulations applicable at the time of its manufacture. The conventions applied during design and construction are specified in the Declaration of Conformity or the Declaration of Incorporation. The conventions must also be observed for installation, operation, inspection and maintenance, as must the applicable occupational health and safety regulations.
Danger to persons! Non-observance of the regulations can result in the death of persons or serious accidents. To ensure work safety, thorough instruction in regard to this product manual and the regulations is necessary.
General information
Warranty ─
ABUS assumes no liability for damages that were caused by improper use, inadequately trained personnel, incorrect performance of work, as well as any changes, reconstruction or other modification of the crane or crane components which was not approved by ABUS.
─
Any warranty claim becomes invalid if components were modified without consent, the crane or crane components were installed, used or serviced in any way other than that described in this product manual, or if parts other than original ABUS replacement parts were used.
─
Safe operation of the crane or crane components is only guaranteed if original ABUS replacement parts are used.
Creating a risk assessment Which provision applies in individual cases will greatly depend on the crane’s use and the national regulations. Review and observe all applicable and current regulations, including the occupational health and safety regulations. Refer also to the Declaration of Conformity or Declaration of Incorporation.
This product manual is based on the regulations and directives applicable in Germany and the European Union. If the crane is operated in a different country, the instructions given in this product manual still apply. They then supplement the national regulations. The content specified in this product manual should then be considered the minimum requirements, which must be met in any case. The national regulations supplement these requirements, but do not reduce them. Exception: If the national regulations represent an explicit contradiction to the contents of the product manual, the national regulations have priority.
Page 8
In connection with the crane, dangerous situations can arise in all operating modes (during operation, at a standstill, during maintenance work) and in all product phases. Why, when and where these hazards occur as well as who causes them and how, depends on a great number of different conditions. Among these are the application area of the crane, the conditions and work routine within the building, the interaction with other machines, etc. The hazards described in this and all other product manuals refer to the standard applications of the crane and especially cover the dangers arising directly from the crane itself. In order to take all other arising hazards into account, the end user must create a risk assessment and factor in all possible risks in all modes of operation. The end user must then undertake the appropriate measures and precautions to minimise or eliminate these risks. The end user is responsible for the risk assessment and the implementation of appropriate countermeasures.
General information
Instructions regarding safety: For anyone who performs work with or on the crane, or works nearby
1.2 Instructions regarding safety: For anyone who performs work with or on the crane, or works nearby
Wear protective clothing!
Observe these instructions for safe handling of the crane. Special hazard notices are located in the corresponding sections in which the danger arises.
Observe the product manuals! In addition to the points described here, all information in the section “Instructions regarding safety” in the other supplied product manuals also applies. These instructions specify basic dangers that can arise from the crane. Additional dangers must be determined through a risk assessment and then eliminated.
Keep out!
There are various hazards on the crane and crane track, e.g. due to the height, electricity, temperature, risk of slippage (from oil and dirt), unintended travelling, etc.
In all work there is a risk of head injury (e.g. collision with load hook), hands being crushed (e.g. on the load hook or when slinging the load) and injuries to the feet (e.g. due to falling lifting tackle). As a result of this people can be injured. Wear suitable protective clothing (e.g. industrial safety helmets, safety shoes with reinforced toes, protective gloves) for all work on or using the crane. The actual combination of personal safety gear will depend on the conditions in the building and the use of the crane, and is determined by the risk assessment.
As a result of this people can be killed or injured. Unauthorised persons are not permitted to step into the crane or onto the crane track. This also applies to cranes and wire rope hoists with walkways. Only trained and authorised persons may enter the crane or crane track.
Page 9
Instructions regarding safety: For anyone who performs work with or on the crane, or works nearby
Do not wear any loose clothing or long hair!
General information
No alcohol, drugs or unallowable medications!
Alcohol, drugs and certain medications can impair a person's reaction time and ability to concentrate. For all items which are worn loosely, (e.g. jewellery, open jackets, ties, scarves, long hair), there is a danger of these inadvertently catching on the crane (e.g. on the load hook when lifting a load or in a motor during repair work). As a result of this people can be injured. Before beginning all work, tie long hair back, do not wear any open clothing and remove any jewellery.
Page 10
This could result in hazards not being recognised quickly enough. Persons working with or on the crane may not be under the influence of drugs, alcohol, or medications which inhibit their reaction time or motor coordination.
General information
Instructions regarding safety: For the end user of the crane
1.3 Instructions regarding safety: For the end user of the crane
No environments at risk of explosion!
Follow these instructions to ensure employees use the crane safely.
Observe the product manuals! In addition to the points described here, all information in the section “Instructions regarding safety” in the other supplied product manuals also applies.
No chemically aggressive environments!
Electrical sparks can occur within the panel on the crane or in the pendant control, causing the gases to explode. As a result of this people can be killed or injured. The entire crane is prohibited from use in areas at risk of explosion. This includes the pendant control or transmitter. If used in areas at risk of explosion, the panel and motors, among other components, must be of an explosion-proof design. This is not the case for the standard version.
Fumes from corrosive materials (e.g. acids and lyes) attack metallic and plastic parts on the crane and corrode them. This could damage the crane and cause the load to fall. The crane may not be used in chemically aggressive environments. Only use cranes in corrosive environments if they have been specially designed for those conditions.
Page 11
Instructions regarding safety: For the end user of the crane
No continuous outdoor operation!
General information
Ensure clear communication!
Continuous operation outdoors could cause damage to the crane which could result in the load falling or electric shock. As a result of this people can be killed or injured. Do not operate the crane outdoors on a permanent basis. The crane is designed for continuous use in weatherproof environments. Temporary use outdoors in rain or snow is permitted. For longer operation outdoors, modifications must be made to the crane. See “Equipping the crane for operation in unprotected environments” page 27. In windy environments, even short-term use is prohibited. If the crane is to be used in windy conditions, modifications must be made to the crane. See “Equipping the crane for operation in unprotected environments” page 27.
Page 12
If persons working simultaneously with the crane (e.g. crane operators and load handlers) cannot make themselves perfectly understood, dangerous situations with the load can occur, such as lifting the load prematurely. As a result of this people can be injured! Especially in loud workplaces, the communication must be agreed upon in advance. Ways of ensuring one is understood include clear hand signals, signal tones or wireless equipment.
General information
Instructions regarding safety: For the end user of the crane
Instruct crane operators and load handlers!
Check the highest hook position!
Special technical expertise is required to correctly sling and safely lift and move loads. Otherwise, accidents could occur. Personnel working with the crane (e.g. crane operators and load handlers) must first have received instruction. The required knowledge must be imparted through regular trainings providing the operator with instruction. The end user is responsible for this instruction. The instruction is to be given based on the following documentation: ─
All supplied ABUS product manuals
─
National training requirements
─
Operating instructions created by the end user
─
General occupational health and safety requirements
─
Regulations based on the risk assessment
It is recommended to document this instruction in writing.
For certain lifting tackles and crane types, dangerous situations can occur if the load hook is run to the very top. For example, a crosshead under the main girder can impact against a double-girder travelling crane. Or a round sling can be torn from the main girder of a crane with a side-mounted trolley. This could cause the load to fall, killing or injuring people. When carrying out a risk assessment, check how high the load hook should be allowed to travel with the respective lifting tackle for which it is designed. Dangerous situations must be determined through a risk assessment and then avoided, for example, by moving the hoist limit switch.
Page 13
Instructions regarding safety: For the end user of the crane
Only with cranes with overlapping operating ranges Avoid dangerous situations arising from use of multiple cranes!
If several cranes are used in succession on a single crane track or above one another on multiple levels, their respective operating ranges may overlap. This can give rise to dangerous situations (e.g. the load from the top crane can collide with the bottom crane). Dangerous situations involving overlapping operating ranges must be determined in advance through a risk assessment and then avoided, for example, by employing an anti-collision device.
Page 14
General information
Only with tandem operation Avoid dangerous situations in tandem operation!
If a load is transported by two separately controlled cranes, there is the danger that the two crane operators will control the cranes differently. If a load is transported by two cranes with a tandem control system, there is a risk that a breakdown of one crane will not be detected immediately. This could cause the load to fall, killing or injuring people. If a load is transported by several cranes, dangerous situations must be determined through a risk assessment and then avoided, for example, by having a supervisor oversee the operation or by employing a tandem control system. The cranes and the load must be monitored continuously during tandem operation.
The crane
General information
Description of the underslung travelling crane
1.4 The crane This section provides a rough overview of the ABUS product range. Other combinations of cranes and trolleys are possible. Additional types of cranes and trolleys are also available.
1
2
3
4
5
Description of the single-girder travelling crane 1
2
3
4 7
6
5
─
1: Main girder (ELV version)
─
2: Trolley (wire rope hoist or chain hoist)
─
3: Crane travel drive
─
4: End carriage
─
5: Bottom block and load hook
─
6: Crane track
6
─
1: Main girder
─
2: Trolley (wire rope hoist or chain hoist)
─
3: Crane travel drive
─
4: Crane trolley
─
5: End carriage
─
6: Crane track
─
7: Bottom block and load hook
Description of the device Wall travelling crane 1
2
Description of the double-girder travelling crane 1
2
3
4
6
6
5
5
4
3
─
1: Main girder
─
2: Trolley (wire rope hoist or chain hoist)
─
3: Crane track
─
1: Main girder
─
4: Bottom block and load hook
─
2: Trolley (wire rope hoist)
─
5: End carriage
─
3: End carriage
─
6: Crane travel drive
─
4: Crane travel drive
─
5: Bottom block and load hook
─
6: Crane track
Page 15
The crane
General information
Description of the semi-goliath crane 1
2
3
Description of the pillar slewing jib crane
4
1
5
2
3
4
11 10 5
6 6
7
─
1: Crane travel drive
─
2: Upper end carriage
─
3: Trolley (wire rope hoist)
─
4: Main girder
─
5: Portal support
─
6: Lower end carriage
Page 16
9
8
─
1: Jib arm
─
2: Trolley power supply
─
3: Hoist trolley
─
4: Mobile control (optional)
─
5: Trolley (wire rope hoist or chain hoist)
─
6: Load hook
─
7: Pendant control
─
8: Pillar
─
9: Pillar base
─
10: Slewing gear
─
11: Jib bracket
The crane
General information Description of the wall jib crane 1
2
Description of the HB crane monorail system 3
4
5
1
2
3
10
6 7
8
6
5
4
9 ─
1: Suspension
─
1: Jib arm
─
2: Trolley track
─
2: Slewing gear
─
3: Hoist trolley
─
3: Trolley power supply
─
4: Trolley (chain hoist)
─
4: Hoist trolley
─
5: Load hook
─
5: Mobile control (optional)
─
6: Trolley power supply
─
6: Trolley (wire rope hoist or chain hoist)
─
7: Load hook
─
8: Pendant control
─
9: Jib bracket
─
10: Wall mounts
Description of the HB crane double-rail system 1
7
2
6
─
1: Suspension
─
2: Trolley track
─
3: Hoist trolley
─
4: Trolley (chain hoist)
─
5: Load hook
─
6: Trolley frame
─
7: Trolley power supply
3
5
4
Page 17
The crane
General information
Description of the HB crane, single-girder crane 1
Description of the HB crane, double-girder crane
2
1
2
3
9
3
4
4 5
9
5
8
6
8 6
1
7 1
─
1: Crane track
─
2: Suspension
─
3: Crane trolley
─
4: Crane girder
─
5: Hoist trolley
─
6: Trolley (chain hoist)
─
7: Load hook
─
8: Trolley power supply
7
─
1: Crane track
─
2: Suspension
─
3: Crane trolley
─
4: Trolley frame
─
5: Hoist trolley
─
6: Trolley (chain hoist)
─
7: Load hook
─
8: Trolley power supply
─
9: Crane girder
Description of the single-rail trolley track 1
2
4
Page 18
3
─
1: Trolley track
─
2: Trolley (wire rope hoist or chain hoist)
─
3: Bottom block and load hook
─
4: Pendant control
The crane
General information Description of the mobile gantry crane 1
2
Description of the solo chain hoist
3 1
8 7 4
4
4
6
5
3
2
─
1: Main girder
─
2: Hoist trolley
─
3: Trolley power supply
─
4: Portal support
─
1: Housing
─
5: End carriage
─
2: Bottom block and load hook
─
6: Pendant control
─
3: Pendant control
─
7: Load hook
─
4. Chain box
─
8: Trolley (chain hoist)
Page 19
The crane
General information
Description of the device Single-rail trolley
Description of the device Side-mounted trolley
1
2
3
1
2
4
5
3 4
6
─
1:Trolley frame
─
2: Hoisting gear
─
3: Hoist motor
─
4: Bottom block and load hook
─
5: Hoist trolley
5
─
1: Hoisting gear
─
2: Trolley frame
─
3: Hoist trolley
─
4: Trolley drive
─
5: Bottom block and load hook
─
6: Hoist motor
Description of the device Double-rail trolley 1
2
3
4
7
Page 20
6
─
1: Hoisting gear
─
2: Trolley frame
─
3: End carriage
─
4: Hoist trolley
─
5: Trolley drive
─
6: Bottom block and load hook
─
7: Hoist motor
5
The crane
General information Performance features The single- and double-girder travelling crane and the underslung travelling crane: ─
The cranes are designed for all-round moving of loads in a building or within a section of a building.
─
The crane travels on a crane track, which is fastened to building supports or concrete supports beneath the hall ceiling or on a separate supporting structure.
─
The cranes have a wire rope hoist or a chain hoist with a manually driven or electric trolley (HF/EF).
─
─
─
The crane is designed for the moving of loads in an arc within the operating range around the wall mounting.
─
The crane is fixedly anchored to the building wall, building support, or a concrete support.
─
The crane has a wire rope hoist or a chain hoist with a manually driven or electric trolley (HF/EF), depending on type.
The HB crane: ─
The HB single-girder and double-girder cranes are designed for all-round moving of lightweight loads within the operating range.
─
The crane is designed for all-round moving of loads within the operating range on a building wall.
The monorail and double-rail systems are designed for moving lightweight loads in a linear direction.
─
The crane travels on a crane track, which is fastened laterally to building supports or concrete supports.
The cranes are suspended from HB crane runways, which are fastened under the hall ceiling or on a separate supporting structure.
─
The crane has a chain hoist as a trolley.
The wall travelling crane: ─
The wall jib crane:
The crane has a wire rope hoist or a chain hoist with a manually driven or electric trolley (HF/EF). The single-rail trolley track:
The semi-goliath crane: ─
The crane is designed for all-round moving of loads within the operating range on a building wall.
─
The semi-goliath crane travels on the building wall with the upper end carriage on a crane track. It runs to the middle of the building with the lower end carriage on the floor of the building.
─
The crane has a wire rope hoist as a trolley.
The pillar slewing jib crane: ─
The crane is designed for the moving of loads in a circular direction or arc within the operating range around the crane pillar.
─
The crane pillar is fixedly anchored to the floor of the building or a foundation specially created for it.
─
The crane has a wire rope hoist or a chain hoist with a manually driven or electric trolley (HF/EF), depending on type.
─
The crane is designed for moving loads in a linear direction within the operating range.
─
The crane track is fastened to the building wall, on building supports, concrete supports, or on a separate supporting structure.
─
The crane has a wire rope hoist or a chain hoist with a manually driven or electric trolley (HF/EF).
The mobile gantry crane: ─
The crane is designed for locationindependent moving of lightweight loads.
─
The crane runs on four castors, freely movable on level ground.
─
The crane has a chain hoist as a trolley.
Page 21
The crane
The solo chain hoist: ─ ─
The solo chain hoist is designed for the stationary lifting and lowering of loads. It is stationary and fastened to an appropriately dimensioned supporting structure.
General information
Technical data Observe the product manuals! In addition to the points described here, all information in the section “Technical data” in the other supplied product manuals also applies.
The single-rail trolley: ─
The wire rope hoist serves as a trolley on single-girder travelling cranes.
─
The wire rope hoist has a hoist trolley with which it travels along the lower flange of the main girder.
Normal ambient conditions during operation: Range Ambient temperature
-10°C to +40°C
Elevation
Up to 1000 m above sea level Ambient conditions for a complete crane including control.
The side-mounted trolley: ─
The wire rope hoist serves as a sidemounted trolley on single-girder travelling cranes.
─
The wire rope hoist has a two-part hoist trolley. One part is used to run the wire rope hoist along the trolley track, which is mounted on the side of the main girder. The load hook hangs from the side of the main girder on which the trolley track is mounted. On the other side of the main girder, the other part of the hoist trolley grips onto the upper flange.
Operation in other ambient conditions (e.g. at a higher ambient temperature) is in many cases possible. For questions regarding individual on-site conditions in the building (e.g. duration and type of heat and its influence on the crane), ABUS Service will gladly be of assistance. See “ABUS Service” page 54.
Only with travel drives and hoist drives This section only applies to travel drives and hoist drives.
The double-rail trolley: ─
The wire rope hoist serves as a trolley on double-girder travelling cranes.
─
The wire rope hoist has two end carriages with which it travels along the trolley track of the main girder.
Range Ambient temperature
-10°C to +40°C
Ambient temperature +40°C to +65°C (for reduced duty cycle) Ambient conditions exclusively for travel and hoist drives.
Travel and hoist drives can also be used at a reduced duty cycle and switching rate from +40°C to +65°C.
Page 22
Storage of the crane
General information Operation at higher ambient temperatures: Duty cycle according to type plate
Modified duty cycle at ambient temperatures of +40°C to +65°C
60 %
30 %
50 %
25 %
40 %
20 %
Switching rate according to type plate
Modified switching rate at ambient temperatures of +40°C to +65°C
420
210
360
180
300
150
240
120
180
90
1.5 Storage of the crane
Observe the product manuals! In addition to the points described here, all information in the section “Storage” in the other supplied product manuals also applies.
If the crane is not installed immediately:
At ambient temperatures of +40°C to +65°C, reduce the duty cycle and switching rate according to the tables.
Operation at higher elevations: At higher elevations, the crane will be less well cooled due to the reduced air pressure.
Reduce the duty cycle and switching rate at higher elevations.
Film
Cover unpainted surfaces and openings with film and mask it.
Unpack components wrapped in film (e.g. pillars and jib arms from the jib crane). Otherwise, condensation collects under the film.
Store unpainted metallic parts, wire rope hoists, chain hoists, electrical and electronic components in a dry, dust-free place.
Store painted metallic parts as dry and dustfree as possible.
Mechanical design life The mechanical design life of the crane is 20 to 25 years.
Rainwater on the main girder Wipe off any rainwater.
Inspection after lengthier storage Should the crane be installed after it has been in storage for a lengthier period:
Perform a visual inspection of all components. They should be neither heavily soiled nor dusty.
Inspect the paintwork. The paint should not be cracked or peeling.
Inspect metallic parts. They should exhibit no rust.
Inspect electrical components. Live parts (e.g. bushes, pins and terminals) should not be oxidised (e.g. discoloured or roughened surface).
Page 23
Instructions regarding safety: Before putting into operation
Installing and connecting
2. Installing and connecting This section applies to anyone who works on the crane prior to its use
The crane is delivered ready-assembled. To install, perform the described points here in the sequence given.
The end user of the crane is responsible for the proper qualifications of the commissioning personnel.
Danger to persons! Persons can be injured if the crane is incorrectly put into operation. If personnel other than that of the ABUS company are employed to perform the commissioning, it is the end user’s responsibility to ensure that these persons are adequately qualified. Follow the procedures described here precisely.
2.1 Instructions regarding safety: Before putting into operation Comply with the following safety instructions before beginning with putting the crane into operation:
Observe the product manuals! In addition to the points described here, all information in the section “Instructions regarding safety” in the other supplied product manuals also applies.
Use suitable lifting platforms and fall protection equipment!
Examples of qualified persons: ─
Persons with comprehensive knowledge from specialist training in engineering and in the electrical systems of cranes.
─
Persons with sufficient experience in the operation, installation and maintenance of cranes.
─
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country.
─
Persons receiving regular training from ABUS.
ABUS assumes no liability for damage due to incorrectly performed commissioning work done by unqualified personnel. ABUS recommends having the commissioning work performed by the ABUS assembly team.
Page 24
Falls from great heights can result in people being killed or injured. Always use suitable lifting platforms and fall protection equipment. If the crane has a walkway on the main girder or on the wire rope hoist, a suitable lifting platform or fall protection equipment must be used for entering the walkway.
Installing and connecting
Cordon off the work area!
Instructions regarding safety: When putting into operation
Only electricians should work on the crane electrical system! Special expertise is required for working on electrical installations. Without this expertise, there is a risk of electric shock. Only trained electricians should work on the crane electrical system!
2.2 Instructions regarding safety: When putting into operation Falling objects (e.g. tools) can kill or injure people. The lifting platforms can also be overturned, e.g. by forklifts. Adequately cordon off the work area.
Switch off cranes on the same crane track!
Comply with the following safety instructions when putting the crane into operation:
Observe the product manuals! In addition to the points described here, all information in the section “Instructions regarding safety” in the other supplied product manuals also applies.
Do not permanently remove the covers!
Other cranes can overturn the lifting platforms or impact the crane that is being serviced. Switch off any other cranes using the same crane track or cranes working above or below. Secure the mains switch so that it cannot be unintentionally switched back on.
Notify personnel of putting the crane into operation! Personnel working in the area may not necessarily be aware of the dangers when putting the crane into operation.
When covers (e.g. panel lids, fan covers, motor covers,...) are removed, dangerous areas are no longer protected. As a result of this people can be injured! Remount covers after working on the crane. Do not permanently remove the covers in order to improve the cooling of components.
They might be hit, for example, by falling tools. Notify personnel in the area regarding the crane being put into operation.
Page 25
Instructions regarding safety: After putting into operation
Protect components from the effects of heat!
Installing and connecting
2.4 Installation overview
Observe the product manuals! In addition to the points described here, all information in the section “Installation overview” in the other supplied product manuals also applies. The effects of heat from work performed on the crane (e.g. welding, open flames, flying sparks) can set parts on fire. This can cause harmful gases to form and parts to become deformed or damaged. Cover the parts or otherwise protect them from becoming too hot. After completing the work, inspect the condition of the parts.
2.3 Instructions regarding safety: After putting into operation Comply with the following safety instructions once putting into operation has been completed:
Observe the product manuals! In addition to the points described here, all information in the section “Instructions regarding safety” in the other supplied product manuals also applies.
Remove tools and separate parts!
Loose parts can fall from the crane during operation, killing or injuring people. Remove tools and separate parts (spare parts, removed parts,...).
Page 26
For assembly of an entire crane installation:
In all supplied product manuals, read the sections “Installation overview” and “Checking the requirements”.
First fulfil the requirements in the building (e.g. for overhead travelling cranes, install the crane track; for jib cranes, prepare the foundation,...).
Then, depending on the individual components, define the order of the installation work.
Finally, follow the respective sections for “Putting into operation” in all product manuals according to the defined order to assemble the crane.
If necessary: Protect the crane from rain, snow, wind or cold. See “Equipping the crane for operation in unprotected environments” page 27.
Next, connect the crane to the mains supply. See “Connecting the crane to the mains supply” page 28.
Finally, carry out the test before initial commissioning. See “Test before initial commissioning” page 33.
Installing and connecting
2.5 Equipping the crane for operation in unprotected environments
Equipping the crane for operation in unprotected environments
Attaching a wind anchor Strong wind can cause the crane to move in an uncontrolled manner (even when switched off). ─
For cranes which are operated completely outdoors: The crane must be able to be secured in a resting position (at the end of the crane track) when work is completed. A wind anchor is located at this resting position for securing the crane.
─
For cranes which are operated partly outdoors: If the crane can be moved inside the building when work is finished, a wind anchor is not necessary.
Long-term usage of the crane only in weatherproof areas. Temporary use in unprotected environments (outdoors in rain, snow or cold weather) is permitted. Should the crane be operated on a long-term or continual basis in environments without protection from the weather (outdoors, in rain, snow or cold), modifications will need to be made to the crane. In windy environments, even short-term use is prohibited. If the crane is to be used in windy conditions, modifications must be made to the crane. For the ambient conditions, see “Technical data” page 22.
Protecting from rain and snow Rain and snow can penetrate the electrical components of the crane and cause malfunctions (e.g. a short).
Attach a rain hood over the crane travel motor.
Attach a rain hood over the entire wire rope hoist.
Attach rain hoods over all panels.
Only with cranes which can only be safely operated up to a defined wind speed This section only applies to cranes which can only be safely operated up to a defined wind speed.
Attaching the wind measuring system The crane must be equipped with a wind measuring system. The wind measuring system warns if a certain wind speed has been exceeded. The crane must then be able to travel to its resting position (at the end of the crane track) within a specified time. A wind anchor is located at this resting position for securing the crane. Alternatively, the wind anchor can be of a design that secures the crane at any desired position. The corresponding wind speed up to which the crane can be operated and the time in which the crane must be able to move to its resting position are both specified in the test log book.
Page 27
Connecting the crane to the mains supply
2.6 Connecting the crane to the mains supply
Installing and connecting
Only with pillar slewing jib cranes Overview: Electrical connection of the crane
Only with overhead travelling cranes
1
2
3
4
Overview: Electrical connection of the crane 1 2
8
3
4
5
6
7
7
6
5
─
The power supply for the crane begins at the sub-distribution (8) of the mains supply.
─
The power supply for the crane begins at the sub-distribution (7) of the mains supply.
─
From there, a line (7) runs to the mains switch (1) of the crane installation.
─
From there, a line (6) runs to the pillar base of the jib crane and is led through the foundation into the pillar (1).
─
The line runs to the mains switch (5) of the crane.
A mains switch is the best option for isolating the entire crane installation. The mains switch must be secured against inadvertent switching back on.
A mains switch is the best option for isolating the entire crane.
The mains switch is usually located under the mains power supply of the crane, e.g. on the building wall or on a building support or concrete support. ─
From the mains switch, the riser (2) extends to the feed unit (3).
─
The feed unit connects the riser with the mains power supply (4) (usually a conductor system) of the crane.
─
The mains power supply contains a mobile current collector (5) which travels with the crane along the crane track.
─
The crane is connected to the mains power supply with the mains disconnector plug (6). This mains disconnector plug is used to isolate the individual crane. The mains disconnector plug can be secured against inadvertent switching back on. Instead of the mains disconnector plug, a separate circuit isolator (in the form a mains switch) can also be mounted on the crane panel.
Page 28
The mains switch must be secured against inadvertent switching back on. The mains switch is located in the pillar at operating height. ─
From the mains switch, a line runs inside the pillar and is led out at the top. For types LS and LSX: The line is led directly out of the pillar. For type VS: The line runs in the pillar up to the slip ring (3).
─
For types LS and LSX: The line out of the pillar is connected directly to the trolley power supply (4). For type VS: From the slip ring, the line runs either to the jib arm panel (2) and from there to the trolley power supply (4) or directly from the slip ring to the trolley power supply.
Connecting the crane to the mains supply
Installing and connecting
Only with wall jib cranes
Only with HB cranes, monorail system and double-rail system
Overview: Electrical connection of the crane 1
2
Overview: Electrical connection of the HB crane
3 1 2
6 6
5
The power supply for the crane begins at the sub-distribution (6) of the mains supply.
─
From there, a line (5) runs to the mains switch (4) of the crane.
─
From there, a line (5) runs to the mains switch (1) of the HB crane installation. A mains switch is the best option for isolating the entire HB crane installation. The mains switch must be secured against inadvertent switching back on.
The mains switch must be secured against inadvertent switching back on.
─
From the mains switch, the riser (1) extends to the crane.
─
For types LW and LWX: The line is connected directly to the trolley power supply (4). For type VW: The line runs either to the jib arm panel (2) and from there to the trolley power supply (4) or directly to the trolley power supply.
5
The power supply for the HB crane begins at the sub-distribution (6) of the mains supply.
A mains switch is the best option for isolating the entire crane.
The mains switch is usually located under the crane, e.g. on the building wall or on a building support or concrete support.
4
─ 4
─
3
The mains switch is usually located under the mains power supply of the HB crane, e.g. on the building wall or on a building support or concrete support. ─
From the mains switch, the riser (2) extends to the feed unit (3).
─
There the line is connected with the trolley power supply (4).
Page 29
Connecting the crane to the mains supply
Only with HB cranes, single-girder crane and double-girder crane Overview: Electrical connection of the HB crane 1 2
3
4
5
Installing and connecting
─
The HB crane is connected to the mains power supply. If the HB crane installation consists of a single HB crane, the mains power supply is connected directly to the HB crane.
─
6
If the HB crane installation consists of several HB cranes, there is a circuit isolator on the crane. This circuit isolator is used to isolate the individual HB cranes. The circuit isolator must be secured against inadvertent switching back on.
Only with single-rail trolley tracks Overview: Electrical connection of the crane 8
7
─
The power supply for the HB crane begins at the sub-distribution (8) of the mains supply.
─
From there, a line (7) runs to the mains switch (1) of the HB crane installation.
1
2
A mains switch is the best option for isolating the entire HB crane installation. The mains switch must be secured against inadvertent switching back on. The mains switch is usually located under the mains power supply of the HB crane, e.g. on the building wall or on a building support or concrete support.
5
4
3
─
The power supply for the crane begins at the sub-distribution (3) of the mains supply.
─
From there, a line (4) runs to the mains switch (5) of the crane.
─
From the mains switch, the riser (2) extends to the feed unit (3).
─
The feed unit connects the riser with the mains power supply (4) of the crane.
A mains switch is the best option for isolating the entire crane.
─
For conductor systems: The mains power supply contains a mobile current collector (5) which travels with the HB crane along the HB crane runway. For festoon cable systems: The line of the mains power supply hangs in loops on the HB crane runway and is towed by the HB crane.
The mains switch must be secured against inadvertent switching back on.
Page 30
The mains switch is usually located under the crane, e.g. on the building wall or on a building support or concrete support. ─
From the mains switch, the riser (1) extends to the crane.
─
There the line is connected to the trolley power supply (2).
Connecting the crane to the mains supply
Installing and connecting
Only with mobile gantry cranes
Only with solo wire rope hoists
Overview: Electrical connection of the crane
Overview: Electrical connection of the crane
1
4
1
3
3
2
2
─
The power supply for the solo wire rope hoist is connected according to the on-site conditions in the building.
From there, a suitable line with a CEE plug (3) runs to the mains disconnector plug (2) of the crane.
─
The mains disconnector plug (1) on the wire rope hoist can be secured against inadvertent switching back on.
A line then runs to the mains switch (1) of the crane.
─
However, it is still recommended that the line (3) have a mains switch as general mains switch (2) for the entire crane installation.
─
The power supply for the crane begins at a three-phase socket (4).
─
─
The mains switch is located on one of the portal legs on the crane.
Only with solo chain hoists Overview: Electrical connection of the crane
Checking the on-site mains supply
1
For cranes without voltage adapting transformer: Compare the operating voltage and mains frequency of the crane with the mains voltage and frequency of the local mains supply. The operating voltage and mains frequency are specified on the type plates on the crane and in the test log book. Operating voltage and mains voltage as well as mains frequency must be matched for one another.
3 ─
─
2
The power supply for the solo chain hoist is connected according to the on-site conditions in the building. The line (3) must have a mains switch as general mains switch for the entire crane installation (2) or a plug-in connection as a mains disconnector plug.
For cranes with voltage adapting transformer: The mains voltage of the local mains supply must be converted to the operating voltage of the crane by a voltage adapting transformer. Compare the operating voltage and mains frequency at the input of the voltage adapting transformer with the mains voltage and frequency of the local mains supply.
The bayonet coupling (1) on the chain hoist cannot be secured against switching back on and is therefore not suitable as a mains disconnector plug.
Page 31
Ensuring electromagnetic compatibility (EMC)
Installing and connecting
Connecting the crane Danger from electric shock! Work on electrical systems and components may only be performed by a qualified electrician when the system is in a voltagefree state.
Lay the lines, attach the mains switch and connect the crane.
2.7 Ensuring electromagnetic compatibility (EMC)
Electrical devices and lines normally generate electromagnetic fields. These fields can negatively affect other devices and cause malfunctions. To best avoid such disturbances, certain basic principles must be observed when working with electrical equipment.
For any electrical work performed on the crane:
Checking the rotary field The crane can only be operated on a 3-phase mains supply with a clockwise rotary field.
Unlock the emergency stop switch. Press the ‘Lift’ button halfway.
Observe the following points amongst others: ─
Do not lay signal lines together with currentconducting lines.
─
With frequency converters: guide connection cables for braking resistance and connection cables for motors through the cable fittings in the panel and lay them in a direct path to the frequency converter.
─
Lay the shields of shielded cables over a wide area and earth them.
─
Do not twist, braid or solder shields. Instead, use the supplied installation material.
─
Earth the unused wires of cables in the panel.
The load hook must run slowly upward or remain stopped (if the top emergency limit switch has already been triggered).
If the load hook instead travels downward:
In order for the crane to operate without faults, all electrical components and all connection cables must be installed by professionals.
The phases in the mains supply have been interchanged. Correct the interchanged phases. If possible, correct the phases at the point where they were interchanged. Only in exceptional cases should the phases be interchanged again directly on the power line.
Page 32
Test before initial commissioning
Installing and connecting
2.8 Test before initial commissioning Before the crane can be put into operation for the first time, a test must be carried out. The end user is responsible for this test prior to initial commissioning.
Requirements for the examiner The end user of the crane is responsible for the proper qualifications of the examiner.
Danger to persons! Persons can be injured if the inspection is performed incorrectly. If personnel other than that of the ABUS company are employed to perform the inspection, it is the end user's responsibility to ensure that these persons are adequately qualified.
Examples of qualified persons: ─
Persons with comprehensive knowledge from specialist training in engineering and in the electrical systems of cranes.
─
Persons with sufficient experience in the operation, installation and maintenance of cranes.
─
─
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country.
Overview: Inspecting the crane The qualified person inspecting the crane is responsible for the type and scope of the test. The items to be checked in the following list represent a general overview regarding the scope of testing of ABUS cranes. Depending on the type, not all components will be present on the crane. The decision as to whether the crane is in perfect condition may be made only by the person inspecting the crane. Any inadequacies, if found, must be eliminated. The examiner decides whether the crane has to be tested again afterward. If locally applicable regulations specify further tests, these are likewise to be carried out. The examiner tests the operational crane. In doing so, it must be ensured that no one is subjected to avoidable dangers.
At least the following points must be checked: Check the general condition. The components of the crane installation may not be damaged or rusted, or exhibit any other dangerous material changes.
Check the condition of the supporting structure. It should not exhibit any damage.
Check that the crane has been correctly installed and connected. It must be installed and connected in accordance with this and other product manuals.
Check the hoist drive, trolley drive and crane travel drive. They must be functioning flawlessly. For the test for switching on, see the product manual “Operating the ABUS crane”.
Test the brakes on the hoist drives, trolley drives and crane travel drives. They must be functioning flawlessly. For the test for switching on, see the product manual “Operating the ABUS crane”.
Check the hoist limit switches (switching points for safety limit switches and emergency limit switches). The hoist must switch off at the appropriate switching points.
If available: Check the operating limit switches. The hoist must switch off at the appropriate switching points.
Check the travel limit switch. The crane travel drives and the trolley drives must switch off at the appropriate switching points.
Check screws. All screws must be tightened and secured. If they are not, tighten the screws with the appropriate tightening torque and secure them.
If available: Check warning devices. They must function as intended.
Persons receiving regular training from ABUS.
Page 33
Shutting down the crane
Check the overload protection (e.g. load indicator system LIS or friction clutch). It must function as intended.
Check all other safety devices on the crane. They must function as intended.
If available: Check the condition of the wind anchor. It must function as intended.
Check the signage. The required signs on the crane must be present and legible. Otherwise, replace the signs.
Installing and connecting Documenting the test before initial commissioning Also in countries which do not require a test log book, it is recommended to document the test in the test log book. Test log book of crane
Perform a static test of the maximum load capacity. Test using a test load with 1.25 times the maximum load capacity of the crane.
Perform a dynamic test of the maximum load capacity. Test using a test load with 1.1 times the maximum load capacity of the crane.
Only if necessary: Perform additional country-specific tests.
Only within the EU: Check whether there is a Declaration of Conformity or a Declaration of Incorporation.
Checking the test log book Also in countries which do not require a test log book, it is recommended to document the test in the test log book.
─
Type and scope of the test
─
Items of the test still to be evaluated
─
Inadequacies detected
─
Assessment of whether the crane may be operated
─
Decision on whether a re-check is necessary The test log book and the complete documentation for the crane must be within easy reach of all persons working on or with the crane.
Check the test log book:
─
It must be available
─
It must be within easy reach of all persons working on or with the crane.
─
It must be clearly identified as belonging to the crane.
─
All tests carried out (e.g. test before initial commissioning, regular inspections, tests of the crane track, etc.) must be documented.
Document the result of the entire test in the test log book.
2.9 Shutting down the crane Should the crane need to be put out of service for a longer period:
Page 34
Switch off the crane. See the product manual “Operating the ABUS crane”.
Secure the mains switch so that it cannot be unintentionally switched back on.
Installing and connecting
Disassembly
2.10 Disassembly If the crane is to be disassembled: ABUS recommends having personnel who performed the initial commissioning carry out the disassembly. See “Installing and connecting” page 24.
Disassemble the crane by reversing the sequence of steps described in the section “Putting into operation” in all product manuals.
Dispose of high-tensile bolts, high-tensile nuts and self-locking nuts. They are only to be used once.
2.11 Reassembling the crane If a disassembled crane is to be reassembled: ABUS recommends having personnel who performed the initial commissioning carry out the reassembly. See “Installing and connecting” page 24.
Reassemble the crane as described in the section “Putting into operation” in all product manuals.
Be sure to use new high-tensile bolts, new high-tensile nuts and new self-locking nuts.
After reassembly, a new test before initial commissioning is required. See “Test before initial commissioning” page 33.
Page 35
At the start
Inspection
3. Inspection This section applies to anyone who inspects and accepts the crane in accordance with occupational health and safety requirements
The crane must be regularly inspected in order to guarantee safe operation. The end user is responsible for this regular inspection.
Requirements for the examiner The end user of the crane is responsible for the proper qualifications of the examiner.
3.1 At the start Danger to persons! Persons can be injured if the inspection is performed incorrectly.
Test intervals
If personnel other than that of the ABUS company are employed to perform the inspection, it is the end user's responsibility to ensure that these persons are adequately qualified.
The regular inspection is performed at least once annually. Under certain conditions, more frequent regular inspections may be necessary. Reasons include: ─
Frequent operation at the load capacity
─
Working in multiple shifts
─
Frequent use
─
Dusty or chemically aggressive environment
The end user is responsible for checking the prerequisites and determining the test intervals. ABUS will gladly assist you if questions arise.
Page 36
Examples of qualified persons: ─
Persons with comprehensive knowledge from specialist training in engineering and in the electrical systems of cranes.
─
Persons with sufficient experience in the operation, installation and maintenance of cranes.
─
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country.
─
Persons receiving regular training from ABUS.
Scope of the test
Inspection 3.2 Scope of the test The qualified person inspecting the crane is responsible for the type and scope of the test.
Overview: Inspecting the crane Observe the product manuals! In addition to the points described here, all information in the section “Scope of the test” in the other supplied product manuals also applies.
The items to be checked in the following list represent a general overview regarding the scope of testing of ABUS cranes. Depending on the type, not all components will be present on the crane.
In addition to the points described here, all points outlined in the other supplied product manuals must also be checked. The decision as to whether the crane is in perfect condition may be made only by the person inspecting the crane. Any inadequacies, if found, must be eliminated. The examiner decides whether the crane has to be tested again afterward. If locally applicable regulations specify further tests, these are likewise to be carried out.
─
─
For an overview of the points to be checked: See “Test plan and maintenance schedule” page 47. For an overview of the lubricants changed in a general overhaul or regular inspection, see “Lubricants” page54.
Additionally, at least the following points must be checked: Check the general condition. The components of the crane installation may not be damaged or rusted, or exhibit any other dangerous material changes.
Check the condition of the supporting structure. It should not exhibit any damage.
Check that the crane has been correctly installed and connected. It must be installed and connected in accordance with this and other product manuals.
Check the hoist drive, trolley drive and crane travel drive. They must be functioning flawlessly. For the test for switching on, see the product manual “Operating the ABUS crane”.
Test the brakes on the hoist drives, trolley drives and crane travel drives. They must be functioning flawlessly. For the test for switching on, see the product manual “Operating the ABUS crane”.
Check the hoist limit switches (switching points for safety limit switches and emergency limit switches). The hoist must switch off at the appropriate switching points.
If available: Check the operating limit switches. The hoist must switch off at the appropriate switching points.
Check the travel limit switch. The crane travel drives and the trolley drives must switch off at the appropriate switching points.
Check screws. All screws must be tightened and secured. If they are not, tighten the screws with the appropriate tightening torque and secure them.
If available: Check warning devices. They must function as intended.
Check the overload protection (e.g. load indicator system LIS or friction clutch). It must function as intended.
Check all other safety devices on the crane. They must function as intended.
If available: Check the condition of the wind anchor. It must function as intended.
Check the signage. The required signs on the crane must be present and legible. Otherwise, replace the signs.
Check weld seams. They should not be cracked or broken.
Check the condition of the paintwork. It should not be scratched or peeling. Otherwise, remove peeling paint and touch up the paint coat.
Check the load hook. See “Checking the load hook”, page 39.
Page 37
Scope of the test
Check the hoist drive, trolley drive and crane travel drive for tightness. The drives should not exhibit any exterior cracks or traces of leaked lubricant. Check the air gap and brake lining thickness of the brakes on the hoist drives, trolley drives and crane travel drives. The air gap width must match that specified in the corresponding product manual. The brake lining thickness must match that specified in the respective product manual. If this is not the case, adjust the air gap and replace the brake lining. If necessary: Check the load capacity. Check the load capacity using a test load approaching the maximum load capacity of the crane.
Check the lubrication of all moving parts. See “Lubricants” page 54.
If applicable: Inspect conductor system. See “Inspecting the conductor system” page 40.
Only with wire rope hoists
Examine the wire rope. See “Inspecting the wire rope” page 41.
Check the wire rope (on the cable drum and on the fixed point crosshead) and check the cable guide. The components should not be damaged, heavily worn, broken or loose.
Check the wheel flange wear of the wheels on the wire rope hoist.
Check the braking distance of the trolley drive.
Check the diameter of the guide rollers on the wire rope hoist.
Check the wheel diameters on the wire rope hoist.
Check the condition of the safety buffer on the wire rope hoist.
Check the condition of the bottom block (visual inspection).
Check the edge protection on the bottom block (visual inspection).
Check the rope wedge protrusion.
Only with chain hoists
Inspect the chain. See “Inspecting the chain” page 42.
Check additional components. See the product manual for the chain hoist.
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Inspection
Check the test log book. See “Checking the test log book” page 45.
Determine the already elapsed portion of the theoretical service life. See “Checking the remaining service life” page 44.
Only if necessary: Perform additional country-specific tests.
Document the test. See “Documenting the test” page 45. Also in countries which do not require a test log book, it is recommended to document the test in the test log book.
Checking the load hook
Inspection
3.3 Checking the load hook
Only with wire rope hoists
Only with chain hoists
STE 355
025
single 30.8
22.8
STE 355
05
single 37.5
29.5
34 CrMo 4
1
single 44.0
38.0
34 CrMo 4
1.6
single 49.5
45.6
34 CrMo 4
If the load hook has been widened to a greater degree than is allowed or if the base height is below the permissible limit, replace the load hook.
If the load hook is deformed (even if within the measurements given above): Inspect the surface for cracks.
The widening ‘e’ may not be larger than the value in the table. (The table specifies the maximum widening.)
─
The measured distance ‘y’ minus 10% may not be larger than the value in the table. (The table specifies the nominal measurement. The nominal measurement may not be exceeded by more than 10%.)
─
The measured base height ‘f’ may not be smaller than the value in the table. (The table specifies the minimum base height.) Min. base height 'f' [mm]
18.1
─
Compare the measured values with the table.
Nominal distance ‘y’ [mm]
Material
single 26.4
Measure the base height 'f' of the load hook.
Max. widening ‘e’ [mm]
Min. base height 'f' [mm]
012
Max. widening ‘e’ [mm]
Type of load hook
The measured values should neither exceed nor fall short of the values in the table.
Type of load hook
Measure the base height 'f' of the load hook.
Measure the widening ‘e’ of the load hook or distance ‘y’ between the two stamped markings.
Size of load hook
Measure the widening ‘e’ of the load hook.
Size of load hook
1
single
44
Test log book
38
1.6 single
49.5
Test log book
45.6
2.5 double 44
Test log book
47.5
2.5 single
Test log book
55.1
55
4
double 49.5
Test log book
57
4
single
Test log book
63.7
6
double 61.6
93
71.3
6
single
130
80.8
61.6
78.1
Page 39
Type of load hook
Nominal distance ‘y’ [mm]
Min. base height 'f' [mm]
Inspection
Size of load hook
Max. widening ‘e’ [mm]
Inspecting the conductor system
8
double 69.3
104.5
80.8
8
single
145
90.3
10
double 78.1
117.5
90.3
10
single
160
100.7
12
double 88
132.5
100.7
12
single
180
112.1
16
double 99
148.5
112.1
16
single
200
125.4
20
double 110
165.5
125.4
20
single
138
225
142.5
25
double 123
185
142.5
25
single
154
255
161.5
32
double 138
207
161.5
32
single
176
290
180.5
40
double 154
233
142.5
88
99
110
123
3.4 Inspecting the conductor system
Only with conductor system as mains power supply or trolley power supply This section is only applicable if a conductor system is used as the mains power supply or the trolley power supply.
Danger from electric shock! The conductor system is under live current. Before performing any work on the conductor system, switch off the crane and secure it against being switched back on.
Danger due to failure of protective conductor! The protective conductor is also connected to the crane through the conductor system. If the conductor system and the current collector are not carefully inspected and maintained, it is possible that the protective conductor may be broken.
40 single 198 320 201.4 The nominal distance ‘y’ for load hooks size 1 to 6 is specified in the test log book.
If the load hook has been widened to a greater degree than is allowed or if the base height is below the permissible limit, replace the load hook.
If the load hook is deformed (even if within the measurements given above): Inspect the surface for cracks.
Inspecting the conductor system
Inspect the sections of the conductor system, the joints of the sections and the suspensions. The parts should not be broken, deformed or otherwise damaged.
Inspect the inside of the conductor system. It should not be heavily soiled (e.g. due to rubbing of the carbon strip or dirt in the surroundings).
Inspect the sections of the conductor system. The surface of current-conducting rails must be smooth.
If the conductor system is heavily soiled or the surface of the rails is not smooth, blow off with compressed air or clean with a cleaning trolley. The cleaning trolley is supplied through ABUS Service. See “ABUS Service” page 54.
Page 40
Inspecting the wire rope
Inspection
Inspecting current collectors
Check the running characteristics of the current collector. It must run smoothly and without resistance in the conductor system.
Take the current collector out of the conductor system.
Check the thickness of the carbon strips. The carbon strips should not show more wear than is permissible. How much wear the carbon strips are allowed to have is either specified on the current collector (according to the conductor system) or the maximum wear is indicated by a marking on the carbon strip itself.
Check the wheels of the current collector. They must run smoothly and be free of damage.
If the current collector does not run smoothly or the carbon strips are more heavily worn than is allowed, replace the current collector completely, or (if possible) replace the carbon strips.
3.5 Inspecting the wire rope
Only with wire rope hoists
Inspect the entire wire rope for damage. The damage shown here or any similar damage should not be detectable on the wire rope. Examples of damage:
The joining of the wire rope has opened. The inner strands of the wire rope are visible.
Loops have formed in the wire rope.
There is a kink in the wire rope. This results from violent external forces being applied to the wire rope.
The wire rope is flattened at one point. This results from the wire rope being pinched.
A bird cage has formed in the wire rope. This results from violent untwisting of the wire rope.
The wire rope has a corkscrew-type deformation.
Page 41
Inspecting the chain
Check the entire wire rope for broken wires. The wire rope may not exhibit more broken wires in a length of 6 times its diameter or 30 times its diameter than is specified for these lengths on the ABUS manufacturer's certificate for wire ropes in the test log book. Examples of broken wires:
Inspection
3.6 Inspecting the chain
Only with chain hoists
Inspect the condition of the chain (lubrication, corrosion, surface damage) and check the chain's wear (length of the chain over 11 chain links). See the product manual for the chain hoist. Examples of damage:
Multiple broken wires. Broken wires are signs of normal wear of the wire rope. They occur when the wire rope is bent on the reels under load.
The chain link is heavily worn. Broken wire with protruding wire end.
If damage such as that pictured or similar damage is detected on the wire rope, replace the wire rope with a new one.
If the wire rope has broken wires, but not exceeding the permissible number, shorten the test interval until the next test.
If the wire rope has more broken wires than permitted, replace the wire rope with a new one.
Page 42
The chain link is mechanically damaged.
Inspection
3.7 Basics for determining the remaining service life
Basics for determining the remaining service life
Examples: Maximum stress only in exceptional instances
Otherwise very little stress
To avoid accidents with the crane due to wear and age, it is essential to always ensure that the hoist operates within a safe working period.
Actual hours of use (S) and theoretical service life (D) The hoist operates within a safe operating period if the actual hours of use (S) are fewer than the number of hours representing the theoretical service life (D).
Usually little stress Example of the “light” load spectrum (Km = 0.5) Maximum stress only in exceptional instances
Otherwise little stress
The theoretical service life (D) is determined and specified by ABUS according to the generally accepted engineering standards. The theoretical service life is given in full-load hours. A full-load hour is defined as the hoist having operated at its maximum load capacity for one hour. The actual hours of use (S) of the hoist must be determined by the end user. The value must be determined based on the operating hours, the load spectrum and additional factors.
Frequently Consistently high stress medium stress Example of the “medium” load spectrum (Km = 0.5 to 0.63)
Load spectrum In order to also take into account the operating phases of the hoist in which the hoist was not operating at maximum load capacity, but instead lifted lesser loads, there are four different load spectrums (Km). The load spectrum (Km) is a mathematical factor. It specifies how great a load is actually placed on the hoist during operation.
Otherwise medium stress
There are four load spectrums ─
Light (Km = 0.5)
─
Medium (Km = 0.5 to 0.63)
─
Heavy (Km = 0.63 to 0.8)
─
Very heavy (Km = 0.8 to 1.0)
Frequently maximum stress Example of the “heavy” load spectrum (Km = 0.63 to 0.8)
In the light load spectrum, for example, the hoist often runs with an empty load hook and transports light loads (in relation to its maximum load capacity). In the very heavy load spectrum, for example, the hoist seldom runs with an empty load hook and nearly always transports loads at its maximum load capacity. The load spectrum thus specifies the degree to which the hoist is subjected to its maximum load capacity or only to lesser operating demands.
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Checking the remaining service life
Otherwise high stress
Inspection Determining the remaining service life
Constant maximum stress Example of the “very heavy” load spectrum (Km = 0.8 to 1.0)
3.8 Checking the remaining service life The actual hours of use (S) must be documented within the scope of a regular inspection at least once yearly. The remaining service life will continue to be evaluated during the regular inspection. This is done by determining whether the actual hours of use (S) are still fewer than the number of hours representing the theoretical service life (D). If the remaining service life is very limited or zero, the hoist may no longer be used. In this case, a general overhaul of the entire hoist by ABUS as manufacturer is required.
The exact procedure for determining the remaining service life can be found in FEM 9.755.
Overview: The classification according to FEM for the hoist drive can be read on the type plate.
Read the corresponding theoretical service life D in the table.
Classification according to FEM
1Bm
1Am
2m
3m
4m
Light (Km = 0.5)
3200
6300 12500 25000 50000
Medium (Km = 0.5 to 0.63)
1600
3200 6300
12500 25000
Heavy (Km = 0.63 to 0.8)
800
1600 3200
6300
12500
Very heavy (Km = 0.8 to 1.0)
400
800
3200
6300
Load spectrum
1600
Determine the actual hours of use. This can be done using a load population recorder, an operating hours counter, through documentation of usage or by estimating.
Page 44
Compare the theoretical service life (D) and the determined actual hours of use (S).
The calculated remaining service life of the hoist is to be be documented in the test log book.
If the theoretical service life of the hoist has been reached: Take the hoist out of service and have ABUS perform a general overhaul.
Checking the test log book
Inspection
3.9 Checking the test log book Also in countries which do not require a test log book, it is recommended to document the test in the test log book.
Check the test log book:
─
It must be available
─
It must be within easy reach of all persons working on or with the crane.
─
It must be clearly identified as belonging to the crane.
─
All tests carried out (e.g. test before initial commissioning, regular inspections, tests of the crane track, etc.) must be documented.
3.10 Documenting the test Also in countries which do not require a test log book, it is recommended to document the test in the test log book.
3.11 Acceptance test after substantial changes Once substantial changes have been made, these require an acceptance test. This test is identical to the test before initial commissioning. See “Test before initial commissioning” page 33. The test is only necessary on the parts of the crane that have undergone substantial change.
Examples of substantial changes are: ─
Changing the power supply
─
Replacement of trolleys
─
Converting or modifying the travel drive or hoist drive
─
Increasing the maximum load capacity of a crane installation
─
Extension of a crane track
─
Using cranes on different crane tracks
─
Welding on load-bearing structural elements
─
Design modifications to a supporting structure
─
Conversion of components of the supporting structure. This includes the crane track, the mountings, the building beams, the building supports, the concrete girders and the concrete supports.
─
Change of the operating conditions of the crane installation in relation to the classification according to FEM.
─
Conversion to a different type of control (e.g. radio remote control).
─
Changing the mode of operation in regard to the operating time class and the load spectrum (e.g. switching from single-shift operation to multiple-shift operation).
Test log book of crane
Document the result of the entire test in the test log book.
─
Type and scope of the test
─
Items of the test still to be evaluated
─
Inadequacies detected
─
Assessment of whether the crane may be operated
─
Decision on whether a re-check is necessary The test log book and the complete documentation for the crane must be within easy reach of all persons working on or with the crane.
Page 45
Testing of components subject to especially high stress
Inspection
─
3.12 Testing of components subject to especially high stress During operation of the crane, situations can arise in which the individual components are subject to higher stress than expected. This can result in damage that might be detected too late in the regular inspection at the previously specified test intervals. Nevertheless, safe operation must be ensured for these components as well.
It may thus be necessary to check individual components of a crane or entire modules especially frequently. These additional tests are then regularly required at briefer intervals in addition to the regular inspection. Examples: ─
The risk assessment has revealed that certain components (e.g. brakes or wire ropes) are subject to especially high stress. Example: In a food-processing facility, a wire rope is not permitted to be lubricated for reasons of hygiene. The risk assessment clearly shows that this wire rope is subject to especially high stress. It must therefore be checked more frequently in addition to the regular inspection.
─
The repeated failure of a component has subjected it to especially high stress. Example: On a crane, the brake lining became worn a second time within a short period due to especially high stress. It must therefore be checked more frequently in addition to the regular inspection.
─
The operating conditions were changed and it is not known if these operating conditions place more stress on the crane than before. Example: The crane is used for a new operation. The load-bearing components of the crane, especially the wire rope, must be checked more frequently in addition to the regular inspection until damage due to the new operating conditions can be ruled out.
Page 46
The crane was placed under unusually high stress due to a near-accident. Example: A load was inadvertently caught with the crane. The load-bearing components of the crane, especially the wire rope, must be checked more frequently in addition to the regular inspection until damage can be ruled out.
The end user is responsible for the inspection of components under especially high stress. The end user also specifies the inspection and test intervals at which the highly stressed components are to be checked. These test intervals can be considerably shorter than the regular inspection. ABUS Service will gladly provide assistance if needed. See “ABUS Service” page 54. The end user of the crane is responsible for the proper qualifications of the examiner. For the qualifications, see “Test before initial commissioning” page 33.
Test plan and maintenance schedule
Inspection
These tasks are therefore listed in all product manuals in the section “Tests”. See “Scope of the test” page 37.
3.13 Test plan and maintenance schedule
─
In this test plan and maintenance schedule you will find listed all the tests and maintenance tasks which must be performed on the crane at various intervals. This test plan and maintenance schedule is a summary of the information from different chapters. Information on the tasks to be carried out can be found under the following:
Tasks which must be done every day (these are primarily functional tests), usually performed by the crane operator prior to beginning work. These tasks are therefore listed in all product manuals under “Operation” in the section “Check before beginning work” as well as in the product manual “Operating the ABUS crane”.
Additionally observe the sections “Check before beginning work and switching on” and “Tests” in the other supplied product manuals.
Tasks performed in a regular inspection (these are primarily basic functional tests) are normally performed by ABUS Service, by maintenance personnel or specialist service companies.
Regular inspection
X
X
Are the hoist drive and travel drives functional?
X
X
X
X X X
X
X
Are the brakes functional on the hoist drive and travel drives?
X
X
X
X X X
X
X
Is the emergency stop switch functional?
X
X
X
Is the overload protection functional?
X
X
For hoists without an operating limit switch: Is the top emergency limit switch functional?
X
X
X
X
For hoists with an operating limit switch: Is the top operating limit switch functional?
X
X
X
X
For hoists with an operating limit switch: Is the top emergency limit switch functional?
X
X
X
Is the safety limit switch functional?
X
HF EF
X X X
HB crane
X
Jib crane
Daily
Chain hoist
Overhead travelling crane
─
These tasks are therefore listed in the section “Maintenance”. See “Lubricants” page 54.
Observe the product manuals! The points listed here are a summary of the sections “Check before beginning work and switching on” and “Tests” in this product manual.
Wire rope hoist
─
Lubricant change, which must be performed in a general overhaul or regular inspection, is normally performed by ABUS Service, by maintenance personnel or specialist service companies.
Functional tests
X
X X
X
X X X
X
X X X
X
X X
X
X
Are the trolley travel and crane travel limit switches functional (braking function / shut-down)?
X
X
X
X
If available: Are the warning devices functional?
X
X
X
X
Are all other safety devices functional?
X
X
If available: Is the wind anchor functional?
X
Inspection of components
Page 47
X
Can any damage be detected (rust, loose parts, leaking oil, missing screws,...)?
X
X X X
X
X
Can any damage be detected on the supporting structure?
X
X
X X X
X
X
Is the crane properly installed and connected?
X
X
X X X
X
X
Are all screws tightened and secured?
X
X
X
Is the load hook turnable and otherwise OK?
X
X
X
Can any damage be detected on the wire rope or the chain?
X
X
X
Can any broken wires be detected on the wire rope?
X
X
X
Can any damage be detected on the mountings of the wire rope (on the cable drum and on the fixed point crosshead) or on the cable guide?
X
X
Is the rope wedge protrusion correct?
X
X
Are the required signs present and legible?
X
X
Can any damage be detected on the weld seams?
X
X
Can any damage be detected on the paintwork?
X
Is the load hook worn, misshapen or damaged?
X
X
Are the gear units of the travel drives and hoist drives sealed?
X
X
X X X
X
X
X X X
X
X X X
X
X
X
Regular inspection
HF EF
X
Daily
Chain hoist
X X X
Wire rope hoist
X
HB crane
Jib crane
Inspection
Overhead travelling crane
Test plan and maintenance schedule
X
X
X
X X X
X
X X X
X
X
Is the air gap and the brake lining thickness of the brakes on the hoist drives and travel drives correct?
X
X
X X X
X
X
Does the crane reach its maximum load capacity?
X
X
X X X
X
X
Are all moving parts lubricated?
X
X
X
If applicable: Is the conductor system in order, clean and running smoothly on the current-conducting rails?
X
X
X
If applicable: Are the carbon strips on the current collector still adequate and does the current collector run smoothly?
X
X
X
X
Are the wheel flanges of the wheels worn?
X
X
X X X
X
Is the braking distance of the travel drives OK?
X
X
X
If available: Is the diameter of the guide rollers OK?
X
X
X
Is the wheel diameter OK?
X
Is the bottom block OK?
X
Is the edge protection on the bottom block OK?
X
X
Are the safety buffers OK?
X
X
Is the test log book OK?
X
Has the theoretical service life been reached?
X
Do country-specific tests need to be performed?
X
X
X X
X X
X X X
X
X X X
X
X
X
X X X
X
X
Page 48
X
Switching off the crane
Maintenance
4. Maintenance This section applies to anyone who maintains, repairs or modifies the crane.
The end user of the crane is responsible for the selection and proper qualifications of the maintenance personnel.
Danger to persons! Persons can be injured if the crane is incorrectly serviced.
4.1 Switching off the crane Before performing any work on the crane:
Otherwise, components of the crane electrical system will be carrying voltage.
If personnel other than that of the ABUS company are employed to perform maintenance on the crane, it is the end user's responsibility to ensure that these persons are adequately qualified. Follow the procedures described here precisely.
It could also happen that another person inadvertently uses the crane, resulting in objects being thrown from the crane or persons falling from the lifting platforms.
Danger from electric shock! If an emergency stop button has been pressed, there will still be voltage in the panel and in the pendant control. Completely switch off the crane before working on it!
Examples of qualified persons: ─
Persons with comprehensive knowledge from specialist training in engineering and in the electrical systems of cranes.
─
Persons with sufficient experience in the operation, installation and maintenance of cranes.
─
─
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country. Persons receiving regular training from ABUS.
Switch off the crane.
If the crane must remain switched on for maintenance work (e.g. changing the wire rope):
Take other measures to ensure that the risk of electric shock is prevented and that other persons do not inadvertently use the crane.
ABUS assumes no liability for damage due to incorrectly performed maintenance work done by unqualified personnel. ABUS recommends having the maintenance work performed by ABUS Service. Use only original ABUS replacement parts. Otherwise, all warranty claims will be rendered invalid.
Page 49
Switching off the crane
Maintenance
Switching off the crane at the mains switch Mains switch
Only with cranes with crane panels This section only applies if the crane has a crane panel (e.g. overhead travelling cranes and, depending on the version and options, possibly also jib cranes and HB cranes).
Switching off the crane with a mains disconnector plug This is primarily useful if the entire crane installation cannot be switched off with a general mains switch. Mains disconnector plug
Padlock
Turn the mains switch to 0. Secure with one or more padlocks.
Socket
Pull the mains disconnector plug out of the socket on the crane panel.
Secure the socket with a padlock so that the mains disconnector plug is not unintentionally re-inserted. Only with chain hoists: The bayonet coupling on the chain hoist cannot be secured against switching back on and is therefore not suitable as a mains disconnector plug.
Page 50
Maintenance
4.2 Instructions regarding safety: Prior to maintenance
Instructions regarding safety: Prior to maintenance
Cordon off the work area!
Comply with the following safety instructions before beginning with maintenance:
Observe the product manuals! In addition to the points described here, all information in the section “Instructions regarding safety” in the other supplied product manuals also applies.
Use suitable lifting platforms and fall protection equipment!
Falling objects (e.g. tools) can kill or injure people. The lifting platforms can also be overturned, e.g. by forklifts. Adequately cordon off the work area.
Switch off cranes on the same crane track!
Falls from great heights can result in people being killed or injured.
Other cranes can overturn the lifting platforms or impact the crane that is being serviced.
Always use suitable lifting platforms and fall protection equipment. If the crane has a walkway on the main girder or on the wire rope hoist, a suitable lifting platform or fall protection equipment must be used for entering the walkway.
Switch off any other cranes using the same crane track or cranes working above or below. Secure the mains switch so that it cannot be unintentionally switched back on.
Notify personnel that maintenance work will be performed! Personnel working in the area may not necessarily be aware of the dangers when maintenance is performed on the crane. They might be hit by falling tools, or they might mistakenly try to use the crane being serviced. Notify personnel in the area that maintenance work will be performed.
Page 51
Instructions regarding safety: During maintenance
Only electricians should work on the crane electrical system! Special expertise is required for working on electrical installations.
Maintenance
Protect components from the effects of heat!
Without this expertise, there is a risk of electric shock. Only trained electricians should work on the crane electrical system!
4.3 Instructions regarding safety: During maintenance Comply with the following safety instructions during maintenance:
Observe the product manuals! In addition to the points described here, all information in the section “Instructions regarding safety” in the other supplied product manuals also applies.
Do not permanently remove the covers!
When covers (e.g. panel lids, fan covers, motor covers,...) are removed, dangerous areas are no longer protected.
The effects of heat from work performed on the crane (e.g. welding, open flames, flying sparks) can set parts on fire. This can cause harmful gases to form and parts to become deformed or damaged. Cover the parts or otherwise protect them from becoming too hot. After completing the work, inspect the condition of the parts.
4.4 Instructions regarding safety: After maintenance Comply with the following safety instructions once maintenance has been completed:
Observe the product manuals! In addition to the points described here, all information in the section “Instructions regarding safety” in the other supplied product manuals also applies.
Remove tools and separate parts!
As a result of this people can be injured! Remount covers after working on the crane. Do not permanently remove the covers in order to improve the cooling of components.
Loose parts can fall from the crane during operation, killing or injuring people. Remove tools and separate parts (spare parts, removed parts,...).
Page 52
Releasing the crane
Maintenance
4.5 Releasing the crane
Observe at least these points when making extensive changes to the crane: ─
The crane must be able to be switched off by a mains switch or otherwise be isolated from the mains supply at any time.
─
The unit must be connected to a protective conductor according to the local and national regulations, the user must be protected from the voltage and the motors protected from overloading.
─
An emergency stop device must be available at all times.
─
If the hoist motors or travel motors are controlled via frequency converter by a third party, the frequency converter manufacturer's specifications for installation and adjustment must be observed.
Release after repair work by the end user:
Check whether all work has been fully completed.
Check whether the crane is in a secure and operational state.
Check whether all separate parts, tools, aids, etc. have been removed.
Put the crane into operation. Perform a thorough functional test of the entire crane. See the product manual “Operating the ABUS crane”.
4.6 Modifying the crane ABUS accepts no liability for modifications or changes which were not approved or agreed upon.
To keep voltage peaks from damaging the windings of the hoist motor or travel motor, a general mains filter must be used if the frequency converter is used by a third party. ABUS recommends using the ABULiner control system, since the frequency converter is optimally matched for the motors used.
The Declaration of Conformity or Declaration of Incorporation issued by ABUS becomes invalid if independent reconstruction or modifications to the crane are performed.
Page 53
ABUS Service
4.7 ABUS Service
Maintenance
4.8 Lubricants
Only in Germany
If available, have the product number, serial number and customer number handy.
Call the ABUS Service Centre:
─
Phone: +49-2261-37-237 If calling outside the usual business hours, leave a message on the answering machine.
Do not lubricate the hubs on the brakes!
ABUS Service will return your call promptly.
Observe the product manuals! In addition to the points described here, all information in the section “Lubricants” in the other supplied product manuals also applies.
If necessary, send a problem description by fax or e-mail:
─
Fax: +49-2261-37-265
─
E-mail: [email protected]
Only outside Germany
Do not lubricate the hubs on the brakes! If the hub on the brake of the hoist motor or travel motor is lubricated, the lubricant can run onto the brake lining and considerably impair the braking. This could cause the load to slip or delay the stopping of the crane.
Note: Synthetic lubricants may not be mixed with mineralbased lubricants!
Call the local ABUS branch or crane service partner. Your local ABUS branch or crane service partner will provide details of contact data, contacts and availability.
Page 54
Changing lubricants
Disassemble the respective components (travel drive, hoist drive,...) and lay them open.
Remove the old lubricant at operating temperature.
Remove residual lubricant with a suitable cleaning agent.
Refill or apply new lubricant. Reassemble the respective components and check that they are sealed.
Lubricants
Maintenance
Only with wire rope hoists
Hoisting gear GM 1000
Hoisting gear GM 800
Lubrication ex works using lubricant with the standard designation “CLP ISO VG 680 DIN 51502” Lubrication ex works using lubricant with the standard designation “SAE POW-90 DIN 51502”. Quantity: 1600 ml Quantity: 1500 ml Alternatively: use lubricant with the standard designation “CLP ISO VG 680 DIN 51502”
The hoisting gear is lubricated for its entire service life. At the end of its service life (in a general overhaul), assess whether the lubricant needs to be changed.
The hoisting gear is lubricated for its entire service life. At the end of its service life (in a general overhaul), assess whether the lubricant needs to be changed.
Hoisting gear GM 2000
Lubrication ex works using lubricant with the standard designation “CLP ISO VG 320 DIN 51502”
Quantity: 500 ml Alternatively: use lubricant with the standard designation “CLP ISO VG 680 DIN 51502”
The hoisting gear is lubricated for its entire service life. At the end of its service life (in a general overhaul), assess whether the lubricant needs to be changed.
Page 55
Lubricants
Maintenance
Hoisting gear GM 3000
Hoisting gear GM 5000
Lubrication ex works using lubricant with the standard designation “CLP ISO VG 320 DIN 51502”
Lubrication ex works using lubricant with the standard designation “SAE 80W-90 DIN 51502”.
Quantity: 800 ml
Quantity: 4000 ml
Alternatively: use lubricant with the standard designation “CLP ISO VG 680 DIN 51502”
Alternatively: use lubricant with the standard designation “CLP ISO VG 680 DIN 51502”
The hoisting gear is lubricated for its entire service life. At the end of its service life (in a general overhaul), assess whether the lubricant needs to be changed.
The hoisting gear is lubricated for its entire service life. At the end of its service life (in a general overhaul), assess whether the lubricant needs to be changed.
Hoisting gear GM 6000, GM 7000
Lubrication ex works using lubricant with the standard designation “CLP ISO VG 680 DIN 51502”
Quantity GM 6000: 13000 ml Quantity GM 7000: 27000 ml
Page 56
The hoisting gear is lubricated for its entire service life. At the end of its service life (in a general overhaul), assess whether the lubricant needs to be changed.
Lubricants
Maintenance
Only with wire rope hoists
Gearing in the cable drum
Lubricant repository in the cable drum
Lubrication ex works with Moly Paul “PBC” AN 6758.
Lubrication ex works with Moly Paul “PBC-SF” AN 303678
Quantity GM 800: 25 g Quantity GM 1000: 25 g Quantity GM 2000: 50 g Quantity GM 3000: 50 g Quantity GM 5000: 70 to 75 g Quantity GM 6000: 70 to 75 g Quantity GM 7000: 70 to 75 g
Fill the lubricant repository (behind the gearing):
─
When the hoisting gear is disassembled and reassembled
─
When carrying out a general overhaul
─
After 10 years at the latest
Quantity: Apply lubricant with brush to coat surface completely.
Lubricate the gearing in the cable drum:
─
When the hoisting gear is disassembled and reassembled
─
When carrying out a general overhaul
─
After 10 years at the latest The specification of 10 years applies to single-shift operation with an average daily hoist running time of less than one hour with a medium or limited load spectrum. If the hoist is used more intensively or the operating conditions are more difficult (e.g. multiple-shift operation, higher ambient temperature, aggressive environmental conditions), shorter intervals will be necessary.
The specification of 10 years applies to single-shift operation with an average daily hoist running time of less than one hour with a medium or limited load spectrum. If the hoist is used more intensively or the operating conditions are more difficult (e.g. multiple-shift operation, higher ambient temperature, aggressive environmental conditions), shorter intervals will be necessary.
Page 57
Lubricants
Gearing on output shaft on the hoisting gear, pins on the hoisting gear
Maintenance
Cable guide
Lubrication ex works using lubricant with the standard designation “KHC 2 K-60 DIN 51502”. Lubrication ex works with Moly Paul “PBC” AN 6758.
Quantity: Apply lubricant with brush to coat surface completely.
─
Lubricate pins: When the hoisting gear is disassembled and reassembled Lubricate the gearing on the output shaft:
─
When the hoisting gear is disassembled and reassembled
─
When carrying out a general overhaul
─
After 10 years at the latest The specification of 10 years applies to single-shift operation with an average daily hoist running time of less than one hour with a medium or limited load spectrum. If the hoist is used more intensively or the operating conditions are more difficult (e.g. multiple-shift operation, higher ambient temperature, aggressive environmental conditions), shorter intervals will be necessary.
Page 58
Lubricate the cable guide from the beginning to the 8th to 10th turn and behind the last turn (the area which does not contact the wire rope):
─
When changing the wire rope
─
When changing the cable guide
─
At a regular inspection
─
When carrying out a general overhaul
Lubricants
Maintenance
Wire rope and cable drum
Lubrication ex works with Moly Paul “Chainlife S” AN 2717.
Alternatives: ─
Castrol “Viscogen KL 23”
─
Klüber “Grafloscon CA 901 Ultra Spray”
─
Optimol “KL 23”
─
Shell “Malleus GL 95”
Rope guide runner on the cable guide
Lubrication ex works using lubricant with the standard designation “KHC 2 K-60 DIN 51502”.
Lubricate the rope guide runner on the cable guide:
─
When changing the wire rope
─
When changing the cable guide
─
At a regular inspection
─
When carrying out a general overhaul
Lubricate the wire rope and cable drum behind the 8th to 10th turn up to the last turn:
─
When changing the wire rope
─
At a regular inspection
─
When carrying out a general overhaul
Bottom block
Lubrication ex works with Moly Paul “PBC” AN 6758.
Quantity: Apply lubricant with brush to coat surface completely.
Lubricate the journals on the crosshead:
─
When the load hook is disassembled and reassembled
─
When carrying out a general overhaul
Page 59
Lubricants
Maintenance
Only with wire rope hoists for double-girder travelling cranes
Only with wire rope hoists with LISSE
Hinge pin
Flanged bolt on the rope socket of the fixed point crosshead
Lubrication ex works with Moly Paul “PBC” AN 6758.
Quantity: Apply lubricant with brush to coat surface completely.
─
Lubrication ex works with Moly Paul “PBC” AN 6758.
Quantity: Apply lubricant with brush to coat surface completely.
Lubricate the hinge pin: When the end carriage is disassembled and reassembled
Apply lubricant to the rope socket before installing the rope socket: Do not lubricate the flanged bolt or the fixed point crosshead. No lubricant should contact the fixed point crosshead.
Hinge pin
Lubrication ex works with Moly Paul “PBC” AN 6758.
Quantity: Apply lubricant with brush to coat surface completely.
─
Lubricate the hinge pin: When the end carriage is disassembled and reassembled
Page 60
─
When removing and installing the rope socket
─
When changing the wire rope
─
When carrying out a general overhaul
Lubricants
Maintenance
Only with wire rope hoists with LISSE Flanged bolt on the rope socket of the fixed point crosshead
Only with wire rope hoists GM 800, GM 1000, GM 2000, GM 3000, GM 5000, GM 6000 Bearing bush (on flanged bolt) on the deflection roller crosshead and on the fixed point crosshead
Lubrication ex works with Moly Paul “PBC” AN 6758.
Lubrication ex works with Moly Paul “PBC” AN 6758.
Quantity: Apply lubricant with brush to coat surface completely.
Quantity: Apply lubricant with brush to coat surface completely.
Apply lubricant to the rope socket before installing the rope socket: Do not lubricate the measurement bolt or the fixed point crosshead. No lubricant should contact the fixed point crosshead.
─
When removing and installing the rope socket
─
When changing the wire rope
─
When carrying out a general overhaul
Lubricate bearing bush (on flanged bolt):
─
When removing or installing the deflection roller crosshead or fixed point crosshead
─
When carrying out a general overhaul
Page 61
Lubricants
Only with wire rope hoist GM 7000
Maintenance Self-aligning roller bearing on the cable drum
Deflection roller crosshead
Lubrication ex works using lubricant with the standard designation “Multi-use grease NGLI2 with solid matter MoS2 KF2”.
Lubrication ex works with Molycote “D321 R antifriction coating” AN 18930
Quantity: Apply a liberal coating of lubricant with brush.
Quantity: Apply lubricant to coat surface completely.
Lubricate the self-aligning roller bearing:
─
When removing and installing the selfaligning roller bearing
─
When carrying out a general overhaul
Lubricate the contact surfaces of the deflection roller crosshead:
─
When removing or installing the deflection roller crosshead
─
When carrying out a general overhaul
Only with wire rope hoists with guide rollers or cranes with guide rollers Cylindrical roller bearings of the guide rollers
Lubrication ex works using lubricant with the standard designation “Multi-use grease NGLI2 with solid matter MoS2 KF2”. Quantity: Apply a liberal coating of lubricant with brush.
─
Page 62
Lubricate the cylindrical roller bearing: When removing and installing the guide rollers
Lubricants
Maintenance
Only with wheels of size 350, 420, 500 on the end carriage and with wheels of size 200 on the single-rail trolley
Only with 8-wheel cranes Flanged bolt on the coupling bar
Self-aligning roller bearings in wheel
Lubrication ex works with Moly Paul “PBC” AN 6758.
Lubrication ex works using lubricant with the standard designation “Multi-use grease NGLI2 with solid matter MoS2 KF2”.
Quantity: Apply a liberal coating of lubricant with brush.
─
Quantity: Apply lubricant with brush to coat surface completely.
─
Lubricate the flanged bolt: When the coupling bar is disassembled and reassembled (e.g. when the inner wheels are removed and installed).
Lubricate the self-aligning roller bearing: When removing and installing wheels
Page 63
Lubricants
Maintenance
Only with E and AZP drives Gear unit in drives E 100, E 130, E 160, E 200, AZP 130, AZP 160, AZP 200, AZP 280
Gearing on the output shaft on the gear unit of the drive
Lubrication ex works with Moly Paul “PBC” AN 6758.
Quantity: Apply lubricant with brush to coat surface completely. Lubrication ex works with Klüber “Centoplex CX 4/375”
Quantity E 100: 40 g Quantity E 130: 50 g Quantity E 160: 50 g Quantity E 200: 90 g Quantity AZP 130: 50 g Quantity AZP 160: 90 g Quantity AZP 200: 160 g Quantity AZP 280 (reduction ratio i=125.7, i=62.92, i=48.45): 240 g Quantity AZP 280 (reduction ratio i=86.67, i=61.11, i=48.33, i=41.17, i=42.86): 160 g
The gear unit in the drive is lubricated for its entire service life. At the end of its service life (in a general overhaul), assess whether the lubricant needs to be changed.
Page 64
Lubricate the gearing on the output shaft:
─
When the drive is disassembled and reassembled
─
After 10 years
─
When carrying out a general overhaul
Lubricants
Maintenance
Only with AZF drives
Only with AZF V drives
Gear unit in drives AZF 350, AZF 420
Gear unit in drives AZF V420, AZF V500
Lubrication ex works using lubricant with the standard designation “CLP ISO VG 460 DIN 51502”
Lubrication ex works using lubricant with the standard designation “ATF Type II D”.
Quantity: 1200 ml Quantity: 3000 ml
The gear unit in the drive is lubricated for its entire service life. At the end of its service life (in a general overhaul), assess whether the lubricant needs to be changed.
The gear unit in the drive is lubricated for its entire service life. At the end of its service life (in a general overhaul), assess whether the lubricant needs to be changed.
Page 65
Lubricants
Only with AZF and AZF V drives
Maintenance
Only with underslung travelling cranes
Gearing on the output shaft on the drive gear unit, pins on the gear unit
Gear rims on the wheel
Lubrication ex works with Moly Paul “PBC” AN 6758.
Lubrication ex works using lubricant with the standard designation “Multi-use grease NGLI2 with solid matter MoS2 KF2”.
Quantity: Apply lubricant with brush to coat surface completely.
Lubricate pins:
─
When the gear unit is disassembled and reassembled
Lubricate the gearing on the output shaft:
─
When the drive is disassembled and reassembled
─
After 10 years
─
When carrying out a general overhaul
Page 66
Quantity: Apply a liberal coating of lubricant with brush.
Lubricate gear rims:
─
When the drive is disassembled and reassembled
─
When carrying out a general overhaul
Regularly check that the gear rims are completely lubricated and the lubricant is not soiled.
If the lubricant is dirty: Clean the gear rims and reapply lubricant.
Lubricants
Maintenance
Only with HB cranes
Only with jib cranes
Gear unit in drives HBF 520, HBF 1040
Gear rims on supporting rolls
Lubrication ex works using lubricant with the standard designation “ATF Type II D”.
Quantity: 800 ml
The gear unit in the drive is lubricated for its entire service life. At the end of its service life (in a general overhaul), assess whether the lubricant needs to be changed.
Lubrication ex works using lubricant with the standard designation “Multi-use grease NGLI2 with solid matter MoS2 KF2”.
Quantity: Apply a liberal coating of lubricant with brush.
Lubricate gear rims:
─
When the slewing drive is disassembled and reassembled
─
When carrying out a general overhaul
Regularly check that the gear rims are completely lubricated and the lubricant is not soiled.
If the lubricant is dirty: Clean the gear rims and reapply lubricant.
Page 67
Wiring diagrams
Gear unit in slewing drives
Lubrication ex works using lubricant with the standard designation “CLP PG DIN 51502”.
Quantity for pillar diameter 273: 0.34 l Quantity for pillar diameter 323: 0.56 l Quantity for pillar diameter 355: 0.56 l Quantity for pillar diameter 406: 0.56 l Quantity for pillar diameter 457: 0.56 l Quantity for pillar diameter 558: 1.05 l Quantity for pillar diameter 660: 1.05 l Quantity for pillar diameter 762: 2.26 l
The gear unit in the slewing drive is lubricated for its entire service life. At the end of its service life (in a general overhaul), assess whether the lubricant needs to be changed.
4.9 Wiring diagrams
─
The wiring diagrams of the crane are found in the crane's documentation folder and on the CD ROM “ABUDoku”.
─
For overhead travelling cranes: A copy of the wiring diagrams can also be found in the crane panel.
Page 68
Maintenance
Declaration of Conformity, Declaration of Incorporation
Maintenance
4.10 Declaration of Conformity, Declaration of Incorporation
Declaration of Incorporation If the crane is sold by ABUS as a component, in separate components or for installation in another machine, a Declaration of Incorporation is issued in terms of the machinery directive of Appendix II 1B. It can be found in the test log book of the crane.
Only within the EU Declaration of Conformity
Putting into service is then prohibited until it has been ascertained that the installation into which the ABUS components are to be installed meet all requirements of the EU directive versions applicable at the time of issuance.
If the crane is sold by ABUS as a stand-alone machine, a Declaration of Conformity is issued. It can be found in the test log book of the crane.
A test must be performed on the ABUS components prior to initial commissioning, before the Declaration of Conformity for the entire installation is issued. See “Test before initial commissioning” page 33.
The Declaration of Conformity or Declaration of Incorporation issued by ABUS becomes invalid if independent reconstruction or modifications to the crane are performed.
1
1
2
2
3
3
4
4
5
5
─
1: ABUS company address
─
1: ABUS company address
─
─
2: Person responsible for putting together the special technical documentation
2: Person responsible for putting together the special technical documentation
─
─
3: Technical specifications identifying the crane
3: Technical specifications identifying the crane
─
─
4: Information on the fundamental standards underlying development and production.
4: Information on the fundamental standards underlying development and production.
─
5: Signature of responsible person
─
5: Signature of responsible person
Page 69
AN 120197EN001
2014-02-28
Kransysteme
Product Manual Single girder travelling crane ELV, ELK and ELS ABUS single girder travelling crane
Order No.
110-034551
ABUS Kransysteme GmbH Sonnenweg 1 51647 Gummersbach Germany Tel. 0049 – 2261 – 37-0 Fax. 0049 – 2261 – 37-247 [email protected]
Distribution or reproduction of this document, or the utilisation and disclosure of its contents without explicit approval is prohibited. Violations will incur liability for damage compensation. All rights are reserved in regard to patent issue or registered designs.
Fixing the end carriages onto the main girder
(page 15)
Lifting the overhead travelling crane onto the crane track
(page 20)
Installing the mains power supply
(page 21)
Installing the cross-type limit switch
(page 21)
Fastening the end carriages tightly
(page 23)
Disassembling the powered wheel
(page 32)
Disassembling the non-powered wheel
(page 39)
AN 120139EN006
2016-03-17
Original operating instructions
Single girder travelling crane: various sizes, versions and options This product manual applies for overhead travelling cranes in various sizes, versions and with various options. The work steps described and the technical data will vary according to the overhead travelling crane size, versions and options. The parts of this product manual which do not apply to all overhead travelling cranes, but only apply under certain conditions, are enclosed in a dashed box. The sizes, versions and options to which the section applies are specified at the start of the box.
End carriage (size)
Wheel diameter (end carriage)
Size
End carriage (options)
Derailing protection device
Guide rollers
Clamping piece
Wheel design (version)
Wheel with wheel flange
Wheel without wheel flange
Main girder (version)
ELV main girder
ELK main girder
ELS main girder
Trolley power supply (version)
Energy chain
Festoon cable system
Trolley (type)
Wire rope hoist, type E Wire rope hoist, type E Wire rope hoist, type S (single-rail trolley) for single (single-rail trolley) for single (side-mounted trolley) for girder travelling cranes in girder travelling cranes in single girder travelling modular design “GM compact design cranes modular”
Wire rope hoist, type U (lower flange trolley) for single girder travelling cranes
Crane travel drive (version)
Crane travel drive AZP (Size 130, 160, 200, 280)
Crane travel drive AZF (Size 350, 420)
Crane travel drive AZF V (Size 420 V with adapter)
Contents
Contents 3. INSPECTION ................................... 25 1. GENERAL INFORMATION..................... 5 1.1 At the start ................................................ 5 1.2 The single girder travelling crane ............. 7 1.3 Transporting the overhead travelling crane on a lorry ...................................... 10 1.4 Loading and unloading the overhead travelling crane ....................................... 10 1.5 Disposing of the overhead travelling crane ...................................................... 11
2. INSTALLATION ................................. 12 2.1 Installing the crane track ......................... 12
3.1 At the start .............................................. 25 3.2 Scope of the test .................................... 25 3.3 Inspecting the wheel flange wear ........... 26 3.4 Checking the braking distance ............... 26 3.5 Checking the wear on the guide rollers .. 27 3.6 Checking the diameter of the wheels...... 28 3.7 Inspecting the condition of the safety buffer ...................................................... 29
4. MAINTENANCE ............................... 30
2.2 Checking the requirements ..................... 13
4.1 Instructions regarding safety when performing maintenance work ................ 30
2.3 Installation overview ............................... 14
4.2 Changing the fuses................................. 31
2.4 Fixing the end carriages onto the main girder ...................................................... 15
4.3 Disassembling the powered wheel ......... 32
2.5 Connecting the crane travel drives ......... 18
4.4 Installing the powered wheel .................. 34 4.5 Disassembling the non-powered wheel .. 39
2.6 Connecting connection cables to crane panels ..................................................... 18
4.6 Installing the non-powered wheel ........... 40
2.7 Installing the safety buffers ..................... 18
4.7 Replacing the cross-type limit switch ...... 42
2.8 Pre-installing the mains power supply .... 19
4.8 Wiring diagram of the cross-type limit switch ..................................................... 42
2.9 Repairing damage to paintwork .............. 19 2.10 Attaching operating direction signs ......... 19
4.9 Checking after a lightning strike ............. 43 4.10 Screwing with tightening torque .............. 43
2.11 Lifting the overhead travelling crane onto the crane track ................................ 20
4.11 ABUS Service ......................................... 45
2.12 Installing the mains power supply ........... 21
4.12 Lubricants ............................................... 46
2.13 Installing the cross-type limit switch........ 21 2.14 Fastening the end carriages tightly ......... 23 2.15 Overview of screw tightening torques ..... 23
Page 4
General information
At the start
1. General information
This section applies to anyone who lifts loads using the crane, performs work on the crane, or works nearby.
1.1 At the start
Instructions for the product manual
Using this product manual
Read the product manual through carefully before beginning work. Also be sure to observe additional product manuals for accessories and components.
The following symbols are used in this product manual:
Afterwards, keep the product manual available in the vicinity of the crane. It must be accessible to all who work with or on the crane.
Danger to persons! This warning notice indicates hazards for persons and provides instructions for avoiding these hazards. Danger from electric shock! This warning notice indicates hazards for persons due to incorrect handling of the electrical system and electricity. Danger due to falling load! This warning notice describes hazardous situations that can lead to the suspended load falling.
This is an instruction regarding an action and prompts you to perform a work step.
●
This is the result of an action and describes what happens on the device.
─
This is a list.
Only with... A section that appears in a box framed by a dotted line is only applicable for certain types, versions or options. Which type, version or option this is can be seen in the first line. You can find out whether or not the section is applicable for your crane by referring to the section “Various types, sizes, versions and options” at the beginning of this manual.
In the case of reselling or hiring out, always provide the product manual together with the crane.
Regulations The installation has been built and tested according to European standards, rules and regulations applicable at the time of its manufacture. The conventions applied during design and construction are specified in the Declaration of Conformity or the Declaration of Incorporation. The conventions must also be observed for installation, operation, inspection and maintenance, as must the applicable occupational health and safety regulations.
Danger to persons! Non-observance of the regulations can result in the death of persons or serious accidents. To ensure work safety, thorough instruction in regard to this product manual and the regulations is necessary.
Which provision applies in individual cases will greatly depend on the crane’s use and the national regulations. Review and observe all applicable and current regulations, including the occupational health and safety regulations. Refer also to the Declaration of Conformity or Declaration of Incorporation.
Page 5
At the start
Warranty ─
ABUS assumes no liability for damages that were caused by improper use, inadequately trained personnel, incorrect performance of work, as well as any changes, reconstruction or other modification of the crane or crane components which was not approved by ABUS.
─
Any warranty claim becomes invalid if components were modified without consent, the crane or crane components were installed, used or serviced in any way other than that described in this product manual, or if parts other than original ABUS replacement parts were used.
─
Safe operation of the crane or crane components is only guaranteed if original ABUS replacement parts are used.
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General information
General information
The single girder travelling crane
1.2 The single girder travelling crane Description of the device View of the crane: 1
2
4
3 5
7
6
Detailed view of end carriage: 4 8
11
10
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1: Main girder (ELK version here)
─
2: Trolley power supply (energy chain version here)
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3: Crane panel
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4: End carriage
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5: Crane travel drive (AZP version here)
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6: Pendant control
─
7: Trolley (wire rope hoist)
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8: Joint face
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9: Wheel, powered
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10: Wheel, not powered
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11: Safety buffer
5
4
5
9
Page 7
General information
The single girder travelling crane
Performance features
The end carriages: ─
The end carriages are fully-automatic, welded box girders.
─
The end carriages are connected to the main girders using high-tensile bolts.
─
The end carriages (according to the respective width of the crane track) have wheels with wheel flanges, which enable even running on the crane track and prevent the overhead travelling crane from derailing.
─
The end carriages have safety buffers to prevent damage if the crane runs into the end of the crane track or into another crane.
─
The end carriages can be fitted with an additional derailing protection on all four wheels (option).
─
The end carriages can be fitted with guide rollers (option) to equalise the tolerances of the crane track. For this, one of the two end carriages is fitted with two horizontal guide rollers on both wheels. These run left and right close to the crane track. The crane is thus closely guided on one side. The other side has very wide wheels to compensate for the tolerance.
The single girder travelling crane EL: ─
The overhead travelling crane is manufactured as an ELV overhead travelling crane from a solid-walled I-beam.
─
The overhead travelling crane is manufactured as an ELK overhead travelling crane from a welded, torsion-rigid box girder. All four outer welds are welded at the same time.
─
The overhead travelling crane is manufactured as an ELS overhead travelling crane from a welded, torsion-rigid box girder, on which the trolley runs on the upper flange and lifts the load laterally next to the main girder.
─
The overhead travelling crane is equipped with a wire rope hoist, type E (single-rail trolley), S (side-mounted trolley) or U (lower flange trolley). The single-rail trolley can be executed in a compact design or as a modular wire rope hoist “GM modular”.
─
The standard crane is equipped with a mobile control. This ensures the position of the pendant control is independent of the trolley position.
─
─
─
The crane is controlled using the pendant control “ABUCommander”. The pendant control has two-stage buttons with which the crane can be controlled at low and high speed for travel or lifting. As a variation, the crane can also be controlled using a radio remote control. The trolley and the mobile control come as standard with an energy chain connected to the rest of the crane’s electrics. As a variation, the trolley and the mobile control can be connected to the rest of the crane’s electrics with a festoon cable system. The crane is supplied with power via a conductor system. This is mounted parallel to the crane track. The conductor system is designed according to the conditions (thermal stress, length, voltage drop,…).
The single girder travelling crane with two trolleys: ─
The crane is equipped with two trolleys. These can be controlled using a joint pendant control (or transmitter). This improves safety during the transportatio of e.g. long or bulky loads.
─
The trolleys are labelled “Trolley I” and “Trolley II” on the wire rope hoist and on the pendant control.
Page 8
The other end carriages (without guide rollers) can also be fitted with a derailing protection device on both wheels (option).
The end carriages of the sizes 280, 350 and 420: ─
The end carriages of the sizes 280, 350 and 420 have a clamping piece on the powered wheel.
─
The end carriages of the sizes 280, 350 and 420 have a special rigidity aid on the inside, called a clamp brace, which transfers the stress from the main girder to the end carriages.
General information
The crane travel drives: ─
The drives are designed as pole-variable rotary current motors with electromagnetic brakes and gear units.
─
The drives have a low and a high speed. The ratio of the two speeds is 1:4.
─
The drives have a modular construction of motor and gear unit to enable easy replacement.
The single girder travelling crane
The crane electrical system: ─
The crane electrical system is stored in the crane panel on the end carriage.
─
The crane electrical system has the protection rating IP 55.
─
The crane electrical system is protected by regular fuse links in its main fuse.
─
The crane electrical system has mechanically interlocked directional contactors. This ensures that the drives cannot be connected to both directions of travel at the same time. This would cause a short circuit.
─
Using plug-in connections in the connector housing directly on the drive, the drives can be quickly separated from the rest of the crane’s electrics.
─
The drives can be continuously adjusted in speed by the ABULiner frequency converter (optional).
─
The crane electrical system is particularly service-friendly due to screwless terminals and wiring in cable ducts.
─
The drives are connected to the motor protection switch in the crane panel.
─
─
The acceleration of the drives to high speed is switched on after a brief time delay. The delay avoids the drive running in a starting current in inching mode (rapid switching back and forth). This would eventually damage the motor.
The crane electrical system is switched centrally through the main contactor. It is located in the crane panel. If the emergency stop button is pressed or if an emergency stop is triggered for other reasons, the main contactor switches off the power for all drives.
─
As a result of plug-in connections between all crane components, the crane electrical system is particularly maintenance-friendly.
─
─
When braking from the high to low speed, for a short period only two of the three phases of the drive are switched to the low speed. In doing so, the drive does not jerk to a halt but brakes softly. As a result, the load does not swing as greatly. This function controls the standard SU1 device. When braking from high speed to a complete stop, for a short period prior to stopping the drive is switched to low speed. In doing so, the drive initially brakes dynamically. There is thus less wear on the brake lining and the lining does not need to be replaced so frequently. (Optional, control by the SU2 device)
The crane travel limit switches: ─
Crane travel limit switches are mainly used in the direction of the crane track end as motion restrictors.
─
The crane travel limit switches (option) can be designed with a braking and/or shut-down function.
─
The crane travel limit switches switch the crane to low speed with the braking function just before the end of the crane track. This prevents the crane from running into the end of the crane track at high speed and causing the load to swing.
─
The crane travel limit switches with the shutdown function (option) completely switch off the crane travel drive immediately before the end of the crane track. The shut-down function is particularly useful for certain safety switches.
Page 9
General information
Transporting the overhead travelling crane on a lorry
1.3 Transporting the overhead travelling crane on a lorry
Observe the following points amongst others:
Attaching the main girders Clamping buffer
Danger from falling components! The crane can fall from the lorry and kill or injure people if it is not correctly loaded and secured. Crane transportation and load securing should only be carried out by trained persons.
Edge protection
Observe the following points, amongst others:
Secure the load according to regional regulations. Lay suitable blocks of wood on the loading area beneath the main girders. It is best to lay the blocks of wood beneath the main girders in the places they were laid before to avoid damage to the paint.
Secure the main girders to the loading area with suitable lifting tackle.
Also secure individual components such as end carriages, trolleys, etc. to the loading area using suitable lifting tackle.
Secure all loose parts and wiring. Cover unpainted surfaces and openings with film and secure with adhesive tape.
Lifting tackle Place suitable lifting tackle around the main girders. Cover all edges of the main girder with suitable edge protection.
Only with energy chains If the profile rails (in which the energy chain
is) protrude to the side, lay wooden beams (wider than the profile rails) over the profile rails so that they are not damaged on lifting.
Only for ELK and ELV main girders Adjust the trolley or lifting tackle in such a way that the main girder hangs straight when it is lifted.
1.4 Loading and unloading the overhead travelling crane
Danger from falling components! The crane can fall and kill or injure people if it is not correctly attached and lifted. Attachment and loading should only be carried out by trained persons.
Page 10
Secure the trolleys with clamping buffers so that they do not slip on lifting.
Only for ELS main girders Secure the trolley onto the main girder with a tension belt or similar.
Adjust the lifting tackle in such a way that the main girder hangs vertically and horizontally straight when it is lifted. Due to the laterally running trolley track and the overhanging trolley, the main girder is unbalanced on one side.
General information
Disposing of the overhead travelling crane
Setting down the main girders
Set down the main girders on stands which have sufficient load capacity. With the trolley installed underneath the main girder: The stands must be at least high enough that the rope is not buckled or pinched. Ideally, the stands should be high enough that the trolley load hook hangs freely.
1.5 Disposing of the overhead travelling crane If the overhead travelling crane needs to be disposed of:
Dismantle the overhead travelling crane to the extent possible.
Observe local regulations concerning disposal and recycling.
Dispose of the individual parts sorted by material in an environmentally sound manner.
─
Dispose of electronic components as scrap electronic parts.
─
Plastic parts should be recycled with plastic waste.
─
Remove brake linings and friction clutch linings and dispose of these multiple components as hazardous waste.
─
Remove oil or grease from the crane travel drives and dispose of as a lubricant.
─
Sort lines, plug-in connections and pendant controls by material and bring them to a recycling centre.
─
The end carriages and main girders should be recycled as scrap metal.
Page 11
Installation
Installing the crane track
2. Installation
This section applies to anyone who works on the crane prior to its use
The crane is delivered ready-assembled. To install, perform the described points here in the sequence given.
The end user of the crane is responsible for the proper qualifications of the commissioning personnel.
Danger to persons! Persons can be injured if the crane is incorrectly put into operation. If personnel other than that of the ABUS company are employed to perform the commissioning, it is the end user’s responsibility to ensure that these persons are adequately qualified. Follow the procedures described here precisely.
Examples of qualified persons: ─
Persons with comprehensive knowledge from specialist training in engineering and in the electrical systems of cranes.
─
Persons with sufficient experience in the operation, installation and maintenance of cranes.
─
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country.
─
Persons receiving regular training from ABUS.
ABUS assumes no liability for damage due to incorrectly performed commissioning work done by unqualified personnel. ABUS recommends having the commissioning work performed by the ABUS assembly team.
Depending on the size, design and method of transport of the crane, some work steps will already have been completed ex works. Skip these work steps.
Page 12
2.1 Installing the crane track So that the overhead travelling crane travels steadily, smoothly and without great wear and tear, the crane track must be properly installed. Otherwise the overhead travelling crane will travel unsteadily and the wheels will wear out more rapidly. The design and installation of the crane track must be taken into consideration upon construction of the building and planned together with the architects and structural engineers.
Observe the following points amongst others:
The building supports and building beams or concrete supports or concrete girders as well as the brackets should be designed in such a way that the crane track can be welded onto them without difficulty.
Only have welding work done by companies certified as per EN 1090 EXC-3.
Monitor welded joints according to this standard.
Design welded joints to at least quality class B of DIN EN ISO 5871.
Clean the anchor plates (in the concrete brackets) or the steel brackets (to the building supports) prior to welding. They must be free of dirt, rust, scaling, paint, grease and oil.
Cut the crane track joints at an angle of 45 degrees. Deburr the cut edges and clean. The gaps between the crane tracks should be as small as possible. The abutting crane track segments should not be misaligned laterally nor offset in height.
For bolted crane tracks: firmly tighten all bolts with the correct tightening torque.
Clean the crane tracks. They must be free of grease, oil, paint and dirt.
Secure the crane track with suitable end stoppers.
Provide the entire crane track with an appropriate corrosion protection (e.g. paint)
Installation
Checking the requirements
2.2 Checking the requirements
Height of the crane tracks in relation to each other E:
The following requirements must be met in order for the crane to be installed:
Checking the crane track ─
The tolerances of the crane track must correspond to the following criteria.
Cross-sectional view. ─
Where S ≤ 10 m, the following applies: maximum difference in height E = ± 10 mm.
─
Where S > 10 m the following applies: difference in height of the crane tracks E (in mm) must not be greater than E = ± Span S / 1000.
The tolerances specified correspond to DIN EN 1090 for Class 2 crane classifications.
Site of a crane track in floor plan B:
Deviation from span A:
View from above. ─
Deviation B across the entire length of the crane track: B = ± 5 mm.
─
Within 2 m, the deviation may not be greater than b = ± 1 mm.
View from above. ─
When S ≤ 16 m, then A = ± 5 mm applies.
─
When S > 16 m, then: A = ± [5 + 0.25 (S16] mm applies. With S in m and the result in mm.
Height of crane track C: Position of the end stoppers in relation to each other F:
Wall (view from the side) View from the side. ─
Deviation C across the entire length of the crane track: C = ± 10 mm.
─
Deviation C across the entire length of the crane track must not be greater than C = ± Crane track length / 1000 mm.
─
Within 2 m, the deviation may also not be greater than c = ± 2 mm.
View from above. ─
The offset of end stoppers F must not be greater than F = ± Span S /1000.
─
Maximum offset F = ± 10 mm.
Page 13
Installation
Installation overview
Incline of the crane track from the horizontal vertex G:
2.3 Installation overview The following sections show how the single girder travelling crane is assembled.
Cross-sectional view. ─
Deviation G = 0.6 % of the width K.
─
Where overhead travelling cranes are delivered disassembled, the end carriages are affixed first.
─
The crane travel drives are then connected on the ground.
─
The connection cables are then connected to the crane panels on the ground.
─
The safety butters are then installed on the ground.
─
The mains power supply is then pre-installed on the ground.
─
The crane is then raised onto the crane track using a truck-mounted crane.
─
The mains power supply is then installed on the crane track and connected.
─
The crane travel limit switch is then installed.
─
As a final step the screws of the end carriages are tightened with the correct tightening torque.
Incline of the crane tracks to each other:
View from the side (perspectively) ─
Incline of the crane tracks to each other: Incline between A1 and B1 (wheel base) – incline between A2 and B2 (without algebraic sign) must not be greater than L (distance between A1 and B1) / 1000.
Checking the layout plan ─
The supplied overhead travelling crane must correspond to the overhead travelling crane that was provided for in the layout plan.
Only with multiple overhead travelling cranes on the crane track Checking the crane position ─
The order of the overhead travelling cranes on the crane track must be decided.
Page 14
Perform the following steps in the sequence specified.
Installation
Fixing the end carriages onto the main girder
2.4 Fixing the end carriages onto the main girder
Preparing the screw connection Danger of fatal injury! The crane and the load can fall if the end carriages are not correctly screwed onto the main girders. Prepare and screw in the screws carefully!
Travelling cranes with end carriages which are a maximum of 2.5 m wide can, in the majority of cases, be transported fully assembled on the road. If the end carriages are installed, skip this section. Continue with “Installing the safety buffers ” on page 18. For travelling cranes with end carriages which are more than 2.5 m wide, the end carriages are dismantled for transportation. Continue reading.
Residual paint
Assigning the end carriages Letter position markers
Joint face Thoroughly clean the joint faces on the entire surface. There should not be any rust, dirt, paint or similar impurities on them. Lift the end carriages in front of the main girders. The hole patterns must overlap.
Joint faces Look for the letter position markers A and B (for the installation sequence) on the main girders and end carriages. Lay both end carriages on the joint faces of the main girder in such a way that the letter position markers match.
Page 15
Installation
Fixing the end carriages onto the main girder
Checking the high-tensile bolts
─
Clamp brace
Lubrication
Size
Check the high-tensile bolts. The high-tensile bolts must meet these requirements:
Material
Bolting on the end carriage
High-tensile bolt (hexagonal)
10.9 HV tZn
M20
Washer
C 45 HV tZn
HV 21
MoS2
High-tensile nut (hexagonal)
10 HV tZn
M20
MoS2
The high-tensile bolts and mounting plate with high-tensile nuts may only be installed a maximum of two times. If they are installed more than twice, scrap the high-tensile bolts as well as the mounting plates with the hightensile nuts and use new ones. Should it be necessary to loosen the hightensile bolts during installation (e.g. because the hole pattern does not fit exactly) the same high-tensile bolts can be used again.
─
The high-tensile nuts and washers must be galvanised and lubricated with MoS2.
─
High-tensile bolts that have been installed on a crane for a lengthier period may not be used again.
Mounting plate
Only with end carriages of size 280, 350 and 420: Do not move, dismantle or damage the clamp brace in the end carriage.
Place the mounting plate in the end carriage and hold it so the hole pattern properly overlaps.
High-tensile bolt with washer
The end carriages are initially only installed by manually screwing until hand-tight. They are finally firmly screwed (with a tightening torque) only after the crane is on the crane track and the trolley and all other components are installed. By doing so, the main girders can settle and the crane is not warped on the crane track. See “Fastening the end carriages tightly”, page 23.
Page 16
Place the washers on the high-tensile bolts with the bevel (chamfered edge) to the head of the screw.
Insert the high-tensile bolts and washers from the outside into the screw holes and screw on so they are somewhat loose.
Screw on the second end carriage following the same sequence of steps.
Installation Sealing the access portal Access portal
Fixing the end carriages onto the main girder
Only for rainwater or condensation water This work step only applies if the crane comes into contact with rainwater or condensation water (e.g. outdoor operation, semi-exposed building etc.)
Sealing the joint faces The gap between the two joint faces must be sealed so that no water can penetrate and rust the metal parts.
Joint
Cap Seal the access portal with a cap.
Sealant Squeeze sealant (supplied) with a cartridge applicator gun into the joints between the main girders and the end carriages. Only left, right and above. The joints below remain free so that entrapped water can drain off.
Smooth the sealant in the joint. Clean away any smeared sealant. If necessary, reapply the sealant. The sealant can be handled “wet on wet”, no drying time is necessary.
Page 17
Installation
Connecting the crane travel drives
Crane panel
2.5 Connecting the crane travel drives Connection cable
Connector housing Drive Lay the connection cable for the drive.
Connectors and coupler plugs Insert connectors and coupler plugs in the socket on the crane panel. Lay the connection cables in the cable duct. Secure the connection cables with cable clips.
Lay the connection cable in the connector housing.
Plug the coupler plug into the drive and close the housing cover.
Secure the connection cable with cable ties to the end carriage.
2.7 Installing the safety buffers In case the safety buffers are not installed: Buffer plate
2.6 Connecting connection cables to crane panels Cable fasteners
Installation channel Push the installation channel on the crane panel onto the bolt on the end carriage. Fasten the installation channel with cable fasteners.
Page 18
Safety buffer Screw safety buffers (4x) into the buffer plates.
Installation
Pre-installing the mains power supply
2.8 Pre-installing the mains power supply
2.10 Attaching operating direction signs
Threaded bracket
Mount Pipe clamp Attach the mount to the end carriage on which the crane panel is installed.
Bolt the mount onto the threaded bracket.
Threaded bracket
Tightening torque
M8
25 Nm
M10
50 Nm
M12
75 Nm
Operating direction signs Rotate the operating direction signs to match how they are marked in the layout plan.
For spans under 10 m only: Attach operating direction signs for the crane and trolley under the middle of the main girder.
Only for spans greater than 10 m: Attach operating direction signs for the crane and trolley to the left and right, in each case 2.5 m away from the end carriage.
Slide on the two pipe clamps and secure them.
2.9 Repairing damage to paintwork
Repair damage to paintwork caused during transportation and installation.
Page 19
Lifting the overhead travelling crane onto the crane track
2.11 Lifting the overhead travelling crane onto the crane track
Installation
Only for ELK and ELV main girders Adjust the trolley or lifting tackle in such a way that the main girder hangs straight when it is lifted.
Danger from falling components! The crane can fall and kill or injure people if it is not correctly attached and lifted. Attachment and lifting should only be carried out by trained persons.
Secure the trolleys with clamping buffers so that they do not slip on lifting.
Only for ELS main girders Secure the trolley onto the main girder with a tension belt or similar.
Adjust the lifting tackle in such a way that the main girder hangs vertically and horizontally straight when it is lifted. Due to the laterally running trolley track and the overhanging trolley, the main girder is unbalanced on one side.
Attaching the main girders Lifting tackle
Placing the overhead travelling crane on the crane track
Clamping buffer Place suitable lifting tackle around the main girder and insert it. Cover all edges of the main girder with suitable edge protection.
Only with energy chains If the profile rails (in which the energy chain
is) protrude to the side, lay wooden beams (wider than the profile rails) over the profile rails so that they are not damaged on lifting.
Page 20
Observe the occupational health and safety requirements and lift the overhead travelling crane.
Rotate the overhead travelling crane in such a way that the direction corresponds to that in the layout plan.
Place the overhead travelling crane with wheels onto the crane track.
For guide rollers only: Do not set the overhead travelling crane down with the guide rollers. Otherwise, they will be damaged.
Check whether all wheels come into contact with the crane track.
Installation
Installing the mains power supply
2.12 Installing the mains power supply
2.13 Installing the cross-type limit switch
Installing the mains power supply to the crane track
Only with cross-type limit switch
Install the mains power supply parallel to the crane track. See the product manual for the mains power supply.
Installing the mains power carrying fork on the overhead travelling crane
This section is only applicable if the overhead travelling crane has a cross-type limit switch in the direction of crane travel. Where and for which travel limit the cross-type limit switch is designed is specified on the wiring diagram.
Installing the cross-type limit switch Danger due to malfunction! If the cross-type limit switch is screwed on too tightly, the parts on the inside can become jammed and no longer function properly.
Vertical square tube
The tightening torque of 4 Nm must be precisely observed. Locking washer
Screw the vertical square tube onto the mount using pipe clamps (2x). 15 Nm.
Screw the mount for the current collector to the vertical tube. See the product manual for the conductor system.
Hexagonal nut
Fillister-head Mounting bracket screw M5x50 Screw the mounting bracket onto the crosstype limit switch with the fillister-head screws M5x50 (2x). Screw on the mounting bracket using locking washers and M5 hex nuts (2x). 4 Nm.
Insert the current collector in the conductor system and fasten it to the mount. See the product manual for the conductor system.
Connect the current collector to the crane panel and lay the cable neatly.
Page 21
Installation
Installing the cross-type limit switch
Attaching the actuating cam Installing the cross-type limit switch on the mains power carrying fork
End stopper
The cross-type limit switch can be installed on the mains power carrying fork, for example. Crane travel limit switches
Turn the crane travel limit switch to the position 0.
Conductor system Actuating cam Suspend a load on the load hook which corresponds to the maximum load capacity of the crane. Determine the necessary distance between the actuating cam and the end stopper: For braking function: The distance must be such that the crane is only travelling at a low speed shortly before the end stopper.
The position of the cross-type limit switch is marked with an arrow that can be rotated further, depending on the switching state.
For shut-down: The distance must be such that the crane is at a standstill shortly before the end stopper.
Hold the crane travel limit switch on the square tube so that the actuating cam operates the crane travel limit switch.
Screw the crane travel limit switch onto the vertical square tube using pipe clamps (2x). 15 Nm.
Add 0.5 m to 1 m to the calculated distance. This will compensate the brake wear on the crane travel drive.
Install the actuating cam for the crane travel limit switch to the crane track or conductor system at the determined distance.
Connecting the cross-type limit switch
Route the connection cable (round cable or flat cable) from the cross-type limit switch to the panel.
Route the connection cable with cable fitting into the panel.
If necessary, connect the connection cable to a coupler plug or connector.
Fasten the connection cable with cable ties, cable ducting and adhesive clips.
Page 22
Installation
Fastening the end carriages tightly
Once all components have been installed, the entire crane has settled as a result of the weight, and the stress is relieved. For this reason, the end carriages can only now be tightened with the tightening torque.
2.15 Overview of screw tightening torques End carriages
Check the high-tensile bolts. The high-tensile bolts must meet these requirements:
Remaining hightensile bolts ─
Only tighten high-tensile bolts with the appropriate torque wrench.
─
Do not use an impact wrench.
─
Do not tighten high-tensile bolts using turnof-nut tightening.
Tighten the central high-tensile bolts on both sides (left and right on the end carriage). Use a torque wrench to 300 Nm.
Next, tighten the remaining high-tensile bolts, alternating between left and right. Use a torque wrench to 300 Nm.
Then tighten all high-tensile bolts in the same sequence. Use a torque wrench to 450 Nm.
High-tensile bolt 10.9 (hexagonal) HV tZn
M20
Washer
HV 21
MoS2
M20
MoS2
C 45 HV tZn
High-tensile nut 10 (hexagonal) HV tZn ─
Size
Material
Central high-tensile bolt
Lubrication
2.14 Fastening the end carriages tightly
The high-tensile bolts and mounting plate with high-tensile nuts may only be installed a maximum of two times. If they are installed more than twice, scrap the high-tensile bolts as well as the mounting plates with the hightensile nuts and use new ones. Should it be necessary to loosen the hightensile bolts during installation (e.g. because the hole pattern does not fit exactly) the same high-tensile bolts can be used again.
─
The high-tensile nuts and washers must be galvanised and lubricated with MoS2.
─
High-tensile bolts that have been installed on a crane for a lengthier period may not be used again.
Initially, only install the end carriages handtight.
Next, place the entire crane on the crane track and install completely. As a result of the weight, the crane settles and the stress is removed.
Then tightly screw all high-tensile bolts (with tightening torque).
Page 23
Installation
Overview of screw tightening torques
Central high-tensile bolt
Remaining hightensile bolts ─
Only tighten high-tensile bolts with the appropriate torque wrench.
─
Do not use an impact wrench.
─
Do not tighten high-tensile bolts using turnof-nut tightening.
Tighten the central high-tensile bolts on both sides (left and right on the end carriage). Use a torque wrench to 300 Nm.
Next, tighten the remaining high-tensile bolts, alternating between left and right. Use a torque wrench to 300 Nm.
Then tighten all high-tensile bolts in the same sequence. Use a torque wrench to 450 Nm.
Threaded bracket
Type and size
Number
Tightening torque
Mount on the mains power carrying fork
M8
Rib nut M8
2x
25 Nm
M10
Rib nut M10
2x
50 Nm
M12
Rib nut M12
2x
75 Nm
Page 24
Pipe clamps on the mains power carrying fork
─
Rib nut M8
─
4x per pipe clamp
─
15 Nm
Crane travel limit switches
─
Rib nut M8
─
4x per pipe clamp
─
15 Nm
Inspection
At the start
3. Inspection
This section applies to anyone who inspects and accepts the crane in accordance with occupational health and safety requirements.
The crane must be regularly inspected in order to guarantee safe operation. The end user is responsible for this regular inspection.
Examples of qualified persons: ─
Persons with comprehensive knowledge from specialist training in engineering and in the electrical systems of cranes.
─
Persons with sufficient experience in the operation, installation and maintenance of cranes.
─
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country.
─
Persons receiving regular training from ABUS.
3.1 At the start Inspection intervals The regular inspection is performed at least once annually. Under certain conditions, more frequent regular inspections may be necessary. Reasons include: ─
Frequent operation at the load capacity
─
Working in multiple shifts
─
Frequent use
─
Dusty or chemically aggressive environment
The end user is responsible for checking the prerequisites and determining the test intervals. ABUS will gladly assist you if questions arise.
Requirements for the examiner The end user of the crane is responsible for the proper qualifications of the examiner.
Danger to persons! Persons can be injured if the inspection is performed incorrectly.
3.2 Scope of the test The qualified person inspecting the crane is responsible for the type and scope of the test.
Overview: Inspecting the crane In addition to the points described here, all points outlined in the other supplied product manuals must also be checked. The decision as to whether the crane is in perfect condition may be made only by the person inspecting the crane. Any inadequacies, if found, must be eliminated. The examiner decides whether the crane has to be tested again afterward. If locally applicable regulations specify further tests, these are likewise to be carried out.
If personnel other than that of the ABUS company are employed to perform the inspection, it is the end user's responsibility to ensure that these persons are adequately qualified.
Page 25
Inspection
Inspecting the wheel flange wear
Additionally, at least the following points must be checked:
Check the wheel flange wear. See “Inspecting the wheel flange wear” on page 26. Only for braking function or shut-down: Check the braking distance of the crane in the limit switch range. See “Checking the braking distance”, page 26.
Check the wear on the guide rollers. See “Checking the wear on the guide rollers” on page 27.
Check the diameter of the wheels. See “Checking the diameter of the wheels”, page 28.
Check the condition of the safety buffer. See “Inspecting the condition of the safety buffer” on page 29.
Check the condition of the crane track and the supporting structure. They must be adequate for the expected loads.
3.4 Checking the braking distance Only for braking function or shutdown The brake on the crane travel drives is worn during operation. This lengthens the braking distance of the crane. The crane may therefore strike the end stopper of the crane track too fast and put excess pressure on the supporting structure (e.g. the building).
Suspend a load on the load hook which corresponds to the maximum load capacity of the crane.
Move the crane into the limit switch range. Check the braking distance: For braking function: the crane must run only at low speed just in front of the end stopper. For shut-down: the crane must come to a standstill just in front of the end stopper.
3.3 Inspecting the wheel flange wear Only for wheels with a wheel flange The undercuts in the wheel flanges are a sign of wear on the wheel flange. Wheel flange
Undercuts Inspect the wheel flanges of the wheels: The wheel flanges must not be worn so much that a continuous crack can be seen in the wheel flange (rather than undercuts). If they are, replace the wheels.
Page 26
If the braking distance is too long: Adjust the brake on the crane travel drive. See the product manual for the crane travel drive.
Inspection
3.5 Checking the wear on the guide rollers
Only for four-roller guide rollers
Checking the wear on the guide rollers
Only for guide rollers The wear on the guide rollers is checked based on the clearance between the guide rollers and the crane track.
Checking the wear
This working step is only applicable if the guide roller unit is made up of four guide rollers per end carriage side.
Guide roller
The guide rollers must be clamped tight first in order to check wear.
Clamping the support tight Rotatable support for Support on the end guide rollers carriage
Crane track Measure the distance between guide roller and crane track on both sides. The distance (between guide roller and crane track) on both sides together may not be greater than that specified in the table.
●
Distance (total) on both sides with new guide rollers
Max. distance (total) to the crane track on both sides.
Size (wheel diameter)
If the distance is greater than this, the guide rollers must be replaced.
Insert a wedge in the gap between the support on the end carriage and the rotatable support in order to clamp the guide roller unit tight.
130
11 mm
5 mm
160
11 mm
5 mm
200
11 mm
5 mm
The rotatable support can now no longer be displaced.
280
11 mm
5 mm
350
14 mm
5 mm
Now measure the distance between the front and rear pairs of rollers and the crane track as described below.
420
14 mm
5 mm
Gap between rotatable support and support on the end carriage Turn the rotatable support in such a way that it is parallel to the crane track.
Page 27
Inspection
Checking the diameter of the wheels
Determining the diameter for new guide rollers If the distance between guide roller and crane track is too large (see previous section), the guide rollers must be replaced. During operation of the crane however, both the guide rollers AND the crane track are subjected to wear. Since only the guide rollers can be replaced, they may need to be exchanged for larger ones than were previously used in order to compensate for the wear on the crane track.
Guide roller If possible: Measure the diameter of the guide roller above the crane track. This area of the guide roller frequently has no contact with the crane track and can therefore be used to determine the original diameter.
Determine the diameter of the new guide roller:
─
The distance between the guide rollers and the crane track should be as close possible to 5 mm (see also previous table). This applies to the entire length of the crane track.
─
The distance between the guide rollers and the crane track may not be smaller than 5 mm. This applies to the entire length of the crane track.
3.6 Checking the diameter of the wheels
The running surfaces of the wheels become worn during operation. This reduces the diameter of the wheels.
Exposing the wheel Buffer plate
From size 160: Remove the plastic washers (4x). Remove the buffer plate.
Measuring the diameter
Page 28
Plastic washer Self-locking nut Unscrew the self-locking nuts (4x).
Measure the diameter of the wheel at multiple points over the width of the wheel.
Inspection
Inspecting the condition of the safety buffer
The diameter may not be smaller than is specified in the table. If the diameter is smaller, the wheel must be replaced. Size
Maximum permissible wear
Minimum diameter of wheel
130
-3 mm
127 mm
160
-3 mm
157 mm
200
-4 mm
197 mm
280
-5 mm
275 mm
350
-5 mm
345 mm
420
-5 mm
415 mm
500
-5 mm
495 mm
Measuring the difference in diameter
3.7 Inspecting the condition of the safety buffer
Safety buffer Check all the safety buffers. The safety buffers must not be broken, pinched, bent or otherwise damaged.
In addition, the power-driven wheels of the crane must be of uniform diameter so that the crane runs evenly on the crane track.
Check the material of the safety buffers all the way round. The plastic must not be cracked anywhere on the surface.
This means that the permissible deviation in the diameter of opposite-lying power-driven wheels is limited.
Press the safety buffers with your finger. The safety buffers must be able to be pressed in slightly and be formable.
If any of the safety buffers is damaged in any way whatsoever, replace all the safety buffers on the entire crane.
If any of the safety puffers cannot be pressed in, replace all the safety buffers on the entire crane.
Only with a 4-wheel crane travel drive and 8-wheel cranes: The diameter does not need to be as similar as possible between all power-driven wheels, but only between the respective opposite-lying wheels of the crane.
Determine the difference in diameter of the opposite-lying power-driven wheels. The difference in diameter may not be larger than is specified in the table. If the respective diameters of the wheels deviate from each other by more than this, the wheels must be replaced. Size
For cranes subject to lesser loads (formerly crane classification B3)
For cranes subject to greater loads (formerly crane classification B4)
130
2 mm
1 mm
160
2 mm
1 mm
200
2 mm
1 mm
280
3 mm
1.5 mm
350
3 mm
1.5 mm
420
3 mm
1.5 mm
500 3 mm 1.5 mm Maximum difference in diameter of the two power-driven wheels.
Page 29
Instructions regarding safety when performing maintenance work
Maintenance
4. Maintenance This section applies to anyone who maintains, repairs or modifies the crane.
The end user of the crane is responsible for the selection and proper qualifications of the maintenance personnel.
Danger to persons! Persons can be injured if the crane is incorrectly serviced. If personnel other than that of the ABUS company are employed to perform maintenance on the crane, it is the end user's responsibility to ensure that these persons are adequately qualified. Follow the procedures described here precisely.
Examples of qualified persons: ─
Persons with comprehensive knowledge from specialist training in engineering and in the electrical systems of cranes.
4.1 Instructions regarding safety when performing maintenance work
Please follow the following safety instructions during all repair work on the crane: ─
Switch off the mains switch. Secure the switch so that it cannot be unintentionally switched back on.
─
Unplug the mains disconnector plug from the socket on the crane panel. Secure the socket with a padlock so that the mains disconnector plug is not unintentionally reinserted.
─
Use suitable lifting platforms and fall protection equipment.
─
Adequately cordon off the work area around the lifting platform.
─
Switch off any other cranes using the same crane track or cranes working above or below the crane undergoing maintenance. Secure the switch so that it cannot be unintentionally switched back on. Otherwise, other cranes could overturn the hoisting platform or crash into the crane undergoing maintenance.
─
Persons with sufficient experience in the operation, installation and maintenance of cranes.
─
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country.
─
─
Persons receiving regular training from ABUS.
Notify personnel in the area that maintenance work will be performed.
─
Only trained electricians should work on the crane electrical system!
─
Even after the emergency stop button has been pressed, life-threatening high voltages are still present in the panels.
ABUS assumes no liability for damage due to incorrectly performed maintenance work done by unqualified personnel. ABUS recommends having the maintenance work performed by ABUS Service. Use only original ABUS replacement parts. Otherwise, all warranty claims will be rendered invalid.
Page 30
Maintenance
Changing the fuses
Changing the control current circuit input fuses F10 and F11
4.2 Changing the fuses Changing the main fuse F1
Fuse holder
If the fuse is used in a circuit breaker: Fuse link
Circuit breaker
Pull out the circuit breaker.
Fuse link Flip open the fuse holder. Open the fuse holder. Replace the fuse link. Close the fuse holder. Click the fuse holder back into place.
Replace the fuse link. Click the circuit breaker back into place.
Changing the control current circuit output fuse F12 If the fuses are individually screwed in: Fuse holder
Screw cap
Unscrew the screw cap. Replace the fuse link. Screw the screw cap back on.
Detach the fuse holder from the mount on the transformer.
Replace the fuse link. Reinsert the fuse holder.
Page 31
Maintenance
Disassembling the powered wheel
Screws
4.3 Disassembling the powered wheel If the wheel is damaged or worn, it must be replaced by a new wheel.
The figures show the disassembly of a size 130 wheel. The removal of larger wheels does not essentially differ from this.
Crane travel drive Unscrew and remove screws (4x). Pull out the crane travel drive.
Preparing the crane Exposing the wheel
Comply with occupational health and safety requirements.
Prop up the end carriage close to the wheel.
Buffer plate
Disassembling the crane travel drive Coupler plug
Connector housing Open the connector housing to the drive. Detach the coupler plug.
Determining the weight of the drive. See the “Technical data” section “Dimensions and weights”.
Secure the drive so that the weight can be held safely and the output shaft will not be subject to load (e.g. insert in round sling).
Page 32
Plastic washer Self-locking nut Unscrew the self-locking nuts (4x). From size 160: Remove the plastic washers (4x). Remove the buffer plate.
Maintenance
Disassembling the powered wheel
Retaining screw
Only for guide rollers, derailing protection device or end carriages of the sizes 280, 350 and 420 This section only applies if the end carriage has guide rollers or a derailing protection device. This work step also applies to end carriages of the sizes 280, 350 and 420. Screws
Rib screws Unscrew and remove all rib screws on the bearing bolt. Do not unscrew and remove the retaining screw(s).
Bearing bolt
Bearing flange
Guide rollers Release screws (2x). Take out the guide rollers or derailing protection device or clamping piece.
Removing the wheel Retaining screw
Wheel Take out the bearing bolt, bearing flange and wheel.
Note: Only for size 420 with crane travel drive 420 V: An adapter is also inserted on the bearing flange. If this cannot be easily taken off, it can remain on the bearing flange when the wheel is removed.
Tip:
Rib screws Unscrew and remove all rib screws on the bearing flange. Do not unscrew and remove the retaining screw(s).
To be able to easily remove the bearing flange from the end carriage, screw two or four screws in the corners of the bearing flange and thereby lift the bearing flange off the end carriage.
Page 33
Maintenance
Installing the powered wheel
4.4 Installing the powered wheel If the wheel is damaged or worn, it must be replaced by a new wheel.
The figures show the assembly of a size 130 wheel. The mounting of larger wheels does not essentially differ from this.
Fitting the wheel Bearing bolt
Bearing flange
Wheel Clamp the wheel in the end carriage. It does not matter which side faces inwards or outwards. Insert the bearing bolt and bearing flange. If necessary, lightly hammer the bearing bolt and bearing flange.
Rib screws Tighten the rib screws in stages. Screws of strength category 100. Wheel Ø Number
Screw
Tightening torque
130
5x
M8 x 25
42 Nm
160
5x
M8 x 25
42 Nm
200
5x
M10x30
85 Nm
280
5x
M12x40
130 Nm
350
8x
M12x40
130 Nm
420
8x
M16x40
330 Nm
Only for size 420 with crane travel drive 420 V This work step only applies if an end carriage size 420 is to be installed with a crane travel drive size 420 V.
Mounting the adapter Bearing flange
Page 34
Pin If necessary: Insert the pins (4x) in the bearing flange.
Maintenance
Installing the powered wheel
Fastening the bearing flange
Tightening torque
Rib screws
Type
Place the adapter on the pins on the bearing flange.
Number
Adapter Bearing flange Turn the adapter to match the hole pattern.
Wheel Ø
Rib screws Tighten the rib screws in stages. Screws of strength category 100.
130
7x
M8 x 25
42 Nm
160
7x
M8 x 25
42 Nm
200
7x
M10x30
85 Nm
280
7x
M12x40
130 Nm
350
10x M12x40
130 Nm
420 with crane travel drive 420
10x M16x40
330 Nm
420 with crane 10x M16x70 travel drive 420 V
330 Nm
Insert the rib screws M16x70 (10x) through the adapter and bearing flange.
Page 35
Maintenance
Installing the powered wheel
Assembling the end carriage
Only for derailing protection device This work step only applies if the end carriage has a derailing protection device.
Only for guide rollers or end carriages of the sizes 280, 350 and 420
Small side
This work step only applies if the end carriage has guide rollers. This work step also applies to all end carriages of the sizes 280, 350 and 420. Screws
160 M10x50
Rib screw
85 Nm
200 M10x50
Rib screw
85 Nm
280 M12x60
Hexagon head screw
130 Nm
350 M20x75 or M20x70
Hexagon head screw
300 Nm
420 M20x75 or M20x70
Hexagon head screw
300 Nm
Page 36
Tightening torque
42 Nm
Tighten screws (2x).
Kind
Rib screw
Insert the derailing protection device.
130 M8x45
Rib screw
42 Nm
160 M10x50
Rib screw
85 Nm
200 M10x50
Rib screw
85 Nm
280 M12x60
Hexagon head 130 Nm screw
350 M20x75 or M20x70
Hexagon head 300 Nm screw
420 M20x75 or M20x70
Hexagon head 300 Nm screw
Type
Tightening torque
130 M8x45
Type
Kind
Tighten screws (2x).
Wheel Ø
Guide rollers Insert guide rollers or clamping piece.
Wheel Ø
Large side Crane travel drive Rotate the derailing protection device in such a way that the large side faces towards the crane travel drive.
Maintenance
Installing the powered wheel
Only with AZP drives Buffer plate
This work step only applies when an AZP drive is to be mounted on the end carriage. Rib screws
Plastic washer Self-locking nut Slide the buffer plate onto the threaded bolt. From size 160: Fit the plastic washers (4x) in place. Tightly screw the self-locking nuts M10 (4x). 6 Nm.
Installing the crane travel drive
Determining the weight of the drive. See the “Technical data” section “Dimensions and weights”.
AZP drive Push the drive in the wheel. Bolt on the drive with the rib screws (4x). Wheel Ø
Type
Tightening torque
130
M8x20
35 Nm
160
M10x25
75 Nm
200
M12x30
115 Nm
280
M16x40
300 Nm
Secure the drive so that the weight can be held safely and the output shaft will not be subject to load (e.g. insert in round sling).
Output shaft
Lubricate the gearing on the output shaft. Lubricant Moly Paul “PBC”, AN 6758.
Page 37
Maintenance
Installing the powered wheel
Coupler plug
Only for crane travel drive AZF This work step only applies if an AZF crane travel drive is to be mounted on the end carriage. Crane travel drive AZF
Fillister-head screws Insert the crane travel drive in the wheel. Bolt on the crane travel drive with the fillisterhead screws and washers (4x). Wheel Ø
Type
Tightening torque
350
M12x100
85 Nm
420 with crane travel drive 420
M12x100
85 Nm
420 with crane travel drive 420 V
M16x140
210 Nm
Page 38
Connector housing Insert the coupler plug. Lay the connection cable in the connector housing. Close the connector housing.
Inspecting the crane
Replace the crane on the crane track. Put the crane into operation. Inspect the function of the wheel.
Maintenance
4.5 Disassembling the non-powered wheel If the wheel is damaged or worn, it must be replaced by a new wheel.
Disassembling the non-powered wheel
Only for guide rollers or derailing protection device This section only applies if the end carriage has guide rollers or a derailing protection device. Screws
The figures show the disassembly of a size 130 wheel. The removal of larger wheels does not essentially differ from this.
Preparing the crane
Comply with occupational health and safety requirements.
Prop up the end carriage close to the wheel.
Exposing the wheel Buffer plate
Guide rollers
Release screws (2x). Take out the guide rollers or the derailing protection device.
Removing the wheel Distance bush
Plastic washer Self-locking nut Unscrew the self-locking nuts (4x). From size 160: Remove the plastic washers (4x). Remove the buffer plate.
Bolt
Wheel Take out the bolt, distance bush and wheel.
Circlip Remove the circlip.
Page 39
Maintenance
Installing the non-powered wheel
Only for guide rollers 4.6 Installing the non-powered wheel
This work step only applies if the end carriage has guide rollers. Screws
If the wheel is damaged or worn, it must be replaced by a new wheel.
The figures show the assembly of a size 130 wheel. The mounting of larger wheels does not essentially differ from this.
Fitting the wheel Distance bush
Bolt
Guide rollers
Insert the bolt and distance bush. If necessary, lightly hammer the bolt and distance bush.
Circlip Attach the circlip and neatly lock into place. Turn the wheel. It must move easily.
Page 40
130 M8x45
Rib screw
42 Nm
160 M10x50
Rib screw
85 Nm
200 M10x50
Rib screw
85 Nm
280 M12x60
Hexagon head screw
130 Nm
350 M20x75 or M20x70
Hexagon head screw
300 Nm
420 M20x75 or M20x70
Hexagon head screw
300 Nm
Type
Tightening torque
Tighten screws (2x).
Kind
Wheel Clamp the wheel in the end carriage. It does not matter which side faces inwards or outwards.
Insert guide rollers.
Wheel Ø
Maintenance
Installing the non-powered wheel
Only for derailing protection device Buffer plate
This work step only applies if the end carriage has a derailing protection device. Small side
Insert the derailing protection device.
Kind
Tightening torque
Tighten screws (2x).
Rib screw
42 Nm
160 M10x50 Rib screw
85 Nm
200 M10x50 Rib screw
85 Nm
280 M12x60 Hexagon head screw
130 Nm
350 M20x75 Hexagon head or screw M20x70
300 Nm
420 M20x75 Hexagon head or screw M20x70
300 Nm
Type
Large side Inner side Rotate the derailing protection device in such a way that the large side faces inwards (towards the crane travel drive).
Wheel Ø
130 M8x45
Plastic washer Self-locking nut Slide the buffer plate onto the threaded bolt. From size 160: Fit the plastic washers (4x) in place. Tightly screw the self-locking nuts M10 (4x). 6 Nm.
Inspecting the crane
Replace the crane on the crane track. Put the crane into operation. Inspect the function of the wheel.
Page 41
Maintenance
Replacing the cross-type limit switch
4.7 Replacing the cross-type limit switch
4.8 Wiring diagram of the cross-type limit switch
If the cross-type limit switch is damaged, it must be replaced. The plug-in connection allows you to carry out the replacement without any wiring work.
Danger due to malfunction! If the cross-type limit switch is screwed on too tightly, the parts on the inside can become jammed and no longer function properly. The tightening torque of 4 Nm must be precisely observed.
─
The contact numbering shown on the wiring diagram starts on the left ascending from 1.
─
The designation of the microswitches starts on the left of the installation position with S1.
3.4
5.6
7.11 9.10
2
180° 3.4
5.6
7.11
3
270°
3.1 5.6
4
360°
3.1
Remove the cover.
5
450° 3.4
Disconnect the coupling of the connecting cable from the circuit board.
0
540° 3.4
Cable fitting Cover Unscrew and remove the screws (2x) on the cover.
The cable fitting on the cover does not need to be unscrewed. The existing cover can be fitted with the attached connection cable to a new cross-type limit switch.
Insert the coupling onto the new cross-type limit switch.
Close the cover. Tighten screws (2x). 4 Nm.
Page 42
5.6
S4 open
90°
7.8
S4 closed
1
S3 open
5.6
S3 closed
3.4
S2 open
0°
S2 closed
0
S1 open
S1 closed
Switch position
Position arrow
Coupling
9.10
9.12
7.8
9.12
5.2 7.8
9.10
5.2 7.8
9.10
7.8
9.10
Maintenance
Move the crane and trolley and listen out for unusual noises made by the wheels and wheel bearings.
Check the crane completely for the correct function. In particular, check hoist limit switches, travel limit switches, overload protection and all the other safety devices. See “General Product Manual for ABUS Cranes”.
Tightening torque
Inspect the wire rope. See “General Product Manual for ABUS Cranes”.
Number
Bearing bolt
Type, size and length
If a crane has been struck by lightning or if it is suspected that a crane has been struck by lightning, the following points must be checked:
4.10 Screwing with tightening torque
Size
4.9 Checking after a lightning strike
Checking after a lightning strike
130
Rib screw M8x25
5x
42 Nm
160
Rib screw M8x25
5x
42 Nm
200
Rib screw M10x30
5x
85 Nm
280
Rib screw M12x40
5x
130 Nm
350
Rib screw M12x40
8x
130 Nm
420
Rib screw M16x40
8x
330 Nm
Page 43
Maintenance
Screwing with tightening torque
Guide rollers, clamping piece, derailing protection device
160 Rib screw M10x50 200 Rib screw M10x50
2x
85 Nm
160
Rib screw M8x25
7x
42 Nm
280 Hexagon head screw M12x60
2x
130 Nm
200
Rib screw M10x30
7x
85 Nm
350 Hexagon head screw M20x75 or M20x70
2x
300 Nm
280
Rib screw M12x40
7x
130 Nm
420 Hexagon head screw M20x75 or M20x70
2x
300 Nm
350
Rib screw M12x40
10x 130 Nm
420 with crane travel drive 420
Rib screw M16x40
10x 330 Nm
420 with crane travel drive 420 V (adapter required)
Rib screw M16x70
10x 330 Nm
Page 44
Tightening torque
42 Nm
Number
7x
Type, size and length
Rib screw M8x25
Size
Tightening torque
130
Type, size and length
130 Rib screw M8x45
Size
Number
Bearing flange
2x
42 Nm
2x
85 Nm
Buffer plate
─
Self-locking nut M10
─
From size 160: Plastic washers
─
4x per buffer plate
─
6 Nm
Maintenance
ABUS Service
Crane travel drive AZP 4.11 ABUS Service
Only in Germany
If available, have the product number, serial number and customer number handy.
Call the ABUS Service Centre:
Size
Type, size and length
Number
Tightening torque
─
130
Rib screw M8x20
4x
35 Nm
160
Rib screw M10x25
4x
75 Nm
200
Rib screw M12x30
4x
115 Nm
280
Rib screw M16x40
4x
300 Nm
Phone: +49-2261-37-237 If calling outside the usual business hours, leave a message on the answering machine.
●
ABUS Service will return your call promptly.
If necessary, send a problem description by fax or e-mail:
─
Fax: +49-2261-37-265
─
E-mail: [email protected]
Crane travel drive AZF Only outside Germany
Call the local ABUS branch or crane service partner.
Tightening torque
Number
Type, size and length
Size
Your local ABUS branch or crane service partner will provide details of contact data, contacts and availability.
350
Fillister-head 4x screw M12x100
85 Nm
420 with crane travel drive 420
Fillister-head 4x screw M12x100
85 Nm
420 with crane travel drive 420 V (adapter required)
Fillister-head 4x screw M16x140
210 Nm
Page 45
Maintenance
Lubricants
4.12 Lubricants
Only with AZF and AZF V drives Gearing on the output shaft on the drive gear unit, pins on the gear unit
Note: Synthetic lubricants may not be mixed with mineralbased lubricants!
Only with AZP drives Gearing on the output shaft on the gear unit of the drive
Lubrication ex works with Moly Paul “PBC” AN 6758.
Lubrication ex works with Moly Paul “PBC” AN 6758.
Quantity: Apply lubricant with brush to coat surface completely.
Lubricate the gearing on the output shaft:
Quantity: Apply lubricant with brush to coat surface completely.
Lubricate pins:
─
When the gear unit is disassembled and reassembled
Lubricate the gearing on the output shaft:
─
When the drive is disassembled and reassembled
─
When the drive is disassembled and reassembled
─
After 10 years
─
After 10 years
─
When carrying out a general overhaul.
─
When carrying out a general overhaul
Page 46
AN 120139EN006
2016-03-17
Kransysteme
Product Manual AZP and E drive Drive for crane or trolley
110-034551 Serial number
250-068733
ABUS Kransysteme GmbH Sonnenweg 1 51647 Gummersbach Germany Tel. +49-2261-37-0 Fax. +49-2261-37-247 [email protected]
Distribution or reproduction of this document, or the utilisation and disclosure of its contents without explicit approval is prohibited. Violations will incur liability for damage compensation. All rights are reserved in regard to patent issuance or registered designs.
Installing the drive
(page 8)
Connecting the drive to an ABUS crane
(page 9)
Overview
(page 14)
Checking the air gap and brake lining thickness
(page 16)
Setting the air gap on the brake
(page 19)
Replacing the brake lining and anchor plate
(page 20)
AN 120009EN001
2013-12-18
Original operating instructions
Drive: various types and sizes This product manual applies to drives of various types and sizes. The work steps described and the technical data will vary according to the type and size of the drive. The areas of this product manual which do not apply to all drives, but are applicable only under certain conditions, are enclosed in a dashed box. At the start of the box, the types and sizes to which the section is applicable are specified.
Type and size
AZP drive AZP drive AZP for single girder travelling cranes and for double-rail trolleys (types D, DA, double girder travelling cranes DQA, Z and ZA) and side-mounted trolleys (type S) Size = wheel diameter 130, 160, 200, 280 Size = wheel diameter 130, 160, 200, 280
E drive for single-rail trolleys (type E) and lower flange trolleys (type U) Size = wheel diameter 100, 130, 160, 200
Contents
Contents 3.1 At the start .............................................. 15
1. GENERAL INFORMATION..................... 4
3.2 Scope of the inspection .......................... 16
1.1 At the start ................................................ 4
3.3 Checking the air gap and brake lining thickness ................................................ 16
1.2 Instructions regarding safety .................... 5 3.4 Checking the O-ring................................ 17 1.3 The drive .................................................. 5 1.4 Loading and unloading the drive............... 6
4. MAINTENANCE ............................... 18
1.5 Disposing of the drive ............................... 7
4.1 Instructions regarding safety when performing maintenance work ................ 18
2. INSTALLING AND CONNECTING ............ 8
4.2 Setting the air gap on the brake ............. 19
2.1 Installing the drive..................................... 8
4.3 Replacing the brake lining and anchor plate........................................................ 20
2.2 Connecting the drive to an ABUS crane ........................................................ 9
4.4 ABUS Service ......................................... 23
2.3 Connecting the drive to a non-ABUS crane ...................................................... 11
4.5 Lubricants ............................................... 23
2.4 Overview of tightening torques ............... 14
3. INSPECTION .................................... 15
Page 3
At the start
General information
1. General information This section applies to anyone who works with the drive, on the drive or nearby.
1.1 At the start
Instructions for the product manual
Using this product manual
Read the product manual through carefully before beginning work. Also be sure to observe additional product manuals for accessories and components.
The following symbols are used in this product manual:
Afterwards, keep the product manual available in the vicinity of the crane. It must be accessible to all who work with or on the crane.
Danger to persons! This warning notice indicates hazards for persons and provides instructions for avoiding these hazards.
Danger from electric shock! This warning notice indicates hazards for persons due to incorrect handling of the electrical system and electricity.
Danger from falling suspended load! This warning notice describes hazardous situations that can lead to the suspended load falling.
─
This is an instruction regarding an action and prompts you to perform a work step. This is the result of an action and describes what happens on the device. This is a list.
Only with... A section enclosed in a dashed box is only applicable for certain types, versions or options. Which type, version or option this is can be seen in the first line. You can find out whether or not the section is applicable for your crane by referring to the section “Various types, sizes, versions and options” at the beginning of this manual.
Page 4
In the case of reselling or hiring out, always provide the product manual together with the crane.
Proper use The AZP drive is planned as a crane travel drive (up to a wheel diameter of 280 mm) or as a trolley drive on a double-rail trolley (types D, DA, DQA, Z and ZA) or as a trolley drive on a side-mounted trolley (type S). The E drive is planned as a trolley drive on a singlerail trolley (type E) or as a trolley drive on a lower flange trolley (type U). The output shaft of the drive is connected directly with the wheels. ─
The drive control can be connected polechangeable with two different travel speeds, with a defined speed or infinitely variable with a frequency converter.
─
The drive can be used as a drive in other machines within its electrical and mechanical performance limits.
─
The drive cannot be operated in a delta connection.
Instructions regarding safety
General information
Regulations The installation has been built and tested according to European standards, rules and regulations applicable at the time of its manufacture. The conventions applied during design and construction are specified in the Declaration of Conformity or the Declaration of Incorporation. The conventions must also be observed for installation, operation, inspection and maintenance, as must the applicable occupational health and safety regulations.
Danger to persons! Non-observance of the regulations can result in the death of persons or serious accidents. To ensure work safety, thorough instruction in regard to this product manual and the regulations is necessary.
Which provision applies in individual cases will greatly depend on the crane’s use and the national regulations. Review and observe all applicable and current regulations, including the occupational health and safety regulations. Refer also to the Declaration of Conformity or Declaration of Incorporation.
1.2 Instructions regarding safety Observe these instructions for safe handling of the crane. Special hazard notices are located in the corresponding sections in which the danger arises.
─
Danger through rotating parts! If a drive is not mounted, the output shaft is not protected. If the non-mounted drive is operated, the output shaft is a source of danger (e.g. it can become caught in loose parts). Do not operate the drive if it is not mounted or take suitable measures to ensure safety.
─
Do not permanently remove the fan cover! If the fan cover is removed, hazardous areas (fast-rotating fan blades) are no longer protected. As a result of this people can be injured! Remount the fan cover after working on the drive. Do not permanently remove the fan cover to improve cooling.
1.3 The drive Description of the device 1
Warranty ─
ABUS assumes no liability for damages that were caused by improper use, inadequately trained personnel, incorrect performance of work, as well as any changes, reconstruction or other modification of the crane or crane components which was not approved by ABUS.
─
Any warranty claim becomes invalid if components were modified without consent, the crane or crane components were installed, used or serviced in any way other than that described in this product manual, or if parts other than original ABUS replacement parts were used.
─
Safe operation of the crane or crane components is only guaranteed if original ABUS replacement parts are used.
2
3
5
─
1: Fan cover
─
2: Connector housing
─
3: Output shaft with gearing
─
4: Gear unit
─
5: Motor
4
Page 5
Loading and unloading the drive
General information
Performance features The AZP and E drives: ─
The drives are designed as pole-variable rotary current motors with electromagnetic brakes and gear units.
─
The drives have a low and a high speed. The ratio of the two speeds is 1:4.
─
The drives have a modular construction of motor and gear unit to enable easy replacement.
─
Using plug-in connections in the connector housing directly on the drive, the drives can be quickly separated from the rest of the crane’s electrics.
─
The drive's gear unit is a maintenance-free, two-stage or three-stage planetary gear.
─
Two drives are used for crane travel on a crane. One or two drives are used for trolley travel on a trolley.
─
1.4 Loading and unloading the drive Observe the following points amongst others:
Only with AZP 130 and 160 drives and E 100, 130, 160 and 200 drives No eyebolts can be screwed into the drive.
Sling the drive in suitable lifting tackle (e.g. round slings).
Only with AZP 200 and 280 drives
The crane can also be equipped with four crane drives (4-wheel crane travel drive, allwheel. Optional). This is required whenever the crane travel drive needs to be particularly sturdy (e.g. for operation outdoors with a headwind, or travelling through curtains)
Lifting tackle
Technical data See the “Technical data” of the respective drive.
Page 6
Eyebolt Drive Screw suitable eyebolt into the drive. Sling suitable lifting tackle into the eyebolt. The drive will not be suspended horizontally depending on the motor.
General information
Disposing of the drive
1.5 Disposing of the drive If the drive must be disposed of:
Dismantle the drive as far as possible.
Dispose of the individual parts sorted by material in an environmentally sound manner.
─
Observe local regulations concerning disposal and recycling.
Dispose of metal parts as scrap metal. The motor stator is permanently shrunk into the housing. Cut the housing open to separate the stator from the housing.
─
Plastic parts should be recycled with plastic waste.
─
Dispose of brake linings as multiple components (hazardous waste).
─
Remove oil or grease from the drive and dispose of as a lubricant.
─
Dispose of cables and plug-in connections as scrap electronic parts.
Page 7
Installing the drive
Installing and connecting
2. Installing and connecting This section applies to anyone who works on the drive prior to its use
To install, perform the described points here in the sequence given.
2.1 Installing the drive The end user of the crane is responsible for the proper qualifications of the commissioning personnel.
Danger to persons! Persons can be injured if the crane is incorrectly put into operation. If personnel other than that of the ABUS company are employed to perform the commissioning, it is the end user’s responsibility to ensure that these persons are adequately qualified. Follow the procedures described here precisely.
The images show the installation of an AZP drive on a crane. There is no major difference between the installation of an AZP drive on a double-rail trolley or side-mounted trolley or an E drive on a single-rail trolley or lower flange trolley.
Only for a drive which is installed on an ABUS crane
Determine the weight of the drive. See the “Technical data” section “Dimensions and weights”.
Secure the drive in such a way that the weight can be held safely and the output shaft is not stressed during installation (e.g. fasten in a carrying strap).
Lubricate the gearing on the output shaft. Apply lubricant with brush to coat surface completely.
Examples of qualified persons: ─
Persons with comprehensive knowledge from specialist training in engineering and in the electrical systems of cranes.
─
Persons with sufficient experience in the operation, installation and maintenance of cranes.
─
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country.
─
Persons receiving regular training from ABUS.
ABUS assumes no liability for damage due to incorrectly performed commissioning work done by unqualified personnel. ABUS recommends having the commissioning work performed by the ABUS assembly team.
Page 8
Recommendation: Moly Paul “PBC” AN 6758.
Connecting the drive to an ABUS crane
Installing and connecting
Rib screws
2.2 Connecting the drive to an ABUS crane Opening the connector housing
Take out the intermediate plate.
Laying the connection cable
Bolt on the drive with the rib screws (4x).
130
AZP
M8x20
35 Nm
160
AZP
M10x25
75 Nm
200
AZP
M12x30
115 Nm
280
AZP
M16x40
300 Nm
Tightening torque
Tightening torque
Type
Type
Drive
Wheel Ø Drive
Wheel diameter
Drive Push the drive in the wheel.
Open the housing cover.
100
E
M8x20
35 Nm
130
E
M8x20
35 Nm
160
E
M8x20
35 Nm
200
E
M10x25 75 Nm
Connection cable
Connector housing
Drive
Lay the connection cable for the drive. Lay the connection cable in the connector housing.
Page 9
Connecting the drive to an ABUS crane
Connecting the drive
Installing and connecting
Only with frequency converter
Only with contactor control Connection cable of drive
Bush multipoint Pin multipoint connector for drive connector on the drive
Pin multipoint connector of drive
Bush multipoint Pin multipoint connector for drive connector on the drive Insert the bush multipoint connector for the drive on the pin multipoint connector on the drive.
Insert the bush multipoint connector for the brake on the pin multipoint connector on the drive.
Rectifier for brake
Pin multipoint connector of drive Insert the connection cable for the drive in the pin multipoint connector on the drive.
Insert the rectifier for the brake in the pin multipoint connector on the drive.
Lay the plug-in connections and connection cable in the connector housing.
Cable lug for shield
Insert the cable shoe for the shield on the drive.
Lay the plug-in connections and connection cable in the connector housing.
Intermediate plate
Page 10
Press the intermediate plate in. Close the housing cover.
Connecting the drive to a non-ABUS crane
Installing and connecting
Low and high speed:
2.3 Connecting the drive to a nonABUS crane
─
The drive is connected in the connector housing on the drive using a plug-in connection. The plug-in connection is available as a set, AN 105581.
─
When connecting, ensure that the rectifier for the brake is provided with alternating current in the connector housing with the drive switched on. This will require a jumper in the circuitry.
─
The drive can be connected three ways: pole-changeable (high and low speeds), with only one of the two speeds, and through a frequency converter.
─
The drive cannot be operated in a delta connection.
─
Heed the duty cycle of the drives for high and low travel speed.
M61: Crane drive 1, M62: Crane drive 2, V61 and V62: Rectifier, U61: Smooth switching relay, K63: Contactor for high speed, K62: Contactor for crane travel forward, K61: Contactor for crane travel backward
Connect the protective conductors to both drives.
Connect contacts 1, 2 and 3 for low speed. Connect contacts 4, 5 and 6 for high speed. When switching from low to high speed (contactor K63) plan a delay of 0.5 seconds in the circuit. The delay avoids the drive running in a starting current for a longer period in inching mode (rapid switching back and forth). This would eventually damage the motor.
Page 11
Connecting the drive to a non-ABUS crane
To prevent excessive fluctuation of the load during braking from high speed to low speed, plan the SU1 device. When braking from the high to low speed, for a short period only two of the three phases of the drive are switched to the low speed. In doing so, the drive does not jerk to a halt but brakes softly.
When high speed is switched (contactor K 63 switched) always switch a single phase of the low speed as well (contact 1). Otherwise there will be no voltage between the star points of the high speed and the low speed and the brake will not be aerated.
When low speed is switched (contactor K 63 not switched) always switch a single phase of the high speed as well (contact 6). Otherwise there will be no voltage between the star points of the high speed and the low speed and the brake will not be aerated.
Installing and connecting High speed only:
M61: Crane drive 1, M62: Crane drive 2, V61 and V62: Rectifier, K62: Contactor for crane travel forward, K61: Contactor for crane travel backward
Page 12
Connect the protective conductors to both drives.
Connect contacts 4, 5 and 6 for high speed.
When switching the drive to high speed (from standstill), allow the drive to run at low speed for 0.5 seconds first. The dlay avoids the drive running in a starting current for a longer period during switch-on. This would eventually damage the drive.
When high speed only is switched, always switch a single phase of the low speed as well (contact 1). Otherwise there will be no voltage between the star points of the high speed and the low speed and the brake will not be aerated.
Connecting the drive to a non-ABUS crane
Installing and connecting
Frequency converter: Low speed only:
Connect the protective conductors to both drives.
Connect contacts 1, 2 and 3 for low speed. When low speed only is switched, always switch a single phase of the high speed as well (contact 6). Otherwise there will be no voltage between the star points of the high speed and the low speed and the brake will not be aerated.
M61: Crane drive 1, M62: Crane drive 2, V61: Rectifier, U61: Frequency converter
Connect the shields for the connection cables to the protective conductor on the drive. Only use shielded connection cables for the drives.
Connect the protective conductors to both drives.
Connect contacts 4, 5 and 6. Connect contacts 7 and 8 for the brake control. The electrical circuit must be open at a frequency of 0 Hz. Brake performance data: 195 Volt DC, 50 Watt.
Page 13
Overview of tightening torques
Installing and connecting
E drive 2.4 Overview of tightening torques
35 Nm
160
Rib screw M10x25
4x
75 Nm
200
Rib screw M12x30
4x
115 Nm
280
Rib screw M16x40
4x
300 Nm
Page 14
Tightening torque
Tightening torque
4x
Number
Number
Rib screw M8x20
Type, size and length
Type, size and length
130
Size
Size
AZP drive
100
Rib screw M8x20
4x
35 Nm
130
Rib screw M8x20
4x
35 Nm
160
Rib screw M8x20
4x
35 Nm
200
Rib screw M10x25
4x
75 Nm
At the start
Inspection
3. Inspection Concerns anyone who inspects and accepts the drive in accordance with occupational health and safety requirements.
The drive must be regularly inspected in order to guarantee safe operation. The end user is responsible for this regular inspection.
3.1 At the start
Requirements for the examiner The end user of the crane is responsible for the proper qualifications of the examiner.
Danger to persons! Persons can be injured if the inspection is performed incorrectly.
Test intervals The regular inspection is performed at least once annually.
If personnel other than that of the ABUS company are employed to perform the inspection, it is the end user's responsibility to ensure that these persons are adequately qualified.
Under certain conditions, more frequent regular inspections may be necessary. Reasons include: ─
Frequent operation at the load capacity
─
Working in multiple shifts
─
Frequent use
─
Dusty or chemically aggressive environment
The end user is responsible for checking the prerequisites and determining the test intervals. ABUS will gladly assist you if questions arise.
Examples of qualified persons: ─
Persons with comprehensive knowledge from specialist training in engineering and in the electrical systems of cranes.
─
Persons with sufficient experience in the operation, installation and maintenance of cranes.
─
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country.
─
Persons receiving regular training from ABUS.
Page 15
Scope of the inspection
3.2 Scope of the inspection
The qualified person inspecting the drive is responsible for the type and scope of the test.
Overview: Inspecting the drive In addition to the points described here, all points outlined in the other supplied product manuals must also be checked. The decision as to whether the drive is in perfect condition may be made only by the person inspecting the crane. Any inadequacies, if found, must be eliminated. The examiner decides whether the drive has to be tested again afterward.
Inspection
3.3 Checking the air gap and brake lining thickness
Overview: Dimension
Value
Reference gap between anchor plate and brake bearing shield
Between 3.1 mm and 3.7 mm
Brake lining thickness
At least 2 mm
Brake lining thickness
New: 4 mm
If locally applicable regulations specify further tests, these are likewise to be carried out.
Additionally, at least the following points must be checked:
Check the air gap and the brake lining thickness. See “Checking the air gap and brake lining thickness” page 16.
Check the O-ring. See “Checking the O-ring” page 17.
Fan cover Take off fan cover.
The air gap can only be accessed with difficulty. Therefore, a reference gap is measured outside on the motor in order to obtain information on the width of the air gap.
Page 16
Checking the O-ring
Inspection
Measuring the reference gap 3.4 Checking the O-ring The area between the brake bearing shield and the anchor plate (reference gap) is protected from dust by an O-ring. The O-ring must not become damaged or missing. Anchor plate
Brake bearing shield
Reference gap Measure the distance between brake bearing shield and anchor plate. If the reference gap is larger than 3.7 mm: adjust the brake. See “Setting the air gap on the brake”, page 19. The brake may be readjusted twice. After that, the brake lining must be replaced. See “Replacing the brake lining and anchor plate”, page 20.
O-ring
Check the O-ring (between brake bearing shield and anchor plate). The O-ring must not be torn, dented or damaged in any other way or be missing completely.
Measuring brake lining thickness
If the O-ring is damaged or missing, fit a new O-ring. See “Replacing the O-ring, plate springs, compression springs and feather key” page 20.
Brake lining
Check the thickness of the brake lining with a calliper.
If the brake lining is less than 2 mm thick, replace it. See “Replacing the brake lining and anchor plate”, page 20.
Page 17
Instructions regarding safety when performing maintenance work
Maintenance
4. Maintenance Concerns anyone who maintains, repairs or modifies the drive.
The end user of the crane is responsible for the selection and proper qualifications of the maintenance personnel.
Danger to persons! Persons can be injured if the crane is incorrectly serviced. If personnel other than that of the ABUS company are employed to perform maintenance on the crane, it is the end user's responsibility to ensure that these persons are adequately qualified. Follow the procedures described here precisely.
Examples of qualified persons: ─
Persons with comprehensive knowledge from specialist training in engineering and in the electrical systems of cranes.
─
Persons with sufficient experience in the operation, installation and maintenance of cranes.
─
Persons with comprehensive knowledge regarding the relevant technical rules, directives and safety regulations applicable in the respective country.
─
Persons receiving regular training from ABUS.
ABUS assumes no liability for damage due to incorrectly performed maintenance work done by unqualified personnel. ABUS recommends having the maintenance work performed by ABUS Service. Use only original ABUS replacement parts. Otherwise, all warranty claims will be rendered invalid.
Page 18
4.1 Instructions regarding safety when performing maintenance work
Please follow the following safety instructions during all repair work on the drive:
─
Switch off the mains switch. Secure the switch so that it cannot be unintentionally switched back on.
─
Pull the mains disconnector plug out of the socket on the crane panel. Secure the socket with a padlock so that the mains disconnector plug is not unintentionally reinserted.
─
Use suitable lifting platforms and fall protection equipment.
─
Adequately cordon off the work area around the lifting platform.
─
Switch off any other cranes using the same crane track or cranes working above or below the crane being serviced. Secure the switch so that it cannot be unintentionally switched back on. Otherwise, other cranes could overturn the hoisting platform or crash into the crane that is being serviced.
─
Notify personnel in the area that maintenance work will be performed.
─
Only trained electricians should work on the crane electrical system!
─
Even after the emergency stop button has been pressed, life-threatening high voltages are still present in the panels.
These safety instructions apply especially to the drive: ─
Do not permanently remove the fan cover! If the fan cover is removed, hazardous areas (fast-rotating fan blades) are no longer protected. As a result of this people can be injured! Remount the fan cover after working on the drive. Do not permanently remove the fan cover to improve cooling.
Setting the air gap on the brake
Maintenance
4.2 Setting the air gap on the brake
If the air gap is narrower than permitted, it must be readjusted. The air gap may be readjusted maximally twice. After that, the brake lining must be replaced. See “Replacing the brake lining and anchor plate”, page 20.
Overview: Dimension
The self-locking nut is now released in order to optimally adjust the air gap of the brake. The releasing of the self-locking nut is oriented to the individual segments of the fan blade.
Value
Reference gap between Between 3.1 mm and brake bearing shield and 3.7 mm anchor plate. Air gap
Setting 0.4 mm
Setting the air gap
Hold the fan blade firmly and release the self-locking nut by the amount of two and one half segments of the fan blade. The air gap is now set to the optimal width of 0.4 mm. To make sure, check that the distance between the brake bearing shield and the anchor plate (reference gap) is between 3.1 mm and 3.7 mm. See “Checking the air gap and brake lining thickness”, page 16.
Close motor
Nut
Hold the fan blade firmly and screw the selflocking nut until hand-tight. The fan blade should just be tight enough that it almost cannot be turned. The air gap is now set to 0 mm. This serves as the starting point for the following setting. Fan cover
Attach fan cover.
Page 19
Replacing the brake lining and anchor plate
4.3 Replacing the brake lining and anchor plate
Maintenance
Removing the anchor plate When replacing the brake lining, it is useful to replace the anchor plate as well. If the anchor plate is not to be replaced, this section may be skipped.
If the brake lining is thinner than permitted, it must be replaced. The brake lining must also be replaced if the air gap has already been readjusted twice. When replacing the brake lining, it is recommended that the anchor plate be replaced as well.
Anchor plate
Removing the old brake lining Fan blade with brake lining
Collar screws
Self-locking nut
Hold the fan blade firmly and unscrew the self-locking nut.
Remove the fan blade with brake lining.
Screw the collar screws (2x) out.
Remove the anchor plate. Ensure that the compression springs do not fall out.
The anchor plate is pressed away from the motor. It is tensioned by a spring.
Replacing the O-ring, plate springs, compression springs and feather key If the O-ring, plate springs, compression springs or the feather key are missing or damaged, they must be replaced. If the components are in a good condition, this section may be skipped. Plate springs
Page 20
Assemble the plate springs as shown in the illustration.
Replacing the brake lining and anchor plate
Maintenance
Feather key
Plate springs
Installing the anchor plate
Tighten the collar screws (2x). 5 - 7 Nm. Secure with thread-locking compound (medium tightness).
Place the O-ring into the groove on the brake bearing shield.
Number of compression springs
Insert the compression springs. Power (see type plate)
Insert the feather key.
Type & size
O-ring Compression springs Push the plate springs onto the motor shaft.
Compression springs Insert new anchor plate and press it against the compression springs.
E 100
0.12 kW
4
E 130 / AZP 130
0.18 kW
4
E 160 / AZP 130
0.28 kW
6
AZP 130
0.37 kW
8
E 200 / AZP 160
0.48 kW
4
AZP 200 / AZP 280
0.65 kW
4
AZP 200 / AZP 280
0.80 kW
6
AZP 280
1.10 kW
8
Page 21
Replacing the brake lining and anchor plate
Maintenance
Installing a new brake lining Fan blade with brake lining
Motor shaft Slide the new fan blade with brake lining onto the motor shaft.
Screw the new self-locking nut loosely to the motor shaft.
Hold the fan blade firmly and release the self-locking nut by the amount of two and one half segments of the fan blade. The air gap is now set to the optimal width of 0.4 mm. To make sure, check that the distance between the brake bearing shield and the anchor plate (reference gap) is between 3.1 mm and 3.7 mm. See “Checking the air gap and brake lining thickness” page 16.
Do not use the old self-locking nut.
Closing the motor Setting the air gap
Fan cover
Nut Hold the fan blade firmly and screw the selflocking nut until hand-tight. The fan blade should just be tight enough that it almost cannot be turned. The air gap is now set to 0 mm. This serves as the starting point for the following setting.
The self-locking nut is now released in order to optimally adjust the air gap of the brake. The releasing of the self-locking nut is oriented to the individual segments of the fan blade.
Page 22
Attach fan cover.
ABUS Service
Maintenance
4.4 ABUS Service
4.5 Lubricants
Only in Germany
Gear unit in drives E 100, E 130, E 160, E 200, AZP 130, AZP 160, AZP 200, AZP 280
If available, have the product number, serial number and customer number handy.
Call the ABUS Service Centre:
─
Phone: +49-2261-37-237 If calling outside the usual business hours, leave a message on the answering machine. ABUS Service will return your call promptly.
If necessary, send a problem description by fax or e-mail:
─
Fax: +49-2261-37-265
─
E-mail: [email protected]
Only outside Germany
Call the local ABUS branch or crane service partner. Your local ABUS branch or crane service partner will provide details of contact data, contacts and availability.
Lubrication ex works with Klüber “Centoplex CX 4/375”
Quantity E 100: 40 g Quantity E 130: 50 g Quantity E 160: 50 g Quantity E 200: 90 g Quantity AZP 130: 50 g Quantity AZP 160: 90 g Quantity AZP 200: 160 g Quantity AZP 280 (gear ratio 125): 240 g Quantity AZP 280 (gear ratio less than 125): 160 g
The gear unit in the drive is lubricated for its entire service life. At the end of its service life (in a general overhaul), assess whether the lubricant needs to be changed.
Page 23
Lubricants
Gearing on the output shaft
Lubrication ex works with Moly Paul “PBC” AN 6758.
Quantity: Apply lubricant with brush to coat surface completely.
Lubricate the gearing on the output shaft:
─
When the drive is disassembled and reassembled
─
After 10 years
─
When carrying out a general overhaul
Page 24
Maintenance
AN 120009EN001
2013-12-18
Kransysteme
Technical data for
ABUS – Travelling crane
with wheel diameter
- 160
110-034551
Factory No. ___________________
Manufacturer ABUS Kransysteme GmbH Sonnenweg 1 D – 51647 Gummersbach
Tel. ##49 2261 / 37–0 Fax. ##49 2261 / 37247 info@abus- kransysteme.de
This document may not be reproduced or given to third parties and its content must not be divulged or used for other purposes without the prior written permission of ABUS. You will be liable to pay compensation for any breach of this provision. All patent and registered design rights reserved.
These installation, operation and maintenance instructions are intended for use in an Englishspeaking country by English–speaking specialist personnel. AN 120069.002_EN
31.10.2016
Original operating manual
Contents 1
Technical Data . . . . . . . . . . . .
3
1.1
Tightening torque . . . . . . . . . . . . . . . .
3
1.2
Sound Emissions . . . . . . . . . . . . . . . . .
4
1.3
Lubricants . . . . . . . . . . . . . . . . . . . . . . .
4
AN120069.002_EN
1.3.1
Lubricants Used in Crane Travel Drives . . . . . . . . . . . . . . .
4
1.3.2
Alternative Lubricants . . . . . . . . . . . . .
4
1.4
Electrical Data of Motors . . . . . . . . . .
5
1.5
Weights and Dimensions . . . . . . . . . .
6
Page 2
1
1.1
Technical Data
Tightening torque
120 Nm
80 Nm
450 Nm 50 Nm
36 Nm
75 Nm
42 Nm2)
25 Nm Fig. 1
AN120069.002_EN
Page 3
1.2
Sound Emissions
As the distance between the noise source and the workplace is normally not fixed in the case of cranes, the sound power level is quoted in addition to the required sound pressure level figure (given for a distance of 3 m in this case). The sound power level may be used to calculate the sound pressure level at any distance (under free field conditions). Travel drive Type
Sound pressure level LP,m dB (A) at 3 m
Sound power level LW,m dB (A)
AZP 160
60
77
The measurements made were based on DIN 45635, Part 61 and were made by the substitution method using a sound power source. The values given only apply to the crane travel drives. The values which apply to the hoist are given in the application operating instructions.
1.3
Lubricants
1.3.1
Lubricants Used in Crane Travel Drives
All ball bearings are permanently lubricated. All gearboxes have been filled with the required amount of lubricant at the factory. Travel drive
Lubricants ex works
Quantity [litres]
AZP 160
Klüber Centoplex CX 4 / 375
0.10
The pinion connecting the motor shaft to the wheel has been lubricated with Moly-Paul PBC grease at the factory.
1.3.2
Alternative Lubricants
for Moly-Paul grease PBC D DEA Glissando M EP 2 D Klüber Klüberpaste 46 MR 401 D Moly-Cote DX D Shell Retinax LX2 D or equivalent greases of other brands with the designation GP 00 K-45 in accordance with DIN 51502. for Klüber Centoplex CX4 / 375 D BP Energrease CS 0 D DEA Glissando EP 0 D Shell Alvania EP (LF) 1 D or equivalent greases of other brands with the designation KOK-35 or GOK-35 in accordance with DIN 51502. Caution ! Synthetic oils must not be mixed with mineralbased oils.
Page 4
Data : 31.10.2016
1.4
Electrical Data of Motors
The serial number of your crane drive motor is given in the travelling crane data sheet in the test book.
AZP 160 Operating voltage Frequency Duty cycle FEM
V Hz %
220-240 50 40
380-415 50 40
460-500 50 40
208-230 60 40
440-480 60 40
Travel speed m/min Part number AN Operating frequenzy FEM c/h Motor rating kW Motor speed 1/min Starting current A Rated current A Power factor - starting Power factor - norm. operation
5/20 313818 240 0.10/0.48 550/2760 0,92/5,90 0,53/1,59 0,71/0,91 0,66/0,80
6/24 313818 240 0.12/0.58 735/3370 0.96/6.50 0.54/1.63 0.64/0.88 0.65/0.83
Travel speed m/min Part number AN Operating frequenzy FEM c/h Motor rating kW Motor speed 1/min Starting current A Rated current A Power factor - starting Power factor - norm. operation
7,5/30 313819 240 0.10/0.48 550/2760 0,92/5,90 0,53/1,59 0,71/0,91 0,66/0,80
9/36 313819 240 0.12/0.58 735/3370 0.96/6.50 0.54/1.63 0.64/0.88 0.65/0.83
Travel speed m/min Part number AN Operating frequenzy FEM c/h Motor rating kW Motor speed 1/min Starting current A Rated current A Power factor - starting Power factor - norm. operation
10/40 313820 240 0.10/0.48 550/2760 0,92/5,90 0,53/1,59 0,71/0,91 0,66/0,80
12/48 313820 240 0.12/0.58 735/3370 0.96/6.50 0.54/1.63 0.64/0.88 0.65/0.83
Travel speed m/min Part number AN Operating frequenzy FEM c/h Motor rating kW Motor speed 1/min Starting current A Rated current A Power factor - starting Power factor - norm. operation
12,5/50 313821 180 0.10/0.48 550/2760 0,92/5,90 0,53/1,59 0,71/0,91 0,66/0,80
15/60 313821 180 0.12/0.58 750/3370 0.96/6.50 0.54/1.63 0.64/0.88 0.65/0.83
AN120069.002_EN
550-600 60 40
Page 5
AZP 160 Operating voltage Frequency Duty cycle FEM
V Hz %
220-240 50 40
Travel speed m/min Part number AN Operating frequenzy FEM c/h Motor rating kW Motor speed 1/min Starting current A Rated current A Power factor - starting Power factor - norm. operation
1.5
Weights and Dimensions
380-415 50 40
208-230 60 40
440-480 60 40
550-600 60 40
15/60 314280 150 0.10/0.48 550/2760 0,92/5,90 0,53/1,59 0,71/0,91 0,66/0,80
The weights, dimensions, etc. of the travelling crane and the load data for the crane track are given in the data sheet and the corresponding diagram in the test book. The weights of crane travel motors are given in the following table:
Page 6
460-500 50 40
Travel drive Type
Weight [kg]
AZP 160
30
Data : 31.10.2016
Kransysteme
Installation Instructions for
E
DQA
D
Z
S
U
ABUS – Wire rope hoist
Model
-E
-Z
-D
-S
- DQA
-U
250-068733
Serial No. __________________
Manufacturer ABUS Kransysteme GmbH Sonnenweg 1 D – 51647 Gummersbach
Tel. ##49 2261 / 37–0 Fax. ##49 2261 / 37247 [email protected]
This document may not be reproduced or given to third parties and its content must not be divulged or used for other purposes without the prior written permission of ABUS. You will be liable to pay compensation for any breach of this provision. All patent and registered design rights reserved.
These installation, operation and maintenance instructions are intended for use in an Englishspeaking country by English–speaking specialist personnel. AN 120055.002_EN / A 766.EN
30.03.2012
Original operating manual
Explanations concerning type designationas GM 2000.6300 H – 20 1. 4 1. 6000.3. E 160.20 travel speed (m/min) track wheel diameter (mm) trolley type: E; D, DQA, DB; Z, ZB; S; U model generation hook path (m) strands under tension load strands motive power unit group rope speed (m/min) type of motor load capacity (kg) model size line of products
Page 2
Data : 30.03.2012
Contents 1
Description . . . . . . . . . . . . . . .
4
1.2
Electrical equipment . . . . . . . . . . . . . .
5
1.1
Components . . . . . . . . . . . . . . . . . . . . .
4
1.2.1
Wire rope hoist . . . . . . . . . . . . . . . . . . .
5
1.1.1
Trolley frame . . . . . . . . . . . . . . . . . . . . .
4
1.2.2
Solo–trolleys (not for size GM 7000)
5
1.1.2
Hoist motor with brake . . . . . . . . . . . .
4
1.1.3
Hoisting gear . . . . . . . . . . . . . . . . . . . .
4
1.1.4
Rope drive . . . . . . . . . . . . . . . . . . . . . . .
4
2
Assembly . . . . . . . . . . . . . . . . .
8
1.1.5
Limit of lift . . . . . . . . . . . . . . . . . . . . . . .
5
2.1
Assembly Instructions . . . . . . . . . . . . .
8
1.1.6
Overload protection type . . . . . . . . . .
5
2.1.1
Mechanical installation . . . . . . . . . . . .
8
1.1.7
Trolley travelling gear . . . . . . . . . . . . .
5
2.1.2
Electrical installation . . . . . . . . . . . . . .
11
AN 120055.002_EN / A 766.EN
Page 3
1
1.1 1.1.1
Description Components
Trolley frame
1.1.1.1 Model E ABUS Series E electric wire rope hoists are equipped with a trolley frame made from welded steel sheets with an integrated counterweight. The track width can be adapted to all normal section girders or steel sheet widths. 1.1.1.2 Model D, DQA and Z ABUS Series D, DB and DQA electric wire rope hoists are equipped with a trolley frame made from welded steel sections or sheets. The connection between the main girder and the trolley track girder is jointed to ensure that all four wheels are evenly loaded when the hoist is not loaded. 1.1.1.3 Model S ABUS Series S electric wire rope hoists are equipped with a trolley frame made from welded steel sections or sheets. The track width can be adapted to normal steel sheet widths. 1.1.1.4 Model U ABUS Series U electric wire rope hoists are equipped with a trolley frame made from welded steel sections or sheets.
(2)
Washer HV 21 Material C 45 DIN 6916 (3) Hexagon nut M 20 Material 10 DIN 6915 (4) Connection plate Ultra sonical S 235 JRG2 DIN EN 10025 Note: Only bare, non-galvanized bolts may be used. Position the main and trolley track girders with the holes matching and insert the high-strength connection bolts (1) (M20, material 10.9) through the hand holes into the trolley track girders. The washers (2) under the bolt head and the nut are essential for effective joints. Tighten the nuts (3) from the outside using a torque wrench. The torque required for the M20 bolts is 554 Nm. The bolts must not be tightened using power drills and the ”angle of rotation” method must not be used. After they have been tightened using the correct torque value, the main girder connection bolts may be loosened and tightened again in the course of assembly. However, if the crane is dismantled after some time in service, new bolts of the same quality must be used when it is reassembled; the old bolts must be scrapped. In the case of larger bolt patterns, the bolts must be tightened alternately up to about 60 % of the specified torque value and then tightened to the full value in a second step. The screws at the ends of the connection assembly must be tightened to the full torque last.
1.1.2
Hoist motor with brake
1.1.1.5 Model GM 7000 ABUS Series D, DB, DQA, Z and ZB electric wire rope hoists are equipped with a trolley frame made from welded steel sections or sheets. The connection between the main girder and the trolley track girder is jointed to ensure that all four wheels are evenly loaded when the hoist is not loaded.
The hoisting gear is driven by a 12 pole, dual speed squirrel cage motor with integral D.C. restified magnetic disc brake. Insulation class F, protection type IP 55. Due to the pole changing there is a standard precision hoisting speed in the ratio of approx. 1:6 or approx. 1:10 to the main hoisting speed. The asbestos–free brake lining achieves a service life of approx. 1x106 shiftings.
In the case of type DQA, the connection between the main girder and the end carriage is articulated on one side and bolted on the other side.
1.1.3
Hoisting gear
1.1.4
Rope drive
Fig 1 The contact surfaces on the trolley track girders and the main girder connection plates (4) must be free from rust, dust, oil, paint and other foreign matter. The contact surfaces are marked *** in Fig 1. The bolted joint consists of the following components: (1) Hexagon bolt M 20 Material 10.9 DIN 6914 Page 4
The transmission of the motor speed to the rope drum is effected through the spur gear in a light alloy casing. The helical gear wheels are hardened and polished or shaved and run in a closed oil bath with lifetime lubrication.
The rope drive corresponds to the FEM–calcuation rules for series hoists. The load hook with safety catch complies with DIN 15400. None of the bearing points need maintenance. The rope guide is made of wear resisting, sliding synthetic material and provides trouble–free rope reel–off and careful treatment of the rope and the rope drum. The high–tensile hoisting rope in special design has considerably higher breaking Data : 30.03.2012
resistance and life than a rope of conventional design and structure. That is why only original ropes from the manufacturer’s should be used as spare parts.
1.1.5
Limit of lift
The lift is limited in the highest and lowest hook position by means of a rotary geared limit switch directly coupled to the rope drum. The standard hoist limit switch (–S31) comes with 3 switching contacts which have the following functions: 1. upper limit safety switch – lifting 2. emergency limit switch – lifting 3. emergency limit switch – lowering The upper limit safety switch (–S31.1) interrupts power to the mainline contactor (K1). This switch point is set by the manufacturer, sealed with lead, and must only be reset by authorized personnel. If for any reason the emergency limit switch (–S31.2), fails to limit the travel of the block in the up direction, the crane is shut down by this upper limit safety switch. Subsequent operation of the hoist should only be attempted by a trained service technician. If no additional operating limit switches are installed, the functions of the emergency limit switches must be checked each time you start work. If the highest and/or lowest hook position is reached in normal operation, the switch or switching circuit must be designed for normal shut ---down. The functions of the operating limit switches must be tested each time you start work. In the case of type Z ABUS electric wire rope hoists (twin hoists), this test, which must always be carried out before starting work, also compensates for the winding of the ropes on the two rope drums. This ensures that the rope is evenly wound on both drums. For this reason alone, regular testing each time you start work with the crane is already absolutely essential. For adjustment of the hoist limit switch see Operating manual for Emergency limit switch in Section 2.
1.1.6
Overload protection type
If required by standards or regulations, the hoists are equipped with an overload protection device (see hoist data sheet). Provided that the hoist is properly operated, this device prevents overloading of the hoist. Attention! Overload protection devices are safety systems and must not be adjusted or overridden. Details of other types of overload safety devices are given in the separate operating instructions attached.
1.1.7
Trolley travelling gear
Maintenance–free, directly driven flanged wheels made by drop–forging or of spherulitic graphite iron and positioned in roller bearings assure good and smooth running and also take care of the running treads. The trolley drive wheels are directly driven by 2, TEFC dual wound squirrel cage motors. D.C. rectified disc brakes are included as standard. Due to the pole AN 120055.002_EN / A 766.EN
changing, there is a standard precision hoisting speed in the ratio of approx. 1:4 to the main hoisting speed. The hoist is balanced at the factory by counterweighting the side opposite the hoist motor.
1.2
Electrical equipment
1.2.1
Wire rope hoist
ABUS wire rope hoist control units feature advanced technology and cover a wide range of applications thanks to their modular design. Movement in all directions is possible in two---stage pole---changing operation. All motors, power and control lines are connected using plug---type connectors for easy maintenance. Attention! Work on electrical systems must be performed only by qualified personnel. The power supply must be disconnected before starting work. Details of the electrical equipment are given in the circuit diagram.
1.2.1.1 Contactor box The contactor box is installed on the wire rope hoist and has IP 55 protection. Reversing contactors are mechanically interlocked with each other. The design of the control systems with ducted wiring and no fuses ensures ease of maintenance. Easy to assemble screwless terminals ensure reliable operation. Each drive system is largely protected against inadmissible overloading by a standard motor circuit breaker or an electronic overload protection device. In order to prevent thermal overloading of the motor as a result of repeated inching operation, the changeover contacts for pole---changing hoist and trolley travel motors are released with a time delay of 0.5 s.
1.2.2
Solo–trolleys (not for size GM 7000)
1.2.2.1 Mains connection line Conductor cross sections for power supply circuits from the distribution assembly via the mains switch to the contact conductor input terminals must be determined by the operator. The mains power cable must be sized so that the voltage at the contact conductor supply point does not fall below the minimum limit of the voltage range even when the start ---up current (see “Technical Data” section 1.3 “Electrical Data of Motors”) of the hoist motor is flowing. 1.2.2.2 Mains switch In accordance with EN 60204, Part 32, it must be possible to disconnect a hoist using a mains switch and to lock out the power supply. Page 5
The mains switch is not included in hoist system (see circuit diagram) and is intended to disconnect the crane or hoist system from the power supply for repair and maintenance work. If necessary, this switch may also be used for emergency shutdowns or emergency stopping. Mains switches may be obtained from ABUS. 1.2.2.3 Disconnector The function of the disconnector, namely the disconnection of the hoist for repair and maintenance work, is performed by the mains connector, The mains connector is installed on the wire rope hoist, on contactor box SKA, with coding ”–X0” For repair or maintenance work, the hoist or crane system must be disconnected by unplugging the mains connector. The mains connector can be secured against unauthorized connection by up to three padlocks. 1.2.2.4 Crane switch The crane switch is installed in the crane contactor box (SKR) or the trolley contactor box (SKA) directly behind the mains connector. The crane switch is a contactor coded ”–K1”. The function of the crane switch is to cut off power supply to all motors in the event of an emergency shutdown (see circuit diagram).
The unit may be moved out of the advance slow ---down area at high speed in the opposite direction. Where there is a high risk or special safety circuitry is required, an ”end shutdown” system is used to slow the system to a halt. A limit switch for both directions of travel switches crane or hoist travel off. The crane can then only be operated in the other direction. For speeds above 30 m/min., an end shutdown system is always combined with an advance slow–down switch. 1.2.2.8 Pendant control A. Operation
3
4
1.2.2.5 Contact conductor The ABUS ASL safety contact conductor system is used for solo trolleys. Four copper busbars (three phase conductors + protective earth) with contact protection are installed in the plastic housing. The contact conductor is installed on mounting brackets parallel to the crane or trolley track. The bracket spacing must be 2000 mm or less. The type of contact conductor depends on operating conditions, the maximum admissible thermal load and the maximum admissible voltage drop. Start–up current must be carefully evaluated taking the high start–up currents of motors with direct starting systems into account. 1.2.2.6
Contactor box
In the case of wire rope hoists installed on solo trolleys, the contactor box (SKA) houses a standard fuse link as the main fuse (F1), the main contactor (K1) and a control transformer with fine fuses on the primary and secondary sides in accordance with the transformer rating. For further information, please refer to Section 1.2.1.1 1.2.2.7 Trolley travel limit switch (optional) Advance slow–down switches to slow the crane or trolley to low speed before the end of the track is reached are normal practice. This configuration prevents the crane or hoist from being run against the end stops at high speed, causing severe load swinging, with the attendant risk of damage and injury. A limit switch recognizes the speed limit in both directions. Page 6
1
2
Fig 2
The drive of the change-pole motor is carried out by the two-step push buttons. A locking mechanism within the pendant control prevents a simultaneous activation of two opposed moving directions. Jogging should be avoided as this might cause contact burning and thus premature wear of the control gear. The following functions can be carried out by the pendant control : no pressure on push-button ⇒ standstill pressed with half pressure (Fig 2.1) ⇒ precision hoisting/slow travel full pressure on push button (Fig 2.2) ⇒ main hoisting/fast travel Data : 30.03.2012
red emergency switch pressed (Fig 2.3) ⇒ standstill, also if other button is turn red emergency switch (Fig 2.4) ⇒ release of all functions B. Emergency stopping The emergency stopping function required by EN 60204, Part 32, is provided by a red mushroom switch operated from ground level and from the point of operation. Attention! An emergency stop is not the same as an emergency shutdown. Only the power supply to the travel drives is cut off and the brakes are operated. The system is not disconnected from the power supply. An emergency stop is initiated by pushing the mushroom switch. The system can be restarted by turning the switch to the left. An emergency stop must be initiated under the following conditions: D if the crane travel motors fail to obey normal control commands and hazardous situations may occur D if the crane operator leaves the control position
AN 120055.002_EN / A 766.EN
1.2.2.9 Replacing fuses The main fuse (F1) is a standard fuse link. To replace the fuse, unscrew the safety cap, remove the old fuse link and push in a new fuse link. The control circuit is protected by a fine fuse (F12) on the secondary side of the control transformer and earthed on one side. The fuse is installed in the connection terminal strip directly on the transformer. To replace the fuse, pull the fuse holder out of its mount, change the fuse and push the fuse holder back into place. Fuses F10 and F11 are mounted on the contactor box terminal strip. To replace these fuses, swing the fuse holder up, change the fuse and swing the holder back into position.
Page 7
2
2.1
Assembly
Assembly Instructions
The hoist must be assembled only by specialist personnel.
2.1.1
Mechanical installation
The installation of ABUS–electric rope hoists must only be carried out by authorized persons. ABUS electric wire rope hoists are supplied as complete units with the wire rope inserted and the bottom block fully reeved. In the case of type E, the counterweight is also installed.
frame split. The hoist must be properly secured and lifted into place. The trolley bolts and nuts must then be re–tightened. During commissioning, it may be found that not all of the four wheels are in contact. In this case, the trolley must be adapted to the track. To do so, attach a load of about 25 % of the load capacity to the load hook and lift it about 5 cm. Then loosen the nuts of the four tensioner bolts one turn and tighten them with the specified torque (see “Technical Data” section 1.6 “Tightening torques”).
2.1.1.2 2.1.1.1 Model E Monorail hoist trolleys are delivered pre–adjusted for the specified flange width. The clearance between the beam and wheel flanges should amount to 1/16th inch on each side.
Model D and Z
The trolley gauge is adjusted to the desired gauge width of the double girder crane.
MA = 25 Nm
1,5–2 mm
1,5–2 mm
Fig 4
Fig 3
If necessary, corrections can be made by inserting washers or by reducing the length of the spacer tubes. If the beam is open at the ends, the trolley can be pushed on. Proper end stops must be installed and are available from ABUS if they are not in place. Rubber wheel stops must be used as end stops. Order them as ABUS clamping buffers. They are attached to the track end as shown in the illustration. (see “Technical Data” section 1.6 “Tightening torques”). If it is not possible to push the hoist on to the end of the beam, the trolley bolts must be loosened and trolley Page 8
Following the installation of the double---rail trolley, the two hooks, which are supplied loose with the trolley and are intended to provide lift ---off protection, must be installed in the openings of the non---driven wheels. The pre---assembled U ---bolt/clamping bracket assembly must be pushed over the hooks so that the long side of the clamping bracket fits into the recess in the hook. The hook must be inserted into the wheel opening from below and pushed in the direction of travel until it fits into the hole (only drilled from one side (Fig 4). In the case of cranes with a rail width above 50 mm and a rail height above 40 mm, the end carriage must be lifted 20 mm before the hooks are installed. The hook must be fastened to the end carriage, across the clamping bracket, using the two nuts. The nuts must be tightened using the specified torque values. Data : 30.03.2012
2.1.1.3 Model DQA The trolley gauge is adjusted to the desired gauge width of the double girder crane.
Fig 5
1
Trolley with wheel flange guidance
1
2 Fig 7
Remove the lock plate (Fig 7, Pos.1). Position the double---rail trolley on the crane bridge in such a way that the hook (Fig 7, Pos.2) passes under the top flange of the crane bridge. Install the lock plate (Fig 7, Pos.1) on the opposite side. The nuts must be tightened using the specified torque values (see ”Technical Data”, Section 1.6, ”Torque Specifications”.
Fig 6 Trolley with roller guidance The double flanges of the wheels protect the trolleys against derailing. They contain information on the admissible wear (1). The wheels are guided by the wheel flanges or by rollers. In the case of flange guidance, the play between the rail and the flanges is 7 mm. In the case of roller guidance, the play between the rail and the rollers is 3 mm. In this case, flanged wheels with increased play are used.
Fig 8
1
Trolley with wheel flange guidance
Fig 9 Trolley with roller guidance The double flanges of the wheels protect the trolleys against derailing. They contain information on the admissible wear (1). The wheels are guided by the wheel flanges or by rollers. In the case of flange guidance, the play between the rail and the flanges is 7 mm. AN 120055.002_EN / A 766.EN
Page 9
In the case of roller guidance, the play between the rail and the rollers is 3 mm. In this case, flanged wheels with increased play are used.
2.1.1.4 Model S The trolley is adapted to the width of the crane track. The lateral play between the trolley rail and the guide rollers is 3 mm.
2
3
1
Fig 12
End stops are required on the track girders to limit travel. 2.1.1.5 Model U Monorail hoist trolleys are delivered pre–adjusted for the specified flange width. The clearance between the beam and wheel flanges should amount to 1/16th inch on each side. Fig 10 Before installing the side–mounted trolley, the two safety plates (Fig 10, Item 5) must be removed. After the trolley has been placed on the crane girder, the safety plates must be screwed back into place and the trolley must be set to a horizontal position by turning the eccentric bolt (Fig 11, Item 3)
1,5---2 mm
1,5---2 mm
Fig 13 1 Fig 11
The mounting screws for the eccentric bolt (Fig 12, Item 3) must be tightened to the appropriate torque specified. (see “Technical Data” section 1.6 “Tightening torques”).
Page 10
If necessary, it may be reduced by inserting washers. With the end of the track freely accessible, the stops must be removed and the trolley pushed on from the side. The stops must then be mounted and secured. The four detailing protection devices must be bolted to the two buffer plates using the specified torque values (see ”Technical Data”, Section 1.6 ”Torque Values”). If the end of the track is inaccessible, the complete trolleys with trolley travel motors must be removed from the two jointed bolts.
Data : 30.03.2012
The electric wire rope hoist is lifted under the track and the four derailing protection devices are bolted to the buffer plates on both sides using the specified torque values (see ”Technical Data”, Section 1.6 ”Torque Values”). The electric wire rope hoist must be lifted under the track and the four derailing protection devices must be
screwed back onto both sides of the buffer plates. The electric wire rope hoist is then secured against derailing. Finally, the trolley must be mounted again and the bolts must be tightened with the specified torque. (see “Technical Data” section 1.6 “Tightening torques”).
_________________________________
2.1.2
Electrical installation
Switch off power supply before starting work at any electrical installation. Have work carried out by trained personnel only. Connect the cables in the crane or trolley control panel as shown in the circuit diagram. Caution ! EN 60204 must be observed! The rope hoist must be wired to a three phase fused disconnect or circuit breaker (per NEMA) properly sized and grounded. The maximum voltage deviations are –5% from the lower and +5% from the upper voltage limit. The hoist can operated in the voltage ranges
AN 120055.002_EN / A 766.EN
shown. See “Technical Data” section 1.3 “Electrical Data of Motors” for cable cross section and fuse protection. 2.1.2.1 Connection to the mains The operator must connect the system to the mains power supply in accordance with EN 60204. 2.1.2.2 Mains switch The mainline disconnect switch must be wired so as to switch off all poles of the incoming power. The mainline switch has to be installed at an easily accessible location and must be secured against erroneous or unauthorized entry.
Page 11
Kransysteme
Installation, Operation and Maintenance Instructions for
ABUS – Lifting gear drive
250-068733
Factory No. ___________________
Manufacturer ABUS Kransysteme GmbH Sonnenweg 1 D – 51647 Gummersbach
Tel. ##49 2261 / 37–0 Fax. ##49 2261 / 37247 [email protected]
This document may not be reproduced or given to third parties and its content must not be divulged or used for other purposes without the prior written permission of ABUS. You will be liable to pay compensation for any breach of this provision. All patent and registered design rights reserved.
These installation, operation and maintenance instructions are intended for use in an Englishspeaking country by English–speaking specialist personnel. AN 120056.001_EN / A 712.EN
13.04.2010
Original operating manual
Contents 1.1
Hoist motor with brake . . . . . . . . . . . .
2
1.3.2
Dismounting the brake . . . . . . . . . . . .
3
1.2
Hoisting gear . . . . . . . . . . . . . . . . . . . .
2
1.3.3
Installation of the brake . . . . . . . . . . .
3
1.3
Hoisting gear brake . . . . . . . . . . . . . . .
2
1.3.4
Replacement of Brake Rotor and Anchor Disk . . . . . . . . . . . . . . . . .
4
1.3.1
Adjustment of the air–gap . . . . . . . . .
3
1.3.5
Emergency Lowering of Load . . . . . .
4
_________________________________
1.1
Hoist motor with brake
1.2
Hoisting gear
The hoisting gear is driven by a 12 pole, dual speed squirrel cage motor with integral D.C. restified magnetic disc brake. Insulation class F, protection type IP 55. Due to the pole changing there is a standard precision hoisting speed in the ratio of approx. 1:6 or approx. 1:10 to the main hoisting speed. The asbestos–free brake lining achieves a service life of approx. 1x106 shiftings.
The transmission of the motor speed to the rope drum is effected through the spur gear in a light alloy casing. The helical gear wheels are hardened and polished or shaved and run in a closed oil bath with lifetime lubrication.
1.3
Hoisting gear brake
Attention! In the case of GM 700 hoists with platforms (models DB and ZB), the following instructions must be observed. If it is necessary to dismantle the hoist drive, the drive unit must not be placed on the platform. Otherwise, the platform may be overloaded and there is a risk of accidents. Attention! An external fan for the hoist motor is not available as an option for size GM 800.
The hoisting gear brake is a magneto–electric disk brake. In order to guarantee safe release, the brake is equipped with an air–gap limiter. The air–gap of the brake must be checked regularly and adjusted to its
Page 2
optimum value of 0.4 ± 0.05 mm (1/64th inch.). This ensures optimm brake performance and minimm wear. In order to prevent the brake lining thickness from falling below the minimum value tmin, the screw–in depth of the socket screws (4) in the magnet assembly (9) is limited. Caution! The following work must be performed with the power supply disconnected. This work must be performed only by specialists. a) Motor without additional unit for ventilation, see Figure 1 M6 : 10 Nm M8 : 25 Nm 1
2
3
14
4
0,4
13 12 11 5
10
6 tmin 9
8
7
Figure 1
Data : 13.04.2010
b) Motor with additional unit for ventilation, see Figure 2 1
2
3
M6 : 10 Nm M8 : 25 Nm
4
0.4
7. Disconnect connectors for power supply to brake. 8. Unscrew the fastening screws (2). 9. Remove magnet assembly (9) complete with anchor disk (6) and socket screws (4). 10. Remove brake rotor (5). 11. Remove locking ring (10). 12. Pull off catch hub (8) by means of the pull–off device. b) Motor with additional unit for ventilation, see Figure 2
13 10 16 15 tmin 9
1.3.1
8
6
7
5 Figure 2
Adjustment of the air–gap
Motor with or without additional unit for ventilation, see Figure 1 or Figure 2 1. Remove the ventilator cowl (1) with the motor being switched off. 2. Remove locking ring (11) 3. Loosen 3 fastening screws (2) by half a turn 4. Screw 3 socket screws (4) about one turn info magnet assembly (9) (screws–in depth limited) 5. Place distance plates (3) (thickness: 0.4 ± 0,05 mm) between anchor plate (6) and magnetic body (9) each next to the 3 socket screws (4) ; tighten the fastening screws (2) so that the distance plates (3) can still be removed. 6. Unscrew the 3 socket screws (4) from the magnet assembly (9) until they make firm constact with the motor bearing shield. 7. Tigthen the fastening screws (2). Then check the evenness of the air gap (at approx. 6 places and readjust, if required. 8. Press in 0–ring (7) 9. Install the ventilator cowl (1) 10. Do a trial run to check the brake.
1.3.2
Dismounting the brake
a) Motor without additional unit for ventilation, see Figure 1 1. Lower the bottom block and place it on the working platform, the ground, etc. 2. Remove ventilator cowl (1) with the motor being switched off. 3. Remove locking ring (11) 4. Pull off fan (14). 5. Remove feather key (12). 6. Press out 0–ring (7). AN 120056.001_EN / A 712.EN
1. Lower the bottom block and place it on the working platform, the ground, etc. 2. Remove ventilator cowl (1) with the motor being switched off. 3. Disconnect connectors for power supply to brake and ventilation system. 4. Undo 3 screws (16) and remove axial flow fan with mounting plate (15). 5. Press out 0–ring (7). 6. Unscrew the fastening screws (2). 7. Remove magnet assembly (9) complete with anchor disk (6) and socket screws (4). 8. Remove brake rotor (5). 9. Remove locking ring (10). 10. Pull off catch hub (8) by means of the pull–off device.
1.3.3
Installation of the brake
a) Motor with additional unit for ventilation, see Figure 1 1. Slightly grease the motor shaft (13), install catch hub (8) and secure with locking ring (10). 2. Push brake rotor (5) on the catch hub (8) and check whether it can be slightly axially displaced. 3. Mount the magnetic body (9) complete with anchor disk (6) and socket screws (4) and slightly tighten by means of the 3 fastening screws (2). 4. Screw 3 socket screws (4) into the magnet assembly (9). (screw–in depth limited) 5. Place distance plates (3) (thickness: 0.4 ± 0,05 mm) between the anchor plate (6) and the magnetic body (9) each next to the 3 socket screws (4); tighten the fastening screws (2) so that the distance plates (3) can still be removed. 6. Unscrew the 3 socket screws (4) from the magnet assembly (9) until they make firm contact with the motor bearing shield. 7. Tighten the fastening screws (2). Then check the evenness of the air gap (at approx. 6 points) and readjust, if necessary. 8. Press in the 0–ring (7). 9. Push on the ventilator (14) and secure with locking ring (11). 10. Connect connectors for power supply to brake. 11. Install the ventilator cowl (1). 12. Carry out test tun to check brake. b) Motor with additional unit for ventilation, see Figure 2 Page 3
1. Slightly grease the motor shaft (13), install catch hub (8) and secure with locking ring (10). 2. Push brake rotor (5) on the catch hub (8) and check whether it can be slightly axially displaced. 3. Mount the magnetic body (9) complete with anchor disk (6) and socket screws (4) and slightly tighten by means of the 3 fastening screws (2). 4. Screw 3 socket screws (4) into the magnet assembly (9) 5. Place distance plates (3) (thickness: 0.4 ± 0,05 mm) between the anchor plate (6) and the magnetic body (9) each next to the 3 socket screws (4); tighten the fastening screws (2) so that the distance plates (3) can still be removed. 6. Unscrew the 3 socket screws (4) from the magnet assembly (9) until they make firm contact with the motor bearing shield. 7. Tighten the fastening screws (2). Then check the evenness of the air gap (at approx. 6 points) and readjust, if necessary. 8. Press in the 0–ring (7). 9. Fasten axial–flow fan with mounting plate (15) to magnet assembly (9) using 3 screws (16). 10. Connect connectors for power supply to brake and ventilation system. 11. Install the ventilator cowl (1). 12. Carry out test tun to check brake and ventilation system.
1.3.4
Replacement of Brake Rotor and Anchor Disk 1
2
Limiting device for lifting
Figure 3
1.1
If the brake lining is worn below tmin (see table) and it is no longer possible to adjust the clearance, the brake rotor (Figure 1 / Figure 2, Item (5) and the anchor disk Figure 1 / Figure 2, Item 6) must both–be replaced. For the replacement of the brake rotor and anchor disk, the following work is necessary: Dismantling of the brake in accordance with sub–section 1.3.2 Dismantling of the anchor disk in accordance with the following instructions: Page 4
1. Screw the socket screws Figure 1 / Figure 2, Item (4) on the dismantled brake into the magnet assembly up to the stop. 2. Remove and destroy the lifting travel limiting screws Figure 3, Item (2) (The emergency lowering bar Figure 3, Item (1) will then be released.) 3. Remove and destroy the socket screws Figure 1 / Figure 2, Item (4) (This rele ases the load on the springs between the anchor disk Figure 1 / Figure 2, Item (6) and the magnet assembly Figure 1 / Figure 2, Item (9) 4. Remove anchor disk. To install the new anchor disk, proceed in reverse order. The socket screws Figure 1 / Figure 2, Item ( (4) and the lifting travel limiting screws Figure 3, Item (2) must be replaced. The clearance between the anchor disk and the magnet assembly Figure 1 / Figure 2, Item (9) must be set to 1.1 mm with the brake dismantled using the lifting travel limiting screws Figure 3, Item (2) Assemble the brake in accordance with sub–section 1.3.3 Wear table for brake linings (lifting motor) tmin (mm)
Typ
L6
H6
U6
800.4
9.3
9.3
9.3
1000.7
9.3
9.3
11.3
2000.3
9.3
11.3
––
3000.4
11.3
12.3
––
5000.3
12.3
13.8
––
6000.3
13.8
––
––
7000.1
13.8
13.8
13.8
1.3.5
Emergency Lowering of Load
Caution ! The hoist must be disconnected from the power supply before the following steps are taken! Figure 1 / Figure 2 / Figure 3 If it is necessary to lower the load in an emergency following a power failure or problems with the hoist motor or brake coil, the following steps must be taken: 1. Remove fan cover Figure 1 / Figure 2, Item (1) 2. Screw stud bolt(s) (M8) into emergency lowering bar Figure 3, Item (1) 3. Open brake(s) by carefully swivelling release bracket(s) and slowly lower the load. Attention! The lowering speed must not exceed the rated speed. The rated speed is reached after a very short time. Lowering with the brakes applied may lead to overheating of the brake linings. Following emergency lowering, the brakes must be inspected and the brake linings replaced. Data : 13.04.2010
Kransysteme
Operation Instructions for
ABUS – Emergency limit switch
Wire rope hoist
GM
-
800 1000 2000 3000 5000 6000 7000
-
2/1 4/1 6/1 4/2 6/2 8/2 10/2
Model
-
E D, DB DA DQA Z, ZB, ZA S U
12/2
250-068733
Serial No. __________________
Manufacturer ABUS Kransysteme GmbH Sonnenweg 1 D – 51647 Gummersbach
Tel. ##49 2261 / 37–0 Fax. ##49 2261 / 37247 [email protected]
This document may not be reproduced or given to third parties and its content must not be divulged or used for other purposes without the prior written permission of ABUS. You will be liable to pay compensation for any breach of this provision. All patent and registered design rights reserved.
These installation, operation and maintenance instructions are intended for use in an Englishspeaking country by English–speaking specialist personnel. AN 120064.003_EN / A 740.EN
15.10.2010
Original operating manual
Contents 1
Limit of lift . . . . . . . . . . . . . . . .
2
Adjustment instruction hoist limit switch . . . . . . . . . .
3
2.1
Hoist limit switch GPK 75.3–1 with 3 switch points . . . . . . . . . . . . . . .
3
2.1.1
Adjustment instructions . . . . . . . . . . .
3
2.1.2
Adjust switch points . . . . . . . . . . . . . .
10
Page 2
3
2.2
Adjustment instruction hoist limit switch GP with option “operating limit switch” with 4 switch points . . . . . . . . . . . . . . .
10
2.2.1
Adjustment instructions . . . . . . . . . . .
10
2.2.2
Adjust switch points . . . . . . . . . . . . . .
11
2.3
Testing the ”restart” function for hoists with transmission limit switches (option) . . . . . . . . . . . . .
12
Data : 15.10.2010
1
Limit of lift
The lift is limited in the highest and lowest hook position by means of a rotary geared limit switch directly coupled to the rope drum. The standard hoist limit switch (–S31) comes with 3 switching contacts which have the following functions: 1. upper limit safety switch – lifting 2. emergency limit switch – lifting 3. emergency limit switch – lowering The upper limit safety switch (–S31.1) interrupts power to the mainline contactor (K1). This switch point is set by the manufacturer, sealed with lead, and must only be reset by authorized personnel. If for any reason the emergency limit switch (–S31.2), fails to limit the travel of the block in the up direction, the crane is shut down by this upper limit safety switch. Subsequent operation of the hoist should only be attempted by a trained service technician.
If no additional operating limit switches are installed, the functions of the emergency limit switches must be checked each time you start work. If the highest and/or lowest hook position is reached in normal operation, the switch or switching circuit must be designed for normal shut ---down. The functions of the operating limit switches must be tested each time you start work. In the case of type Z ABUS electric wire rope hoists (twin hoists), this test, which must always be carried out before starting work, also compensates for the winding of the ropes on the two rope drums. This ensures that the rope is evenly wound on both drums. For this reason alone, regular testing each time you start work with the crane is already absolutely essential. For adjustment of the hoist limit switch see Operating manual for Emergency limit switch in Section 2.
_________________________________
2
Adjustment instruction hoist limit switch
2.1
Hoist limit switch GPK 75.3–1 with 3 switch points
2.1.1
Adjustment instructions
It should be noted that the settings shown in the tables apply to wire rope hoists operated at mains frequency. In the case of hoists equipped with frequency converters, the appropriate values must be taken from the ABUliner documentation. The ABUS–hoist limit switch GP protects the electric wire rope hoist as an independantly working emergency–stop–device to limit the up and down movements at the highest respectively at the lowest hook position. As a further improvement of safety the standard system is always equipped with the “safety limit switch”, a second switch for the highest hook position. If the system is equipped with (optional) operating limit switches, the setting instructions in Section 2.2 must be followed. Switching points 1 and 2 of ABUS hoists are normally set at the factory and sealed with lead seals. Carry out preliminary adjustment using the table ”Settings for limit switch” Switch points must be adjusted by specialist personnel according to respective table ”Setting of lifting limit switches” before the first operation as well as after
AN 120064.003_EN / A 740.EN
maintenance works at the rope drive (e.g. rope exchange). Depending on your choice of the reference edge, values of column C1 and C2 or A1 and A2 or B1 or B2 can be used (see Figur 2 --- Figur 8). C1 and C2 apply only to standard hooks. Adjust the switch points at the adjusting nuts 1 – 3 with a screw driver of 6 mm or an Allan key of 4 mm. 146 turns at the adjusting nut corresponds with 360° at the cam disk. The table ”Setting of lifting limit switches” indicates what hook path corresponds with one turn at the ajusting nut. Turning the adjusting nut to the right = adjust switch point to a lower position Turning the adjusting nut to the left = adjust switch point to a higher position. The standard type GP_ 75 is designed for 75 turns of the cam disk. For larger lifting heights the hoists can be equipped with the type GPM125 for 125 turns. Caution! Following the completion of the adjustments, repeated tests of functions must be carried out to check whether the setting is correct and the unit is not moved up to the safety limit switch. It may be necessary to correct the settings.
Page 3
F adjustment nuts sealing caps
rope guide
max 75 (125) turns
146 =360 ˚
1 2 3
1 2 3 switch cams
planetary gear
.1 1 .2 3 .3 5 B1 A1
6
safety limit switch lifting
.2
emergency limit switch lifting
.3
emergency limit switch lowering
B2 A2
HW
C2
C
C1
.1
Bo 20--40
4
Bu
2
Page 4
Figur 1
Data : 15.10.2010
AN 120064.003_EN / A 740.EN
Page 5
*
4
6
3
4
3
3
GM 800 – E
GM 1000 – E
GM 2000 – E
GM 3000 – E
GM 5000 – E
GM 6000 – E
≤300
≤350
2/1 4/1
2/1 4/1
≤350
≤300
2/1 4/1
2/1
≤300
≤300
flange width *
2/1 4/1
4/1
reeving
830
830 825
664 580
580 500
567 500
400
[mm]
C–Dimension
295
295 377
214 235
180 195
210 229
163
A1
108
108 190
68 89
68 83
106 125
72
[mm]
switch point 1 B1
790
790 805
624 560
540 480
527 480
380
C1 standard hook
395
395 427
314 285
280 245
310 279
213
A2
208
208 240
168 139
168 133
206 175
122
[mm]
switch point 2 B2
890
890 855
734 610
640 530
627 530
430
C2 standard hook
Settings
194
89 178
80 160
65 130
60 120
55
up Bo
194
89 178
80 160
65 130
60 120
55
down Bu [mm]
switch hysteresis
260
119 238
107 214
86 172
77 154
71
[mm]
102 3
87.5 3
73 2.5
59 2.5
56 2
42 2
[mm]
hook path per F–Dimension turn at the adFestlagerseite justment nut
generation
4
6
3
4
3
3
1
hoist type
GM 800 – S
GM 1000 – S
GM 2000 – S
GM 3000 – S
GM 5000 – U
GM 6000 – U
GM 7000 – U
Model S / U
1615
1256 1241
2/1 4/1
2/1
1132
699 550
2/1 4/1
4/1
440
420
343
[mm]
C–Dimension
4/1
4/1
4/1
reeving
329
235 260
270
519 540
405
419
336
A1
88
48 73
83
373 394
293
315
245
[mm]
switch point 1 B1
1575
1216 1221
1112
659 530
420
400
323
C1 standard hook
429
335 310
320
619 590
455
469
386
A2
188
148 123
133
473 444
343
365
295
[mm]
switch point 2 B2
1675
1316 1271
1162
759 580
470
450
373
C2 standard hook
Settings
254
194 97
89
160 80
65
60
55
up Bo
254
194 97
89
160 80
65
60
55
down Bu [mm]
switch hysteresis
342
260 130
119
214 107
86
77
71
[mm]
131 4
102 3
87.5 3
73 2.5
59 2.5
56 2
42 2
[mm]
hook path per F–Dimension turn at the adFestlagerseite justment nut
Wider flanges result in larger C dimensions. In such cases, the increase in dimension C must be added to the switching points C1, A1, B1, C2 , A2 and B2 indicated by the table in “Technical Data” Section 1.4 ”Dimensions and Weights; Model E”.
generation
hoist type
Model E
Setting of limit switch for mains operation
Page 6
Date: 15.10.2010
generation
4
6
3
4
4
4
4
3
3
3
3
3
1
1
1
hoist type
GM 800 – D
GM 1000 – D
GM 2000 – D
GM 3000 – D
GM 3000 – D130 GM 3000--- D160
GM 3000 – D
GM 3000 – D160 GM 3000 --- D200
GM 5000 – D
GM 5000 – D160 GM 5000 --- D200
GM 5000 – D
GM 5000 – D200 GM 5000 --- D280
GM 6000 – D
GM 7000 – D
GM 7000 – D
GM 7000 – D
572 501
2/1 4/1
4/2 8/2
236 516
717 897
520 267 606
2/1 4/1 6/1
6/1
611 606
320
385
440
469 429
250
260
6/1
4/2
4/1
2/1
6/1
4/2
4/1 4/1
315
295 215
2/1 4/1
2/1
195
2000 > 2000
[mm]
[mm] 144
C–Dimension
trolley span
4/1
4/1
reeving
Model D / DB
240 260
522
344 380
235 260 355
370 355
330
287 307
240
224
250
230 225
196
160 175
189
172
A1
53 73
281
103 139
48 73 168
183 168
218
100 120
53
77
138
84 79
50
48 63
85
81
[mm]
switch point 1 B1
196 496
697 877
532 481
480 247 586
591 586
280
365
400
449 409
210
240
275
255 195
175
124
C1 standard hook
340 310
572
444 430
335 310 405
420 405
430
337
345
274
350
280 275
296
260 225
239
222
A2
153 123
331
203 189
148 123 218
233 218
318
150 170
153
127
238
134 129
150
148 113
135
131
[mm]
switch point 2 B2
296 546
747 927
632 531
580 297 636
641 636
380
415
500
499 459
310
290
375
355 245
225
174
C2 standard hook
Settings
254 127
85
254 127
194 97 65
59
178
89
178
53
160
80
160
130 65
60
55
up Bo
254 127
85
254 127
194 97 65
59
178
89
178
53
160
80
160
130 65
60
55
down Bu [mm]
switch hysteresis
342 171
114
342 171
260 130 87
79
238
119
238
71
214
107
214
172 86
77
71
[mm]
hook path per turn at the adjustment nut
87/ 84 3
131 4
131 4
102 3
87.5 3
87.5 3
87.5 3
87.5 3
73 2.5
73 2.5
73 2.5
73 2.5
59 2.5
56 2
42 2
Festlagerseite / hoisting gear [mm]
F–Dimension
AN 120064.003_EN / A 740.EN
Page 7
4
6
3
4
3
3
1
1
GM 800 – DA
GM 1000 – DA
GM 2000 – DA
GM 3000 – DA
GM 5000 – DA
GM 6000 – DA 160 GM 6000 --- DA 200 GM 6000 --- DA1 280 GM 6000 --- DA 280
GM 7000 – DA
GM 7000 – DA
generation
3
4
3
3
1
hoist type
GM 2000 – DQA
GM 3000 – DQA
GM 5000 – DQA
GM 6000 – DQA
GM 7000 – DQA 350 GM 7000 --- DQA 400
Model DQA
generation
hoist type
Model DA
700 620 853 825 813
2/1 4/1 6/1
2/1 4/1
810 712 870 745
2/1 4/1
2/1 4/1 970 998
639 555
2/1 4/1
4/1
525 445
2/1 4/1
[mm]
C–Dimension
913 1370
4/1 6/1
reeving
1284
2/1
949 470 832 1068
621 544
2/1 4/1
2/1 4/1 4/1 6/1
520
429
[mm]
C–Dimension
4/1
4/1
reeving
374 402
335 250
275 264
189 210
125 140
A1
375 517
344
235 260 260 352
240 285
193 225 225
161 175
189
172
A1
133 161
148 63
88 77
43 64
13 28
[mm]
switch point 1 B1
134 276
103
48 73 73 165
53 98
46 79 77
49 63
85
81
[mm]
switch point 1 B1
950 978
830 725
770 692
599 535
485 425
C1 standard hook
893 1350
1244
909 450 812 1048
785 793
660 600 833
581 520
500
409
C1 standard hook
424 452
435 300
375 314
289 260
225 190
A2
425 567
444
335 310 310 402
340 335
290 275 275
261 225
239
222
A2
183 211
248 113
188 127
143 114
113 78
[mm]
943 1400
1344
1009 500 862 1098
885 843
760 650 883
681 570
550
459
C2 standard hook
1000 1028
930 775
870 742
699 585
585 475
C2 standard hook
Settings switch point 2 B2
184 326
203
148 123 123 215
153 148
144 129 127
149 113
135
131
[mm]
switch point 2 B2
Settings
127 85
254
194 97 97 65
178 89
160 80 53
130 65
60
55
down Bu [mm]
127
194 97
178 89
160 80
130 65
up Bo
127
194 97
178 89
160 80
130 65
down Bu [mm]
switch hysteresis
127 85
254
194 97 97 65
178 89
160 80 53
130 65
60
55
up Bo
switch hysteresis
171
260 130
238 119
214 107
172 86
[mm]
hook path per turn at the adjustment nut
171 114
342
260 130 130 87
238 119
214 107 71
172 86
77
71
[mm]
hook path per turn at the adjustment nut
131 4
102 3
87.5 3
73 2.5
59 2.5
Festlagerseite / hoisting gear [mm]
F–Dimension
131 4
131 4
102 3
87.5 3
73 2.5
59 2.5
56 2
42 2
Festlagerseite / hoisting gear [mm]
F–Dimension
Page 8
Date: 15.10.2010
generation
3
3
3
1
1
1
1
1
3
3
1
1
hoist type
GM 5000 – Z
GM 6000 – Z
GM 6000 – Z 280 GM 6000 --- Z 350
GM 7000 – Z
GM 7000 – Z
GM 7000 – Z 420
GM 7000 – Z
GM 7000 – Z V500
GM 5000 – ZA
GM 6000 – ZA 280 GM 6000 --- ZA 350
GM 7000 – ZA
GM 7000 – ZA
1430 1312
8/2 10/2
1253 1163
1195
1378
960
915
717 897
668
638 643
414
1370
2000 > 2000
[mm]
[mm] 413 631
C–Dimension
trolley span
6/2
8/2
8/2
12/2
10/2
8/2
6/2
4/2
8/2
4/2
4/2 8/2
reeving
Model Z / ZB / ZA
517 482
517
493 443
494
761
482
525
522
527
498 448
485
490 504
A1
276 241
276
306 256
307
482
241
284
281
286
311 261
298
303 317
[mm]
switch point 1 B1
1410 1292
1350
1233 1143
1175
1358
940
895
697 877
628
618 623
374
373 611
C1 standard hook
567 532
567
543 493
544
811
532
575
572
627
548 498
585
590 554
A2
326 291
326
356 306
357
532
291
334
331
386
361 311
398
403 367
[mm]
switch point 2 B2
1460 1342
1400
1283 1193
1225
1408
990
945
747 927
728
668 673
474
473 661
C2 standard hook
Settings
64 51
85
97
89
85
51
64
85
127
97
194
178 89
up Bo
64 51
85
97
89
85
51
64
85
127
97
194
178 89
down Bu [mm]
switch hysteresis
85.5 46.5
114
130
119
57
46.5
85.5
114
171
130
260
238 119
[mm]
hook path per turn at the adjustment nut
87/ 84 3
87/ 84 3
102 3
87.5 3
87/ 84 3
87/ 84 3
87/ 84 3
87/ 84 3
87/ 84 3
102 3
102 3
87.5 3
Festlagerseite / hoist gear [mm]
F–Dimension
Model Z
FB
B .. A ..
A ..
C ..
B ..
Model E
C ..
Figur 2
Model D
A ..
B ..
Figur 6
A ..
B ..
C ..
Model S
C ..
Figur 3
Figur 7
A ..
C ..
B ..
Model DA
Model U Figur 4
A ..
C ..
C ..
A ..
B ..
B ..
Model DQA
Figur 8 Figur 5
AN 120064.003_EN / A 740.EN
Page 9
2.1.2
Adjust switch points
Switch point .1 “Safety limit switch lifting” The switch point is adjusted and sealed by the manufacturer to dimension C 1. Changes are only allowed in case of maintenance works and must be carried out by specialist personnel. After maintenance works, we recommend to let the adjustment be checked and sealed by ABUS service personnel. For safety reasons, the dimension C1 must never be lower than the value shown. The installation situation and mode of operation of the wire rope hoist must be taken into consideration (e.g. spreader operation). Depending on the hazard analysis of the operator, it may then be necessary to increase dimensions A1, B1, C1 and A2, B2, C2. Adjustment: Lift the load hook up to 5 mm (with reeving 4/1) or 10 mm (with reeving 2/1) to the highest hook position (dimension C1 + 5 (10) mm). If necessary, previously turn adjusting nut 1 to the left. Turn adjusting nut 1 to the right until switch contact audibly switches. Check switch point by running two starts to the highest hook position and if necessary correct the adjustment. A test run to reach switch point .1 is only possible by manual bridging of the “emergency limit switch lifting.” Switch point .2 “emergency limit switch lifting” Switching point 2 is set to dimension C2 at the factory and sealed with a lead seal. Adjustment: Lift the load hook up to 5 mm (for 4/1) or 10 mm (for 2/1) to the desired hook position (min. dimension C2 + 5 (10) mm). If necessary, previously turn adjusting nut 2 to the left. Turn adjusting nut 2 to the right until switch contact audibly switches. Check switch point by running two starts to the desired hook position and if necessary correct the adjustment in this case. The switch “safety limit switch lifting” must not switch in this case. Switch point .3 “emergency limit switch lowering” The switch point is only preadjusted by the manufacturer. The lowest hook position must be suited to operating conditions so that the unloaded hook never touches the floor. (Formation of slack rope !!) Adjustment: Lowering of load hook to 500 mm above the lowest hook position required. If necessary, turn adjusting nut 3 previously to the right. Turn adjusting nut 3 to the left until switch contact 3 audibly switches. Check switch point by running two
Page 10
tests to the lowest hook position and if necessary correct the adjustment. The dimension HW (see Figur 1) must not exceed the dimension lifting height (≙ “Hakenweg”) see type plate of the hoist. For safety reasons, the dimension F (see Figur 1 and table) must also never be lower than the value shown.
2.2
Adjustment instruction hoist limit switch GP with option “operating limit switch” with 4 switch points
2.2.1
Adjustment instructions
It should be noted that the settings shown in the tables apply to wire rope hoists operated at mains frequency. In the case of hoists equipped with frequency converters, the appropriate values must be taken from the ABUliner documentation. The ABUS–hoist limit switch GP protects the electric wire rope hoist as an independantly working emergency–stop–device to limit the up and down movements at the highest respectively at the lowest hook position. If the highest and/or lowest hook position are reached in normal operation, another switch, the ”operating limit switch” must be installed ahead of the ”emergency limit switch”. Each time work is started, the functions of the operating limit switch must be tested. The reset switches on the trolley contactor box must be used for setting the emergency limit switch (see also 2.3). Switch points must be adjusted by specialist personnel according to respective table ”Setting of lifting limit switches” before the first operation as well as after maintenance works at the rope drive (e.g. rope exchange). Depending on your choice of the reference edge, values of column C1 and C2, or A1 and A2, or B1 or B2 can be used. C1 and C2 apply only to standard hooks. Adjust the switch points at the adjusting nuts 1 – 3 with a screw driver of 6 mm or an Allan key of 4 mm. 146 turns at the adjusting nut corresponds with 360° at the cam disk. The table ”Setting of lifting limit switches” indicates what hook path corresponds with one turn at the ajusting nut. Turning the adjusting nut to the right = adjust switch point to a lower position Turning the adjusting nut to the left = adjust switch point to a higher position.
Data : 15.10.2010
F adjustment nuts sealing caps
rope guide
0 1 2 3 4
max 75 (125) turns
1 2 3 4
planetary gear
.1 1 .2 3 .3 5 .4 7
.2
operating limit switch lifting
.3
operating limit switch lowering
.4
emergency limit switch lowering
B2 A2
emergency limit switch lifting
D
.1
C1
8
C2
6
C
4
effective hook path HW
2
Bo 20--40
=360 ˚
Bu
146
A1
B1
switch cams
2.2.2
Adjust switch points
Switch point .1 “emergency limit switch lifting” The switch point is adjusted and sealed by the manufacturer to dimension C 1. Changes are only allowed in case of maintenance works and must be carried out by specialist personnel. After maintenance works, we recommend to let the adjustment be checked and sealed by ABUS service personnel.
AN 120064.003_EN / A 740.EN
Figur 9
For safety reasons, the dimension C1 must never be lower than the value shown. The installation situation and mode of operation of the wire rope hoist must be taken into consideration (e.g. spreader operation). Depending on the hazard analysis of the operator, it may then be necessary to increase dimensions A1, B1, C1 and A2, B2, C2.
Page 11
Adjustment: Lift the load hook up to 5 mm (with reeving 4/1) or 10 mm (with reeving 2/1) to the highest hook position (dimension C 1 + 5 (10) mm). If necessary, previously turn adjusting nut 1 to the left. Turn adjusting nut 1 to the right until switch contact audibly switches. Check switch point by running two starts to the highest hook position and if necessary correct the adjustment. Switch point .2 “operating limit switch lifting” Switching point 2 is set to dimension C2 at the factory and sealed with a lead seal. Adjustment: Lift the load hook up to 5mm (for 4/1) or 10 mm (for 2/1) to the desired hook position (min. dimension C 1 + 5 (10) mm). If necessary, previously turn adjusting nut 2 to the left. Turn adjusting nut 2 to the right until switch contact audibly switches. Check switch point by running two starts to the desired hook position and if necessary correct the adjustment. The switch “emergency limit switch lifting” must not switch in this case! Switch point .4 (.3) “emergency limit switch lowering” The switch point is only preadjusted by the manufacturer. The lowest hook position must be suited to operating conditions so that the unloaded hook never touches the floor. (Formation of slack rope!) Adjustment: Lowering of load hook to 500 mm above the lowest hook position required. If necessary, turn adjusting nut 4 previously to the right. Turn adjusting nut 4 to the left until switch contact 4 audibly switches. Check switch point by running two tests to the lowest hook position and if necessary correct the adjustment. The dimension HW must not exceed the dimension lifting height (≙ “Hakenweg”) see type plate of the hoist. For safety reasons, the dimension F (see Figur 9 and table) must also never be lower than the value shown. Switch point .3 “operating limit switch lowering” (only for GP with 4 switch points) The switching point can be set to any point between the normal limit switch for the highest hook position and the emergency limit switch for the lowest hook position. The minimum spacing ”D” must be taken from the following table: Reeving
Normal operation 50 / 60 Hz
2/1, 4/2
D = 100
4/1, 8/2, 10/2
D = 50
6/1, 12/2
D = 40
6/2
D = 80
Page 12
Adjustment: Lower load hook down to 50 mm (for 4/1) or 100 mm for (2/1) to the desired lowest hook position. If necessary, turn adjusting nut 3 previously to the right. Turn adjusting nut 3 to the left until switch contact 3 audibly switches. Check switch point by running two starts to the desired hook position and if necessary correct the adjustment. Adjustment screw .0 “block adjustment” (sealed) The purpose of block adjustment is to shift all the switching points by the same amount without changing the switching point spacing. 626 turns of the adjustment screw correspond to 360° on the cam disc for the switching points. After a rope exchange the four switch points can be readjusted simultaneously using the block adjustment. Adjust switch point .1 following the above mentioned instruction by using Adjustment screw 0. Now the other switch points are also in the initial position again. We recommend to let the adjustment be checked and sealed by ABUS service personnel.
2.3
Testing the ”restart” function for hoists with transmission limit switches (option)
If the hoist has passed the operating limit switch and the emergency limit switch has been operated, you must check whether movement in both directions is impossible before restarting the unit. Test Move the hoist up to the top limit switch or down to the bottom limit switch. Override the operating limit switch by turning the ”reset up (down)” switch on the contactor box towards lifting (lowering). If the up (down) button on the control unit is pressed at the same time, the hoist will be moved to the emergency limit switch and the main contactor will be tripped. The crane can no longer be operated from the control unit. Restart Turn the main contactor on by turning the ”reset up (down)” switch on the contactor box towards lowering (lifting). If the down (up) button on the control unit is pressed at the same time, the hoist will leave the area of the operating limit switch and move into the normal operating area. The crane can then be operated normally from the control unit.
Data : 15.10.2010
Kransysteme
Installation Instructions for
ABUS – Rope, rope guide
Wire rope hoist GM -
800 1000 2000 3000 5000 6000
-
2/1 4/1 6/1
Model
4/2 6/2
-
E D DA DB DQA -
S U Z ZB
8/2
250-068733
Serial No. __________________
Manufacturer ABUS Kransysteme GmbH Sonnenweg 1 D – 51647 Gummersbach
Tel. ##49 2261 / 37–0 Fax. ##49 2261 / 37247 [email protected]
This document may not be reproduced or given to third parties and its content must not be divulged or used for other purposes without the prior written permission of ABUS. You will be liable to pay compensation for any breach of this provision. All patent and registered design rights reserved.
These installation, operation and maintenance instructions are intended for use in an Englishspeaking country by English–speaking specialist personnel. AN 120057.002_EN / A 767.EN
30.03.2012
Original operating manual
Contents 1
2
Rope drive . . . . . . . . . . . . . . . .
3
Rope wedge protrusion, spacing between the rope clamp . . . 3
3
Wire rope and rope guide . .
3.1
Removing the wire rope and the rope guide . . . . . . . . . . . . . . .
Page 2
3 4
3.1.1
Size GM 800.4, 1000.6, 2000.3, 3000.4 . .
4
3.1.2
Size GM 5000.3, 6000.3 . . . . . . . . . . .
4
3.1.3
Size GM 3000.4, 5000.3 . . . . . . . . . . .
6
3.2
Installation of a new rope and of the rope guide . . . . . . . . . . . . .
7
3.2.1
Size GM 800.4, 1000.6, 2000.3, 3000.4 . .
7
3.2.2
Size GM 5000.3, 6000.3 . . . . . . . . . . .
8
3.2.3
Size GM 3000.4, 5000.3 . . . . . . . . . . .
12
3.3
Elimination of stretch twisting . . . . . .
12
Data : 30.03.2012
1
Rope drive
The rope drive corresponds to the FEM–calcuation rules for series hoists. The load hook with safety catch complies with DIN 15400. None of the bearing points need maintenance. The rope guide is made of wear resisting, sliding synthetic material and provides trouble–free rope reel–off and careful treatment of the rope and the rope drum. The high–tensile hoisting rope
in special design has considerably higher breaking resistance and life than a rope of conventional design and structure. That is why only original ropes from the manufacturer’s should be used as spare parts. Information on the use and maintenance of the ropes is given in EN 12385---3 ”Steel wire ropes --- Safety --- Information for use and maintenance”.
_________________________________
2
Rope wedge protrusion, spacing between the rope clamp The maximum protrusions of the rope wedges are indicated in the table below.
d
min 1 x d
a,zul
rope socket
Trolley type
d [mm]
a,zul [mm]
800.4
6.5
18 +1
1000.6
8.0
3 +1
2000.3
9.0
0 +2
3000.4
11.0
16 +2
5000.3
14.0
19 +3
6000.3
16.2
28 +3
rope claming wedge
The spacings must be checked during annual inspections. If the maximum a dimension is exceeded, the rope socket and wedge must be replaced.
rope
Following loading with the rated load (once only), the spacing between the rope clamp and the nearest edge (rope wedge or pocket) should be at least 1 x rope diameter.
Figure 1 _________________________________
3
Wire rope and rope guide
Wire rope and rope guide are parts subject to wear whose life can be increased by regular lubrication
AN 120057.002_EN / A 767.EN
according to the maintenance schedule. Clean drum and rope guide before lubrication.
Page 3
3.1
Removing the wire rope and the rope guide
3.1.1
Size GM 800.4, 1000.6, 2000.3, 3000.4
3.1.1.1
Model E, D, DB, DQA and S Type 2/1, 4/1 und 6/1 1
5. Turn the rope guide ring (11) until the joining tie (14,15) can be untightened and removed. 6. Expand the rope guide ring (11) and remove it. 7. Demount the extension spring (17) and remove the rope straining ring (16). 8. Completely reel off the rope and detach rope clamps (12,13).
3.1.2
Size GM 5000.3, 6000.3
3.1.2.1
Model E and DQA Type 2/1
3
2
1
3
2 1
4
1
4
5 5 6 6 8 8
4 9
4
7
9
7
Figure 2
Figure 4 10
12
14 15
11
18
16 14
19
16
15 7
13
11
7
17
13 12 Figure 3
1. Lower the bottom block and place it e.g. on the working platform or on the floor. 2. Set the hoist limit switch so that lowering beyond the lowest hook position becomes possible. 3. Remove the locking stud (4) at the fixed point tie– bar (3), take off the tie–bar, remove the rope sockets (2 and 5–9) and detach the rope ends (6,7,8). 4. Demount the catch (18,19) of the rope guide ring (11). Page 4
Figure 5 1. Lower the bottom block and place it on working platform, ground etc. 2. Set the hoist limit switch in such a way that lowering beyond the lowest hook position becomes possible. 3. Remove the locking stud (4) at the fixed point tie– bar (3), take off the tie–bar, remove the rope sockets (2 and 5–9) and detach the rope ends (6,7 amd 8). Data : 30.03.2012
4. Demount the catch (18,19) of the rope guide ring (11). 5. Loosen the tensioning parts (16) and demount the rope guide (11). 6. Completely reel off the rope and detach rope clamps (12 and 13).
3.1.2.2
Model D, DB and U Type 2/1, 4/1 and 6/1
12
3.1.2.3
13
14 10
3. Remove the tie–bar (14) with its security elements, remove the rope sockets (6–12) and detach the rope end (6,7,8). 4. Demount the catch (20,21) of the rope guide ring (17). 5. Loosen the tensioning parts (22) and demount the rope guide (17). 6. Completely reel off the rope and detach rope clamps (18 and 19).
11 12 11 10
15
6 9
Model DQA Type 4/1 (Figure 6 and Figure 7 )
1. Lower the bottom block and place it on the working platform or floor. 2. Set the hoist limit switch so that a lowering beyond the lowest hook position becomes possible. 3. Remove the tie–bar (14) with its security elements, remove the rope sockets (6–12) and detach the rope end (6,7,8). 4. Demount the catch (20,21) of the rope guide ring (17). 5. Loosen the tensioning parts (22) and demount the rope guide (17). 6. Completely reel off the rope and detach rope clamps (18 and 19).
3.1.2.4
Model Z
8 7
16
Figure 6
1
2
22 20
Typ 8/2 Figure 8 21
1
17
7
2
19 18 Figure 7 1. Lower the bottom block and place it on the working platform or floor. 2. Set the hoist limit switch so that a lowering beyond the lowest hook position becomes possible. AN 120057.002_EN / A 767.EN
Typ 4/2
Figure 9
Page 5
1/2
1. Let down and place bottom block. 2. Set the hoist limit switches at both lifting gears so that lowering beyond the lowest hook position is possible. 3. Remove the catches (7) from both rope guide rings (3) . 4. Loosen the straining parts (8) and demount both rope guides (3). 5. Pull off the lifting motor connector from lifting gear 1 and completely reel off the rope end of lifting gear 2. Detach rope clamps (5). 6. Plug the connector of the lifting motor into lifting gear 1 and pull off the one from lifting gear 2. Let the rope end of lifting gear 1 entirely reel off and detach rope clamps (5).
8 6
7 3
10 5
4
Figure 10 _________________________________
3.1.3
Size GM 3000.4, 5000.3
3.1.3.1
Model E and D Type 4/2
1. Lower the bottom block and place it on the working platform or floor.
2. Set the hoist limit switch so that a lowering beyond the lowest hook position becomes possible. 3. Remove the flights (9, 10) on both cable guides (5). 4. Turn the cable guides until the tension springs (8) can be unhooked. 5. Unhook the tension springs by unlocking the assembly hooks on both cable guides. 6. Allow the cable to run out completely and release the cable clamps (3, 4).
10
5 9 6
3
8
7
4
2
1
Typ 4/2
2 Figure 11
Page 6
Data : 30.03.2012
3.2
Installation of a new rope and of the rope guide
3.2.1
Size GM 800.4, 1000.6, 2000.3, 3000.4
3.2.1.1
Model E, D, DB, DQA and S Type 2/1, 4/1 and 6/1
see Figure 2 and Figure 3 1. Pay out the new original spare rope on the ground under the electric rope hoist. Make sure the rope is twist– and buckling–free.
Figure 12 2. Clean the rope drum (10) and evenly spray it with chailife S spray grease. 3. Push the wire rope (7) from below under the rope clamps (12,13) so that the rope end protrudes by approx. 3 cm. Tighten the fastening screws according to the prescribed torques. Figure 13 (1) and “Technical Data; Wire rope hoist, Section 1.6 -Tightening torques”.
8. Pull the ending rope line through the guide aperture of the rope guide ring and fasten the joining tie (15). 9. Twist the rope guide until the guide edge engages in the slit of the catch (18) at the drum casing. Then fasten the catch on the rope guide ring. (11,18 and 19). 10. Clean the hole in the rope lock (9) and lubricate with PBC installation paste. 11. Reeve the free rope end without twisting and fasten it in the rope sockets (2 and 5–9) of the fixed point tiebar (3). For reeving, see Figure 14. 2/1
4/1
6/1
1
Figure 13 4. Wind the rope around the drum by approx. 6–8 turns ; make sure the rope is taut and twist–free. 5. Conduct the straining ring (16) over the drum and suspend the tension spring (17) in such a way that the straining ring firmly encloses the rope turns. The straining ring frame points towards the hoist gear. 6. Grease the rope drum around the rope guide ring with special grease PG 75. 7. Spread the rope guide ring (11) and lead it over the drum so that its threaded segments engage in the grooves of the rope drum and that the groove engages over the frame of the straining ring.
AN 120057.002_EN / A 767.EN
Figure 14 12. Suspend fixed point tie–bar and install the locking stud (1 and 4). 13. Install a rope clamp (8 see figure Figure 2) at the free rope end. For tightening torque values see “Technical Data; Wire rope hoist, Section 1.6 -Tightening torques”. and rope clamp projections, see section 2. 14. Completely coil up the rope and adjust the hoist limit switch to the highest and lowest position. See “Operating instruction Hoist limit switch”
Page 7
3.2.2
Size GM 5000.3, 6000.3
3.2.2.1
Model E Type 2/1
see Figure 4 and Figure 5 1. Pay out the original spare rope on the ground under the electric rope hoist. Make sure the rope is twist and buckling–free.
Figure 15 2. Clean the rope drum (10) and evenly spray it with chainlife S spray grease. 3. From below, push the wire rope (7) underneath the rope clamps (12,13) until the rope end protrudes by approx. 3 cm. Tighten the fastening screws according to the prescribed torques. Figure Figure 16 (1) and “Technical Data; Wire rope hoist, Section 1.6 -- Tightening torques”.
5. Grease the rope drum around the rope guide ring with the special grease PG 75. 6. Spread the rope guide (11) and lead it over the drum (10) in such a way that its threaded segments engage in the grooves of the rope drum and that the ending rope line (7a) exits through the guide slit. 7. Suspend tension parts (16) and adjust them by turning the eye bolt until the rope guide ring is fitting tight. 8. Twist the rope guide ring (11) until the guide edge engages in the aperture of the catch (15) at the drum casing. Then fasten the catch on the rope guide ring (14). 9. Clean the hole in the rope lock (9) and lubricate with PBC installation paste. 10. Reeve the free rope end without twisting and fasten it in the rope socket (2and 5–9) of the fixed point tie–bar (3). For reeving, see Figure 17
1
Figure 17
Figure 16 4. Wind the rope around the drum (10) by approx. 6–8 turns. Make sure the rope is taut and twist–free.
Page 8
11. Suspend the fixed point tie–bar (3) and install the locking stud (1 and 4). Attach a rope clamp (8 see Figure 4) to the free rope end. For tightening torque values see “Technical Data; Wire rope hoist, Section 1.6 -- Tightening torques”. and rope clamp projections, see section 2. 12. Entirely coil up the rope and adjust the limit switch to the highest and lowest position. See “Operating instruction Hoist limit switch”
Data : 30.03.2012
3.2.2.2
Model D, DB, DQA Type 2/1, 4/1 and 6/1 (see Figure 6 and Figure 7)
1. Pay out the original spare rope on the ground under the electric wire rope hoist. Make sure the rope is twist– and buckling–free.
7. Suspend tension parts (22) and adjust them by turning the eye bolt until the rope guide ring is fitting tight. 8. Twist the rope guide ring (17) until the guide edge engages in the aperture of the catch (21) at the drum casing. Then fasten the catch on the rope guide ring (20). 9. Reeve the free rope end without twisting and fasten it in the rope socket (6,8,9,10,11,15) of the fixed point tie–bar (14). For reeving, see Figure 20. 2/1
4/1
Figure 18 2. Clean the rope drum (16) and evenly spray it with chainlife S spray grease. 3. From below, push the wire rope (7) underneath the rope clamps (18, 19) until the rope end protrudes by approx. 3 cm. Tighten the fastening screws according to the prescribed torques. Figure 19 (1) and “Technical Data; Wire rope hoist, Section 1.6 -- Tightening torques”.
6/1
1
Figure 20 Figure 19 4. Tautly wind the rope around the drum (16) by approx. 6–8 turns. Make sure the rope is twist–free. 5. Grease the rope drum around the rope guide ring with the special grease PG 75. 6. Spread the rope guide (17) and lead it over the drum (16) in such a way that its threaded segments engage in the grooves of the rope drum and that the ending rope line (7a) exits through the guide slit.
AN 120057.002_EN / A 767.EN
10. Clean the hole in the rope lock (9) and lubricate with PBC installation paste. 11. Fit the fixed cross member (14) to the cross member mounting using bolts (13) and bearing bushings (12) and fasten it in place with the lid and screws (10,11). Install a rope clamp (8) at the free rope end. For tightening torque values see “Technical Data; Wire rope hoist, Section 1.6 -- Tightening torques”, and rope clamp projections, see section 2. 12. Entirely coil up the rope and adjust the limit switch to the highest and lowest position. See “Operating instruction Hoist limit switch”.
Page 9
3.2.2.3
Model U
see Figure 6 and Figure 7 1. Pay out the original spare rope on the ground under the electric wire rope hoist. Make sure the rope is twist– and buckling–free.
Figure 21 2. Clean the rope drum (16) and evenly spray it with chainlife S spray grease. 3. From below, push the wire rope (7) underneath the rope clamps (18, 19) until the rope end protrudes by approx. 3 cm. Tighten the fastening screws according to the prescribed torques. Figure 22 (1) and “Technical Data; Wire rope hoist, Section 1.6 -- Tightening torques”.
6. Spread the rope guide (17) and lead it over the drum (16) in such a way that its threaded segments engage in the grooves of the rope drum and that the ending rope line (7a) exits through the guide slit. 7. Suspend tension parts (22) and adjust them by turning the eye bolt until the rope guide ring is fitting tight. 8. Twist the rope guide ring (17) until the guide edge engages in the aperture of the catch (21) at the drum casing. Then fasten the catch on the rope guide ring (20). 9. Clean the hole in the rope lock (9) and lubricate with PBC installation paste. 10. Reeve the free rope end without twisting and fasten it in the rope socket (6,8,9,10,11,15) of the fixed point tie–bar (14). For reeving, see Figure 23.
1 2/1
4/1 Figure 23
Figure 22 4. Tautly wind the rope around the drum (16) by approx. 6–8 turns. Make sure the rope is twist–free. 5. Grease the rope drum around the rope guide ring with the special grease PG 75.
Page 10
11. Fit the fixed cross member (14) to the cross member mounting using bolts (13) and bearing bushings (12) and fasten it in place with the lid and screws (10,11). Install a rope clamp (8) at the free rope end. For tightening torque values see “Technical Data; Wire rope hoist, Section 1.6 -- Tightening torques”, and rope clamp projections, see section 2. 12. Entirely coil up the rope and adjust the limit switch to the highest and lowest position. See “Operating instruction Hoist limit switch”
Data : 30.03.2012
3.2.2.4
Model Z
see Figure 10 1. In order to avoid kinks and twists, first pay out the original wire rope in full length on the floor under the twin lifting gear. 2. Clean the rope drum (1) and evenly spray it with chainlife S spray grease. 3. Plug the connector of the lifting motor into lifting gear 1 and pull off the one from lifting gear 2. Push the wire rope (10) from below under the rope clamps (5) of the rope drum (1) until the rope end protrudes by approxim. 3 cm. Tighten the fastening screws (4) according the prescribed torques. Figure 24 (1) and “Technical Data; Wire rope hoist, Section 1.6 -- Tightening torques”. 1
Figure 24
AN 120057.002_EN / A 767.EN
4. Wind the rope around the drum with approximately 6–8 turns; make sure the rope is taut and twist–free. 5. Grease the rope drum around the rope guide ring with special grease PG 75. 6. Spread the rope guide ring (3) and lead it over the drum until its threaded segments engage in the grooves of the rope drum and the ending rope line (10a) comes out through the guide aperture. 7. Suspend straining parts (8) and adjust them by turning the eye bolts until the rope guide ring is fitting tight. 8. Turn the rope guide ring until the guide edge engages in the aperture of the catch (7) at the drum casing. Then fasten the catch on the rope guide ring (6). 9. Pay out the wire rope until the rope drum (1) is completely covered. 10. Pull off the lifting motor connector from lifting gear 1 and plug it into lifting gear 2. 11. Reeve the free rope end without twisting and push it from below under the rope clamps (5) of the rope drum (2) until the rope end protrudes by approx. 3 cm. Tighten the fastening screws according to the prescribed torques. 12. Apply steps 4–9 also to the rope drum (2). 13. Set the hoist limit switch for highest and lowest position. See “Operating instruction Hoist limit switch”
Page 11
3.2.3
Size GM 3000.4, 5000.3
3.2.3.1
Model E and D Type 4/2
1. Roll out the original replacement wire rope either under the electric wire rope hoist and onto the floor without twists so that no kinks occur, or have ready a kink ---free wire rope wound on a special reel (with two cable ends guided outward). 2. Clean the rope drum (1) and evenly spray it with chainlife S spray grease.
3. Reeve the wire rope (2) without kinks into the bottom block and slide it through at both drum ends under the cable clamps (3,4) until each of the cable ends protrude about 3 cm. Tighten the fastening screws with the specified torque. Figure 25 (1) and “Technical Data; Wire rope hoist, Section 1.6 -- Tightening torques”. 4. Wind the rope around the drum with approximately 6–8 turns; make sure the rope is taut and twist–free. 5. Grease the rope drum around the rope guide ring with special grease PG 75. 10
5 9 6
3
8
7
4
Figure 25 2
1
6. Lay one cable guide (5) around the drum so that the rope fall runs through the guide slot. The guide elements (6) will then lie next to the already wound cable toward the centre of the drum. Insert the plastic ends (7) of the cable guide into one another 7. Aligning the cable guide: The unwinding wire rope must be positioned in the centre of the guide slot and the guide elements must lie flush in a drum groove. 8. Attach the springs (8). The assembly hooks thereby latch into the second position with an audible
2 click. 9. Turn the cable guide until the guide edge on the drum housing engages in the slot of the flight (9). Bolt the flights onto the cable guide. (5, 9 and 10) 10. Perform steps 5---9 on the second cable guide as well. 11. Wind the wire rope completely and reset the hoist limit switch for the highest and lowest hook positions. See “Operating instruction Hoist limit switch”
_________________________________
3.3
Elimination of stretch twisting
Where ropes are used, a tendency to twist develops over the course of time. The result is that the bottom block twist when the rope is unloaded. To eliminate this twist, the bottom block must be lowered to the ground, the rope lock released and the rope turned 180° ”tighter”. The rope must then be attached Page 12
firmly to the bottom block again. The effectiveness of the action taken must be checked by raising and lowering the hoist without a load. It may be necessary to repeat this procedure several times.
Data : 30.03.2012
Kransysteme
Technical data incl. Declaration of Conformity / Declaration of installation for
ABUS – Wire rope hoist
E
S
D
Type GM 3000.4
DA
-E -D - DA - DQA -S
- 2/1 - 4/1
Wheel diameter
DQA
- 130 - 160 - 200 - 280
250-068733
Serial No. ___________________
Manufacturer ABUS Kransysteme GmbH Sonnenweg 1 D – 51647 Gummersbach
Tel. ##49 2261 / 37–0 Fax. ##49 2261 / 37247 [email protected]
This document may not be reproduced or given to third parties and its content must not be divulged or used for other purposes without the prior written permission of ABUS. You will be liable to pay compensation for any breach of this provision. All patent and registered design rights reserved.
These installation, operation and maintenance instructions are intended for use in an Englishspeaking country by English–speaking specialist personnel. AN 120061.004_EN / A 772.EN
15.05.2012
Original operating manual
Contents 1
Technical Data . . . . . . . . . . . .
3
1.5.1
Model GM 3000.4 E2/1 . . . . . . . . . .
10
1.1
Sound Emissions . . . . . . . . . . . . . . . . .
3
1.5.2
Model GM 3000.4 E4/1 . . . . . . . . . .
11
1.2
Electrical Data of Motors . . . . . . . . . .
4
1.5.3
Model GM 3000.4 D2/1 . . . . . . . . . .
12
1.3
Weights and Dimensions . . . . . . . . . .
5
1.5.4
Model GM 3000.4 DQA2/1 . . . . . . .
13
1.3.1
Dimensions series E . . . . . . . . . . . . . .
5
1.5.5
Model GM 3000.4 D4/1 . . . . . . . . . .
14
1.3.2
Dimensions series D . . . . . . . . . . . . . .
5
1.5.6
Model GM 3000.4 DQA4/1 . . . . . . .
15
1.3.3
Dimensions series S . . . . . . . . . . . . . .
5
1.5.7
Model GM 3000.4 DA2/1 . . . . . . . . .
16
1.4
Load Data for Trolley Track . . . . . . . .
6
1.5.8
Model GM 3000.4 DA4/1 . . . . . . . . .
17
1.4.1
Model E . . . . . . . . . . . . . . . . . . . . . . . . .
6
1.5.9
Model GM 3000.4 S2/1 . . . . . . . . . .
18
1.4.2
Model D . . . . . . . . . . . . . . . . . . . . . . . . .
6
1.5.10 Model GM 3000.4 S4/1 . . . . . . . . . .
19
1.4.3
Model S . . . . . . . . . . . . . . . . . . . . . . . . .
9
1.5
Tightening torques . . . . . . . . . . . . . . .
10
2
20
Page 2
Declaration of Conformity . .
Data : 15.05.2012
1
1.1
Technical Data
Sound Emissions
As the distance between the noise source and the workplace is normally not fixed in the case of hoists, the sound power level is quoted in addition to the required sound pressure level figure (given for a distance of 4 m in this case). The sound power level may be used to calculate the sound pressure level at any distance (under free field conditions ± 2dB (A)).
AN 120061.004_EN / A 772.EN
Hoist type
Sound pressure level LP, m dB(A) at 4m
Sound power level LW, m dB(A)
GM 3000.4
67
87
The measurements made were based on DIN 45635, Part 61 and were made by the substitution method using a sound power source.
Page 3
1.2
Electrical Data of Motors
Hoist lifting drives
P [kW]
Type
L6
H6
ED [%]
c/h
Rated and start. current in A with 50 Hz
cos ϕ N
cos ϕ A
380 – 415 V IN
IA
GM 3000.5
1,2/7,6 1,0/6,2 0,8/4,8 0,6/3,7
60 60 60 60
360 420 420 420
6,1/16,8 5,4/13,0 5,1/11,5 4,9/10,0
9,4/75 9,4/75 9,4/75 9,4/75
0,59/0,83 0,52/0,78 0,45/0,73 0,39/0,67
0,68/0,88 0,68/0,88 0,68/0,88 0,68/0,88
GM 3000.5
1,9/12,3 1,5/9,9 1,3/8,0 1,0/6,2
50 60 60 60
300 360 420 420
8,2/22,9 7,8/18,9 7,5/16,3 7,5/14,0
13,8/117 13,8/117 13,8/117 13,8/117
0,71/0,94 0,62/0,93 0,53/0,89 0,45/0,82
0,80/0,77 0,80/0,77 0,80/0,77 0,80/0,77
The ED (c/h) values are the total from the precision and main hoisting speed: They are split up at 1/3 (2/3) into prec. hoisting, and at 2/3 (1/3) into main hoisting operation. The required fuses and feed line cross sections are determined according to the hoist motor data. They are also applicable to electrically operated trolleys. The feed line Cable cross section (A) and cable length (L) are calculated acc. to the following formula:
A= L=
1,73 * L * I A * cos ϕ A u*κ u*κ*A 1,73 * I A * cos ϕ A
(mm2) (m)
u = voltage drop in V (max. 5% of the rated voltage) z.B.: U=400 V
u=U * 5% = 400 * 0,05 = 20 V
κ = conductivity (for copper = 57 m ) Ω * mm2
Trolley drives Trolley
n [min –1]
ED [%]
c/h
P [kW]
E 130 E 160
620 / 2690 595 / 2770
50 50
240 240
AZP 130
620 / 2690
50
AZP 130
595 / 2770
AZP 160
380 – 415 V
cos φ N
cos φ A
0.52 / 2.10 0.57 / 3.20
0.75 / 0.85 0.65 / 0.84
0.91 / 0.91 0.82 / 0.92
0.37 / 0.57
0.52 / 2.10
0.75 / 0.85
0.91 / 0.91
0.06 / 0.28
0.35 / 0.83
0.57 / 3.20
0.65 / 0.84
0.82 / 0.92
240
0.10 / 0.48
0.53 / 1.59
0.92 / 5.90
0.66 / 0.80
0.71 / 0.91
50
240
0.14 / 0.65
0.68 / 1.68
1.45 / 8.10
0.67 / 0.86
0.80 / 0.82
620 / 2780
50
240
0.18 / 0.80
0.92 / 2.10
1.75 / 10.1
0.65 / 0.84
0.75 / 0.85
AZP 280
620 / 2750
50
240
0.14 / 0.65
0.68 / 1.68
1.45 / 8.10
0.67 / 0.86
0.80 / 0.82
AZP 280
620 / 2780
50
240
0.18 / 0.80
0.92 / 2.10
1.75 / 10.1
0.65 / 0.84
0.75 / 0.85
IN
IA
0.04 / 0.18 0.06 / 0.28
0.37 / 0.57 0.35 / 0.83
240
0.04 / 0.18
50
240
550 / 2760
50
AZP 200
620 / 2750
AZP 200
Page 4
Data : 15.05.2012
1.3
Weights and Dimensions
1.3.1
Dimensions series E
Size
Type
Hook path [m]
Dimensions [m] length x width x height
GM 3000.4
2/1
12
1.05 x 1.40 x 0.65 1)
GM 3000.4
2/1
20
1.25 x 1.40 x 0.65 1)
GM 3000.4
2/1
30
1.55 x 1.40 x 0.65 1)
GM 3000.4
4/1
6
1.05 x 1.40 x 0.65 1)
GM 3000.4
4/1
10
1.25 x 1.40 x 0.65 1)
C–Dimension for standard flange widths
Increase in C dimension for each 50 mm increase in flange width
665 1)
62 1)
580 1)
80 1)
1) standard flange widths N=300 mm; For other flange width, the width is changed accordingly. Weights for the hoist are given in the data sheet in the test book.
1.3.2
Dimensions series D
Sizes
Type
Model
GM 3000.4
2/1
D
2.90 x 1.20 x 0.70
GM 3000.4
2/1
DB
2.80 x 2.20 x 1.10
GM 3000.4
2/1
DQA
GM 3000.4 DL=130
4/1
D
2.90 x 1.40 x 0.70
GM 3000.4 DL=160
4/1
D
3.00 x 1.50 x 0.70
GM 3000.4
4/1
DB
2.80 x 2.20 x 1.10
GM 3000.4
4/1
DQA
GM 3000.4
2/1
DA
2.80 x 1.50 x 0.80
GM 3000.4
4/1
DA
2.90 x 1.20 x 0.70
The length is valid for a trolley–span of 2500 mm. 1) The width of trolleys of series DQA is valid for the largest hook travel of the hoist. Weights for the hoist are given in the data sheet included in the test book. Weights for travel drives are given in the table below.
1.3.3
Dimensions m length x width x height
2.90 x 1.80 x 0.70 1)
2.90 x 1.80 x 0.70 1)
Trolley Type
Weight [kg]
AZP 130
20
AZP 160
30
AZP 200
40
Dimensions series S
Sizes
Type
hook travel [m]
GM 3000.4
4/1
6 / 10
1.80 x 1.95 x 0.65 ( 0.80 )
GM 3000.4
2/1
12 / 20
1.65 x 1.90 x 0.65 ( 0.80 )
Weights for the hoist are given in the data sheet in the test book. ( ) Dimensions incl. transport support Weights for travel drives are given in the table below. AN 120061.004_EN / A 772.EN
Dimensions m length x width x height
Trolley
Weight [kg]
AZP 200
40
AZP 280
50 Page 5
1.4
Load Data for Trolley Track
1.4.1
Model E Load case H
Lifting g capacii ty (kg)
Load case HZ
Load case HS
Rmax 1)
RKAmin 1)
FSKA 2)
FMKA 3)
(kN)
(kN/Wheel)
(kN/Trolley)
(kN/Trolley)
FPUKR 4) 4/16 m/min
in (kN/Katze) at 5/20 m/min
7/28 m/min
GM 3000.4 2/1–E Trolley drive E 130 (HW 12m / 20m) 2500
10.3
1.6
1.6
1.0
8.1
9.9
14.3
3200
12.7
1.6
1.9
1.0
8.7
10.5
15.0
4000
15.5
1.6
2.3
1.0
9.5
11.3
15.7
5000
19.0
1.6
2.8
1.0
10.6
12.3
16.7
GM 3000.4 2/1–E Trolley drive E 160 (HW 12m / 20m) 6300
27.3
2.0
3.5
1.2
14.3
15.0
21.0
GM 3000.4 2/1–E Trolley drive E 160 (HW 30m) 2500
13.0
2.0
1.7
1.2
10.4
11.2
17.2
3200
15.6
2.0
2.0
1.2
11.0
11.8
17.9
4000
18.7
2.0
2.4
1.2
11.8
12.7
18.7
5000
22.2
2.0
2.9
1.2
12.9
13.6
19.6
6300
27.3
2.0
3.5
1.2
14.3
15.0
21.0
GM 3000.4 4/1–E Trolley drive E 160 4000
14.0
1.8
2.4
1.1
––
16.4
24.1
5000
18.5
1.8
2.8
1.1
––
17.7
26.8
6300
22.9
1.8
3.5
1.1
––
19.0
28.1
8000
28.5
1.8
4.3
1.1
––
20.7
29.7
10000
35.1
1.8
5.3
1.1
––
22.6
31.7
12500
43.4
1.8
6.5
1.1
––
24.9
––
1) Wheel load without coefficient 2) Load across track according to DIN 4132 – 3.2.1.
1.4.2
3) Load along track according to DIN 4132 – 3.2.2. 4) Total buffer force if ABUS buffers are used
Model D_
Lifting capacity (kg)
Load case H Rmax (kN)
1)
Load case HZ
RKAmin 1)
FSKA 2)
FMKA 3)
(kN/Wheel)
(kN/Trolleytrack)
(kN/Trolley)
Load case HS FPUKR 4)
in
(kN/Trolley) at
5/20 m/min
7,5/30 m/min
GM 3000.4 2/1---D Trolley drive AZP 130 2500
8.2
2.0
2.7
1.2
10.1
14.6
3200
9.9
2.0
3.3
1.2
10.8
15.2
4000
11.9
2.0
3.9
1.2
11.5
16.0
5000
14.4
2.0
4.7
1.2
12.5
17.0
6300
17.5
2.0
5.8
1.2
14.3
20.0
Page 6
Data : 15.05.2012
Lifting capacity (kg)
Load case H Rmax (kN)
1)
Load case HZ
RKAmin 1)
FSKA 2)
FMKA 3)
(kN/Wheel)
(kN/Trolleytrack)
(kN/Trolley)
Load case HS FPUKR 4)
in
(kN/Trolley) at
5/20 m/min
7,5/30 m/min
12.6 13.5 14.3 16.0 18.0
17.4 18.3 19.6 –– ––
21.6
28.6
12.3 12.9 13.6 14.6 17.1
19.3 20.0 20.8 21.8 25.2
14.2 15.1 16.4 18.1 20.1
21.9 22.9 24.2 –– ––
25.1
36.0
11.1 11.8 12.5 13.5 15.0
17.4 18.1 18.9 19.9 21.5
12.8 13.5 14.8 16.5 18.5 21.0
19.0 20.1 21.5 23.0 25.0 27.3
GM 3000.4 4/1---D Trolley drive AZP 130 4000 5000 6300 8000 10000
12.3 14.7 17.9 22.1 27.0
2.35 2.35 2.35 2.35 2.35
3.6 4.4 5.3 6.6 8.0
1.4 1.4 1.4 1.4 1.4
GM 3000.4 4/1---D Trolley drive AZP 160 12500
33.6
3.0
9.7
1.8
GM 3000.4 2/1---DB Trolley drive AZP 130 2500 3200 4000 5000 6300
9.5 11.1 13.0 15.5 19.0
3.5 3.5 3.5 3.5 3.5
2.5 3.1 3.5 4.3 5.1
2.1 2.1 2.1 2.1 2.1
GM 3000.4 4/1---DB Trolley drive AZP 130 4000 5000 6300 8000 10000
13.4 15.8 19.0 23.1 28.1
3.4 3.4 3.4 3.4 3.4
3.5 4.0 4.8 5.8 7.2
2.1 2.1 2.1 2.1 2.1
GM 3000.4 4/1---DB Trolley drive AZP 160 12500
35.3
4.5
9.3
2.7
GM 3000.4 2/1---DQA Trolley drive AZP 160 2500 3200 4000 5000 6300
12.3 15.1 18.2 22.5 24.5
2.6 2.6 2.6 2.6 2.6
3.2 3.8 4.6 5.7 6.9
1.6 1.6 1.6 1.6 1.6
GM 3000.4 4/1---DQA Trolley drive AZP 160 4000 5000 6300 8000 10000 12500 1) 2) 3) 4)
14.0 18.8 23.0 28.3 34.6 43.0
2.7 2.7 2.7 2.7 2.7 2.7
4.1 5.0 5.9 7.2 8.8 10.8
1.6 1.6 1.6 1.6 1.6 1.6
Wheel load without coefficient Load across track to DIN 4132 – 3.2.1. per trolley track Load along track to DIN 4132 – 3.2.2. Total buffer force if ABUS buffers are used
AN 120061.004_EN / A 772.EN
Page 7
Lifting capacity (kg)
Load case H Rmax (kN)
1)
Load case HZ
RKAmin 1)
FSKA 2)
FMKA 3)
(kN/Wheel)
(kN/Trolleytrack)
(kN/Trolley)
Load case HS FPUKR 4) 5/20 m/min
in
(kN/Trolley) at 7,5/30 m/min
GM 3000.4 2/1---DA Trolley drive AZP 130 2500 3200 4000 5000 6300
8.2 9.9 11.9 14.4 17.5
2.0 2.0 2.0 2.0 2.0
2.7 3.3 3.9 4.7 5.8
1.2 1.2 1.2 1.2 1.2
10.1 10.8 11.5 13.5 14.3
14.6 15.1 16.0 17.0 20.0
13.1 14.0 15.3 17.0 18.9 21.4
20.0 21.0 22.3 24.0 25.9 28.3
GM 3000.4 4/1---DA Trolley drive AZP 160 4000 5000 6300 8000 10000 12500 1) 2) 3) 4)
12.7 15.1 18.3 22.5 27.5 33.6
2.89 2.89 2.89 2.89 2.89 2.89
3.3 4.0 5.3 6.6 8.0 9.7
1.75 1.75 1.75 1.75 1.75 1.75
Wheel load without coefficient Load across track to DIN 4132 – 3.2.1. per trolley track Load along track to DIN 4132 – 3.2.2. Total buffer force if ABUS buffers are used
Page 8
Data : 15.05.2012
1.4.3
Model S Load case H
Lifting capacity (kg)
Load case HZ
Load case HS FPUKR 4)
in
(kN/Trolley)
Rmax 1)
Rmin 1)
RGmax
RGmin
FSKA 2)
FMKA 3)
(kN)
(kN/ Wheel)
(kN)
(kN/ Wheel)
(kN/Trolleytrack)
(kN/Trolley)
5/20 m/min
7,5/30 m/min
0.3 0.3 0.3 0.3
1.5 1.9 2.3 2.8
1.6 1.8 2.1 2.3
11.2 12.6 14.2 16.2
15.9 17.3 18.9 20.9
0.2 0.2 0.2 0.2
1.45 1.8 2.2 2.7
1.55 1.8 2.0 2.25
11.0 12.5 14.0 15.8
15.6 17.0 18.5 20.4
0.6 0.6 0.6 0.6 0.6
2.3 2.65 3.25 4.1 5.0
2.5 2.8 3.2 3.6 4.1
14.4 16.8 18.5 21.6 24.7
20.3 22.5 24.5 27.5 31.1
0.4 0.4 0.4 0.4 0.4
2.0 2.5 3.0 3.7 4.6
2.5 2.7 3.0 3.5 3.9
13.9 16.5 18.0 21.0 24.2
20.0 22.0 24.0 27.0 30.8
at
GM 3000.4 2/1–S Trolley drive AZP 200 for S1 (Top flange width 600mm): 2500 3200 4000 5000
30.5 37.0 44.8 54.8
23 29 35 42
19.0 24.0 30.0 37.5
for S2 (Top flange width 700mm): 2500 3200 4000 5000
29.0 36.0 43.0 52.6
22.0 27.0 32.6 39.8
15.9 20.5 25.3 31.4
GM 3000.4 4/1–S Trolley drive AZP 280 for S1 (Top flange width 600mm): 4000 5000 6300 8000 10000
43.0 52.0 64.5 80.0 98.4
5.4 5.4 5.4 5.4 5.4
31.0 38.0 47.2 60.0 74.5
for S2 (Top flange width 700mm): 4000 5000 6300 8000 10000
40.0 49.0 60.0 74.0 92.0
5.1 5.1 5.1 5.1 5.1
25.5 32.0 40.0 50.0 63.0
Dimensions S1 – S3: Dimension sheet M–ES–103–.. 1) 2) 3) 4)
Wheel load without coefficient Load across track to DIN 4132 – 3.2.1. per trolley track Load along track to DIN 4132 – 3.2.2. Total buffer force if ABUS buffers are used
AN 120061.004_EN / A 772.EN
Page 9
1.5
Tightening torques
1.5.1
Model GM 3000.4 E2/1
M24: 150 M30: 290
42 Nm
25 Nm
6,5 Nm 25 Nm 1) 5 Nm
4 Nm 1)
10 Nm
25 Nm 50 Nm
35 Nm
6,5 Nm
85 Nm
120 Nm
1) 2)
locking with Loctite 243 without safety device Safety devices all other screws are self–locking
t from flange thickness t (mm) < 12 60 Nm ≥ 12 80 Nm Tightening torques (in Nm) and safety devices for screwed connections Page 10
Figure 1
Data : 15.05.2012
1.5.2
Model GM 3000.4 E4/1
10 Nm 290 Nm
4 Nm 1)
75 Nm
6,5 Nm 25 Nm1)
75 Nm
25 Nm
5 Nm 35 Nm
50 Nm
6,5 Nm
85 Nm 120 Nm
1) 2)
locking with Loctite 243 without safety device Safety devices all other screws are self–locking
t from flange thickness t (mm) < 12 60 Nm ≥ 12 80 Nm
Figure 2
Tightening torques (in Nm) and safety devices for screwed connections AN 120061.004_EN / A 772.EN
Page 11
1.5.3
Model GM 3000.4 D2/1 50 Nm
75 Nm 42 Nm
10 Nm 25 Nm
42 Nm
42 Nm 42 Nm 5 Nm
50 Nm2)
25 Nm
6.5 Nm 35 Nm
25 Nm1)
25 Nm
42 Nm 85 Nm
5,9 Nm1)
42 Nm
1) 2)
locking with Loctite 243 without safety device Safety devices all other screws are self–locking
Figure 3
Tightening torques (in Nm) and safety devices for screwed connections Page 12
Data : 15.05.2012
1.5.4
Model GM 3000.4 DQA2/1
50 Nm
115 Nm
42 Nm
42 Nm
6.5 Nm
5 Nm
25 Nm
10 Nm
50 Nm2)
25 Nm1)
42 Nm
75 Nm
75 Nm 75 Nm
1) 2)
85 Nm
locking with Loctite 243 without safety device Safety devices all other screws are self–locking
42 Nm
10 Nm1)
42 Nm
Figure 4
Tightening torques (in Nm) and safety devices for screwed connections AN 120061.004_EN / A 772.EN
Page 13
1.5.5
Model GM 3000.4 D4/1 50 Nm
10 Nm 75 Nm
75 Nm
75 Nm 75 Nm
42 Nm
25 Nm
50 Nm
42 Nm 5 Nm 6.5 Nm D130: 35 Nm D160: 75 Nm 25 Nm1)
25 Nm 85 Nm 42 Nm
1) 2)
locking with Loctite 243 without safety device Safety devices all other screws are self–locking
D130: 5,9 Nm1) D160: 10 Nm1)
D130: 42 Nm D160: 85 Nm Figure 5
Tightening torques (in Nm) and safety devices for screwed connections Page 14
Data : 15.05.2012
1.5.6
Model GM 3000.4 DQA4/1
25 Nm
50 Nm 115 Nm
10 Nm
42 Nm
6.5 Nm
5 Nm
75 Nm
75 Nm
25 Nm1)
50 Nm2)
42 Nm
75 Nm
42 Nm
75 Nm
85 Nm
75 Nm
1) 2)
locking with Loctite 243 without safety device Safety devices all other screws are self–locking
10 Nm1)
42 Nm Figure 6
Tightening torques (in Nm) and safety devices for screwed connections AN 120061.004_EN / A 772.EN
Page 15
1.5.7
Model GM 3000.4 DA2/1
50 Nm
10 Nm 42 Nm 25 Nm
50 Nm
42 Nm
450 Nm
35 Nm
5 Nm 6.5 Nm
42 Nm
25 Nm1)
25 Nm
85 Nm
25 Nm
42 Nm
75 Nm 5,9 Nm1) 1) 2)
locking with Loctite 243 without safety device Safety devices all other screws are self–locking
42 Nm
Figure 7
Tightening torques (in Nm) and safety devices for screwed connections Page 16
Data : 15.05.2012
1.5.8
Model GM 3000.4 DA4/1
75 Nm
75 Nm 42 Nm 10 Nm
50 Nm
50 Nm
25 Nm
6.5 Nm
5 Nm 450 Nm
42 Nm 25 Nm1) 25 Nm
85 Nm
42 Nm
35 Nm
42 Nm 10 Nm1) 75 Nm locking with Loctite 243 without safety device Safety devices all other screws are self–locking 1) 2)
85 Nm
Figure 8
Tightening torques (in Nm) and safety devices for screwed connections AN 120061.004_EN / A 772.EN
Page 17
1.5.9
Model GM 3000.4 S2/1
75 Nm
25 Nm
75 Nm
115 Nm 10 Nm 42 Nm
42 Nm
25 Nm
50 Nm2)
6.5 Nm
5 Nm
42 Nm
450 Nm 25 Nm1)
19 Nm 85 Nm 85 Nm
115 Nm
42 Nm
10 Nm1)
85 Nm
1) 2)
locking with Loctite 243 without safety device Safety devices all other screws are self–locking
Figure 9
Tightening torques (in Nm) and safety devices for screwed connections
Page 18
Data : 15.05.2012
1.5.10 Model GM 3000.4 S4/1
50 Nm
115 Nm 50 Nm
25 Nm1)
10 Nm 75 Nm
75 Nm
210 Nm
75 Nm
6.5 Nm 5 Nm
85 Nm
25 Nm 130 Nm
10 Nm1)
130 Nm
450 Nm 19 Nm 300 Nm
42 Nm
1) 2)
locking with Loctite 243 without safety device Safety devices all other screws are self–locking
Figure 10
Tightening torques (in Nm) and safety devices for screwed connections
AN 120061.004_EN / A 772.EN
Page 19
2
Declaration of Conformity
applies if this wire rope hoist is operated as an independent machine.
Declaration of installation under the terms of the machinery directive of Appendix II 1B applies if this wire rope hoist is installed in another machine. In addition, the wire rope hoist must nut be commissioned until it has been confirmed that the machine in which the wire rope hoist is installed conforms in its entirety with the provisions of the stated EC directives in the version in force on the date of issue.
ABUS Kransysteme GmbH Sonnenweg 1 D – 51647 Gummersbach
We Adress
Authorised person for assembly of the special technical documentation: Name, function, company designation Michael Müller Department head of technical documentation ABUS Kransysteme GmbH address Sonnenweg 1 D ---51647 Gummersbach hereby declare, that the product:
ABUS---Wire rope hoist GM 3000.4 E 2/1 , D 2/1 , DB 2/1 , DQA 2/1 E 4/1 , D 4/1 , DB 4/1 , DQA 4/1 S 2/1 , S 4/1 , DA 2/1 , DA 4/1 in series production
Designation Hoist Model
the regulations of the european guideline 2006/42/EG Machines 2006/95/EG Low voltage 2004/108/EG Electromagnetic compatibility is in accordance with the version in force on the date of issue. The following harmonized standards were used: EN ISO 12100 EN 12077 EN 13586 EN 12644--- 1+2 EN 60204 T32 EN 60947 EN 61000--- 6--- 4 EN 61000--- 6--- 2 EN 12385--- 3
Safety of machinery, tools and plants Limiting and indicating devices Access Instructions and marking Electrical equipment of machines; requirements for hoists Low--- voltage switchgear Electromagnetic compatibility; Interference emission Electromagnetic compatibility; Resistance to interferences Steel wire ropes --- Safety --- Information for use and maintenance
and the national standards, instructions and specifications DIN 15018 DIN 15020 FEM 9.511 FEM 9.661 FEM 9.683 FEM 9.755 FEM 9.811 FEM 9.941
Cranes; principles for steel structures Hoists; principles for rope drives FEM groups Size and design of rope drives Selection of hoist motors and of travel motors Action to ensure safe working periods Specification for electric hoists Symbols for controls
and the standards referred to therein. Technical documentation is completely available. The operating instructions belonging to it are in the language of the land of users. Name: Dr. Eckhard Bube
Gummersbach, 15/05/2012
Board of Management
___________________________
_________________________
Signature of authorized person
indication for the subscriber
This declaration is in accordance with EN ISO 17050. The ABUS Kransysteme GmbH entertains security system of quality under DIN EN ISO 9001. Page 20
Data : 15.05.2012
Kransysteme
Installation, Operation and Maintenance Instructions
for
ABUS - Pendant control BJ 24
Type
HT
- 211 ✘ 611 - 1011
-D -S
16735993 / 1 Factory No. ___________________
Manufacturer ABUS Kransysteme GmbH Sonnenweg 1 D - 51647 Gummersbach
Tel. ##49 2261 / 37-0 Fax. ##49 2261 / 37247 info@abus- kransysteme.de
This document may not be reproduced or given to third parties and its content must not be divulged or used for other purposes without the prior written permission of ABUS. You will be liable to pay compensation for any breach of this provision. All patent and registered design rights reserved.
These Installation, Operation and Maintenance Instructions are intended for use in an Englishspeaking country by English- speaking specialist personnel. AN 120028.003_EN
01.02.2016
Original operating manual
Contents 1
General . . . . . . . . . . . . . . . . . . .
3
1.1
Use of Operating Instructions . . . . . .
3
1.2
Use for the Intended Purpose . . . . . .
3
1.3
Standards and Regulations . . . . . . . .
3
1.4
Warranty . . . . . . . . . . . . . . . . . . . . . . . .
3
1.5
Other notes . . . . . . . . . . . . . . . . . . . . . .
4
2
Safety . . . . . . . . . . . . . . . . . . . .
2.1
Organizational Notes . . . . . . . . . . . . . .
4.2
Extension of sheathed control line with BJ24 connector system . . . . . . .
11
4.3
Sheathed control line on mobile control carrier . . . . . . . . . . . . .
12
5
Operation . . . . . . . . . . . . . . . . .
13
4
6
Maintenance . . . . . . . . . . . . . .
13
4
6.1
General . . . . . . . . . . . . . . . . . . . . . . . . .
13
6.2
Replacement of Switch Unit . . . . . . . .
13
6.2.1
Direct control . . . . . . . . . . . . . . . . . . . .
13
6.2.2
Contactor- type control . . . . . . . . . . .
13
6.3
Replacement of Protective Rubber Cap . . . . . . . . . . . .
14
3
Description . . . . . . . . . . . . . . .
5
3.1
Type Overview / Type Codes . . . . . . .
5
3.2
Design . . . . . . . . . . . . . . . . . . . . . . . . . .
6
3.2.1
Controls . . . . . . . . . . . . . . . . . . . . . . . . .
6
6.4
Replacement of Housing . . . . . . . . . .
14
3.2.2
Bayonet Mount . . . . . . . . . . . . . . . . . . .
7
6.5
3.2.3
Strain Relief . . . . . . . . . . . . . . . . . . . . . .
7
Replacement of Microswitch for Emergency Shut - Down Function . .
14
3.3
Technical data . . . . . . . . . . . . . . . . . . .
7
6.6
3.4
Declaration of conformity . . . . . . . . . .
8
Replacement of Surround and Head of Emergency Shut - Down Switch . . . . . . . . . . . . . . .
14
3.5
Circuit Diagrams . . . . . . . . . . . . . . . . .
9
7
Disposal . . . . . . . . . . . . . . . . . .
14
8
Service . . . . . . . . . . . . . . . . . . .
14
4
Adaptation of control line . .
10
4.1
Shortening of sheathed control line with BJ 24 connector system . . . . . .
10
Page 2
Data : 01.02.2016
1
1.1
General
Use of Operating Instructions
These installation, operation and maintenance instructions must be read carefully before using the ABUS pendant control for the first time and must be available to operating personnel at all times during the use of the pendant control. Apart from
. instructions for action these instructions also include hazard, warning and safety instructions highlighted by the following symbols: Caution: Hazard to Personnel If you fail to comply with these instructions, there may be an immediate risk of personal injury; premature damage to the equipment may also result in further risks of injury. Compliance with the instructions given in these warnings is essential. Note: These notes are important for the proper, rational use of the product or may concern special features of the product.
1.2
Use for the Intended Purpose
ABUS HT pendant controls are intended for the control of machinery, preferably for the control from ground level of all types of hoists (electric hoists, site hoists, travelling cranes, etc.). The pendant controls are designed either for use in contactor- type control systems or for direct control. Pendant controls are resistant to attack by oils, greases, fuels, caustic solutions, salts and solvents. They are designed to degree of protection IP 65 in accordance with EN 60529 and may be used at ambient temperatures ranging from - 20° C to +70° C. Other operating conditions and modes of operation will require special investigation and agreement. It may be necessary to obtain the manufacturer’s approval. In particular, the following types of use are classed as use other than for the intended purpose: D the movement of loads by pulling the control line D intentional damage by impact etc.
AN120028.003_EN
D ”inching” operation
1.3
Standards and Regulations
When installing the pendant control, you must comply with the general regulations concerning electrical installation work. During the operation of our products, compliance with the applicable accident prevention regulations and general safety regulations is also essential.
IEC 60364- 5- 56 Regulations concerning the installation of power systems with rated voltages up to 1000 V EN 60204- 32 Safety of machinery: Electrical equipment of machines; requirements for hoists. In the case of special applications, it may be necessary to comply with other applicable regulations.
1.4
Warranty
ABUS will assume no liability for damage to the pendant control or hoists or other equipment controlled using the pendant control arising out of or in connection with the use of the pendant control other than for the intended purpose or work carried out incorrectly or by unauthorized persons. ABUS will assume no liability for any loss or damage suffered by third parties. Caution! If you modify any components under your own responsibility, assemble components other than in accordance with the installation instructions or use any components other than genuine ABUS components, ABUS will be released from any warranty obligations for the entire equipment. ABUS pendant controls are largely maintenance- free. For the safe operation of the product, it is essential to use genuine ABUS parts if any spare parts are required. It is recommended that repair and maintenance work should be carried out by the ABUS service department.
Page 3
1.5
Other notes
We are very pleased that you have decided to use an ABUS pendant control and hope that the pendant control will continue to perform its task reliably and to your complete satisfaction for many years. Pendant controls are designed with ergonomic considerations in mind. The controls of the pendant control are inclined slightly from the vertical to facilitate a natu-
ral attitude of the hand and arm of the operator, reducing fatigue and having a positive effect on the position of the entire body. The newly developed configuration of the controls facilitates optimum single- handed operation with sensory feedback as an added safety feature. In addition to having a visual indication of the position of the controls, the operator’s finger or thumb can feel which control is actually being operated at any time.
_________________________________
2
2.1
Safety
Organizational Notes
Operating, maintenance and repair personnel must have read and understood the operating instructions before starting work. The owner of the product is responsible for ensuring safe and non- hazardous operation. In this connection, compliance with the following requirements is essential: . The operating instructions must be made available to operating personnel and operating personnel must be familiarized with these instructions.
Page 4
. The product must be tested before it is commis-
sioned for the first time and following any major modifications. Please follow the instructions given in the documentation for the machine or equipment controlled using the pendant control.
Data : 01.02.2016
3
Description
3.1
Type Overview / Type Codes
The ABUS range of pendant controls includes the following models, see Fig. 1: ABUS type HT- D pendant control for controlling power circuits (direct control) ABUS type HT- S pendant control for controlling control circuits (contactor–type control) HT 211 D
300
30
30
300
HT 211 S
78
78
380
460
40 30 45 78
40 45 40 40 30
HT 1011 S
HT 611 S
78 Fig. 1
AN120028.003_EN
Page 5
The complete type designation of the pendant control is based on the ABUS type code which is explained below:
HT 6 1
1 D
N 2
2
2
K BJ24 Use of lower row K = crane travel drive S = slewing drive Crane travel: Trolley travel: Hoist drive:
2 = 2–stage 2 = 2–stage 2 = 2–stage
N = emergency shutdown Control type: D = direct control S = contactor–type control 1 reserve space Installation space for emergency shutdown switch Number of Installation spaces (2, 6 or 10) ABUS pendant control
3.2
Design
Fig. 2 shows the external and internal parts of a pendant control
8
1. 2. 3. 4. 5. 6. 7. 8.
7
upper section of housing Emergency stop switch protective cap cover switch unit lower section of housing pin contacts isolator of connector
2
3
4
3.2.1
Controls
The controls and indicators on an ABUS pendant control are installed in two separate control areas depending on their importance and the frequency of use. The section with the controls which are used most often is extremely compact and is inclined towards the operator to facilitate use. The upper section also includes the emergency shut down switch, which has a central control function. The emergency shut - down switch is positioned for optimum operation and ease of access at all times.
Page 6
6
Fig. 2
5
1
Data : 01.02.2016
3.2.2
Bayonet Mount
ABUS pendant controls are designed for ease of use and for comfortable holding and access. You must not attempt to move a load by pulling the pendant control. For maintenance work and in emergencies, the pendant control can easily be disconnected from the strain relief device and from the electrical cabling. The unit is equipped with a quick - acting bayonet mount for this purpose (Fig. 3). The bayonet lock of the sheathed control line consists of the bayonet nut, the conical sleeve and the socket insert with pin contacts. To disconnect the pendant control unit from the control lines, it is only necessary to turn the bayonet nut (2) a quarter of a turn (90° ) to the left.
3.2.3
2
Strain Relief
Strain relief is provided by the sheath of the control line.
Fig. 3
3.3
Technical data
Housing Degree of protection to EN 60529: Protection:
IP65 total insulation to EN 60204- 32 Section 6.2.2
Material:
impact–resistant plastic, weatherproof and corrosion resistant
Ambient temperature range:
-20C to +70C
Switches a. ABUS pendant control unit for direct control designed for the direct switching of power circuits Short circuit current: Rated insulation voltage Ui (Group C) Rated operating current Ie (with 400 V / 50 Hz):
16 A 500 V 5A
Service life in mixed operation: (75% AC3 und 25% AC4, switching frequency 600 operations per hour, duty cycle 40%)
with motor output: 1.5 kW
1.5x106 S
2.2 kW
0.6x106 S
Mechanical service life
2.0x106 S (S = number of switching operations)
b. ABUS pendant control unit for contactor–type control systems designed for the switching of control circuits Short circuit current: Rated insulation voltage Ui (Group C) Rated operating current Ie (with 250 V / 50 Hz):
10 A 500 V 5A
Service life in mixed operation: (AC11 230 V)
(S = number of switching operations)
AN120028.003_EN
2.0x106 S Page 7
3.4
Declaration of conformity
We Address
ABUS Kransysteme GmbH Sonnenweg 1 D - 51647 Gummersbach
Authorised person for assembly of the special technical documentation: Name, function, company designation Michael Müller Department head of technical documentation ABUS Kransysteme GmbH address Sonnenweg 1 D - 51647 Gummersbach hereby declare, that the product: Designation
ABUS pendant control
Types
HT 211, HT 611, HT 1011 in Series production
is in accordance with the european guidlines 2006/95/EG 2014/30/EG
Low voltage Electromagnetic compatibility
referring to the version in force on the date of issue. The following harmonized standards were used: EN ISO 12100 EN 61000- 6- 4 EN 61000- 6- 2
Safety of machinery, tools and plants Electromagnetic compatibility; interference emission Electromagnetic compatibility; resistance to interferences
and the national standards, instructions and specifications EN ISO 13850 EN 60204 T32 EN 60947
Safety of machinery, Emergency shut - down systems Electrical equipment of machines; requirements for hoists Low - voltage switchgear
and the standards referred to therein.
Technical documentation is completely available. The operating instructions belonging to it are in the language of the land of users.
Name: Gerald Krebber Department manager Development Gummersbach, 01.02.2016
___________________________ Signature of authorised person
_________________________ Indication for the subscriber
This declaration is in accordance with EN ISO 170050. The company ABUS Kransysteme GmbH runs a certified quality management system according to DIN EN ISO9001. Page 8
Data : 01.02.2016
3.5
Circuit Diagrams
The diagrams below show the circuitry of ABUS pendant controls and the pin allocation of the control cable connection socket. A
1
A
2
- X2
- S1
1
- S1
1
- X2
2
4
2
3 3 4
- S21
5
- S22
6
7
5
4
- S21
5
- S22
- S42
6
7
- S41
- S62
8
9
- S61
- N222S- B HT 611D - N220-B
2
3262
1 1
Emergency stop
14 24
5 6
2
32 62
31.3 31.4
3 4
012
lowering
31 61
2
34 64
31.1 31.2
29.1 29.2
- X2 1 2
lifting
012
- X2 1 2
- S41
43 53
012
44 54
right
33 63
- S42
43 53
14 24
left
44 54
012
31 61
2
33 63
2
32 62
34 64
3 4
2
13 23
5 6
34 64 33.3
2
33 63
2 2
- S22
7 8
HT 211S - N200-B
33.4
lowering
3161
- S1
13 23
33.1
lifting
44 54
- S21
31.3
1424
43 53
31.1
1 1
- S22012
1323
1
2
31.2
Emergency stop
- S21012
2
1
2
29.1
- S1 2
32.1 32.2
29.2
1
30.1 30.2
33.2
30.1 30.2
31.4
HT 211D - N200-B
9 10
HT 611S - N220-B 33
3
012
4
5
2
3 31.2
31.1
2
- X21
41 4 42 44
lowering
4
3
4
1b 1a
- S41 11 012
right
6
12 14- S42 left
4
5
317 32 34
012
2
6
21 5 22 24
41 6 42 44
3
4 34.3
315 32 34
lifting
21 22 24 4
34.2
115 12 14- S22
012
30
Emergency stop
- S21
34.1
2
32
3 31.2
31.1
29
32
2
1
1a 1b
2
- X21
41 4 42 44
lowering
1a 1b
- S1
21 4 22 24
31.3
315 012 32 34
29
lifting
115 12 14- S22
30
Emergency stop
2
- S21 012
31.3
- S1 1
7
8
Fig. 4 AN120028.003_EN
Page 9
Caution! If the control line is used with an ABUS pendant control for direct control, this blind contact pin must always be in position.
Notes: D If item 24 (4) on the socket insert is not used, this position must be equipped with a coding pin, which - must be removed in combination with a contactortype pendant control - must be broken off at the marked point in combination with a direct control system, so that the pin can no longer be removed
D If S41 / S42 or S61 / S62 are to be used for the control of a slewing drive or other equipment with a rotating motion, symbol (5) should be used instead of symbol (6). D If a symbol is rotated 45° , the guide lugs (7) must be removed.
HT 611D - N202K/S-B 32.1 32.2
1
- S21
2
012
1 1
Emergency stop
- S22
13 23
012
14 24
lifting 2
2
32 62
43 53
1424
backward
44 54
33 63
2
3262
31.3 31.4
3 4
012
3161
2
34 64
31.1 31.2
29.1 29.2
- S62
012
44 54
2
1323
forward
lowering
31 61
- X21 2
- S61
43 53
5 6
33 63 34 64
33.1 33.2
- S1 2
1
2
33.3 33.4
30.1 30.2
11 12
13 14
HT 611D - N222K/S-B 32.1 32.2
1424
lifting
3161 3262
2
29.1 29.2
- X21 2
1323
- S42012
4353
right
1424
left
4454
forward 1424
3363
2
3363
2
3464
3 4
3161 3262
2
5 6
- S61012
2
- S41012
4454 lowering
31.1 31.2
2
4353
31.3 31.4
Emergency stop
- S22012
1323
3464
7 8
- S62012
1323
9 10
4353
backward 4454
3161 3262
2
3363 3464
34.3 34.4
- S21012
2 1 1
1
2
33.1 33.2
- S12
1
2
34.1 34.2
1
32.3 32.4
33.3 33.4
30.1 30.2
1112
1314
HT 611S - N202K/S-B 33
1a 1b
- X21
3
2
3
116 14- S62 012
32 backward
4
31.2
31.1
32
29
2
012
forward12
41 4 42 44
lowering
- S61
4
317 34
2
5
21 5 22 24
41 6 42 44
3
4
9
34.3
315 32 34
012
30
lifting
1b 1a
21 22 24 4
34.1
2
Emergency stop
115 12 14- S22
34.2
- S21 012
1
31.3
- S1
10
11
HT 611S - N222K/S-B 33
- S1
1 2
lifting
115
12 14- S22
012
32
4
315
1b 1a
21
22
24 4
34
lowering
30
Emergency stop
- S21 012
35
42
41
- S41
012
right
116
12 14- S42
012
44
left
32
5
317
1a 1b
21
22
24 6
34
42
41
- S61 012
118
forward12 14 - S62
012
44
32 backward
7
318
21
22
24 8
34
41
42
44
1a 1b
- X2 1
4.1 4
2
3
4
6
7
2
8
36.2
3
9
4 36.3
4 36.1
3 34.2
34.1
5
Shortening sheathed Adaptationofof controlconline
Page 10
2
34.3
4 31.3
3 31.2
31.1
32
29
2
10
11
Fig. 5 Data : 01.02.2016
4.2
Extension of sheathed control line with BJ24 connector system
Any standard sheathed control line may be used for extension in combination with spare parts set AN 102282.
If a control line needs to be extended, you must use a connection element consisting of: 1. coupling 2. socket spacer ring 3. plug spacer ring The coupling sides and the spacer rings are marked with plug and socket symbols. (see Fig. 7).
Bayonet lock BJ 30 socket spacer ring Snap housing BJ 30 Socket part
socket symbol coupling
Connector part
plug symbol
Snap housing BJ 30 plug spacer ring Bayonet lock BJ 30 Fig. 7
AN120028.003_EN
Page 11
4.3
Installation of connection element:
Sheathed control line on mobile control carrier
3b 1 3a
2a 1 2b
Fig. 8
Fig. 9
Extension of control line 1. Insert spacer rings into the bayonet lock in accordance with the symbols. The spacer rings are slotted. 2. a. Insert plug- type connector into coupling. b. Lock bayonet lock. 3. a. Insert plug- type connector into coupling. b. Lock bayonet lock.
Page 12
Data : 01.02.2016
5
Operation
The pendant control is used for the control of the machines to which it is connected (normally hoists and hoist trolleys). The pendant control is ergonomically designed, allowing operation with one hand.
If you release the switch, the unit is decelerated to a standstill. If you operate the emergency stop switch, the unit is stopped immediately, whatever the operating situation.
The two- stage push buttons of the pendant control cab be used for operating pole- changing motors. A mechanical or electrical interlock in the pendant control prevents simultaneous operation in two opposite directions. Inching operation should be avoided. Inching may lead to severe erosion of the contacts and premature wear of the switch unit.
3
The functions of the pendant control are as follows (Fig. 10): 4
. If the button is released
the unit is at a standstill.
. button pressed to first stage (1) precision / slow speed
. button pressed to second stage (2) main / fast speed
1
. Red emergency stop switch pressed (3)
unit is stopped even if another button is pressed.
2
. To reset the unit, turn red emergency stop switch to right. (4).
In combination with infinitely variable speed control, the first stage ensures a constant speed while the second stage activates an acceleration ramp set at the factory. If you release the switch from stage 2 to stage 1, the speed which you have reached is maintained.
Fig. 10
_________________________________
6
6.1
Maintenance
General
Each time you start work, the strain relief components, the pendant control housing and the control cable must be inspected for any damage. Compliance with accident prevention regulations and general safety regulations is essential during the operation of our products (see Section 2 above). Caution: Work on pendant controls must only be performed by electricians or other suitably qualified personnel.
AN120028.003_EN
6.2
Replacement of Switch Unit
6.2.1
Direct control
6.2.2
Contactor- type control
see separate ducumentation AN120086
see separate ducumentation AN120085
Page 13
6.3
Replacement of Protective Rubber Cap
6.5
see separate ducumentation AN120089
Replacement of Microswitch for Emergency Shut- Down Function
see separate ducumentation AN120088
6.6 6.4
Replacement of Housing
see separate ducumentation AN120090
Replacement of Surround and Head of Emergency ShutDown Switch
see separate ducumentation AN120087
_________________________________
7
Disposal
When an ABUS pendant control is no longer needed, it can be disposed of in an environmentally compatible way. ABUS pendant controls are high- quality products with a long service life which require almost no maintenance. For disposal of the pendant control, proceed as follows: dismantle the pendant control into its constituent materials (plastic, rubber and metals).
Recycle the separated materials. If recycling is not possible, dispose of the pendant control as special waste.
_________________________________
8
Service Note: The ABUS service centre can be reached day and night on the following numbers:
Page 14
Phone: Fax:
##49 2261 / 37 - 237 ##49 2261 / 37 - 265
Data : 01.02.2016
Kransysteme
Operation Instructions
for
ABUS load indication system
LIS – SV
16735993 / 1
Factory No. ____________________
Manufacturer ABUS Kransysteme GmbH Sonnenweg 1 D – 51647 Gummersbach
Tel. ##49 2261 / 37–0 Fax. ##49 2261 / 37247 [email protected]
This document may not be reproduced or given to third parties and its content must not be divulged or used for other purposes without the prior written permission of ABUS. You will be liable to pay compensation for any breach of this provision. All patent and registered design rights reserved.
These installation, operation and maintenance instructions are intended for use in an English– speaking country by English–speaking specialist personnel. AN120077.000_EN
01.03.2016
Original operating manual
1
General . . . . . . . . . . . . . . . . . . .
3
4.2
LIS–FC Signal Converter System . . .
8
1.1
System Description . . . . . . . . . . . . . . .
3
4.3
LAZ / GLZ Load Indicator . . . . . . . . . .
9
1.2
Use for the Intended Purpose . . . . . .
3
1.3
Notes on warranty . . . . . . . . . . . . . . . .
3
1.4
Replacement of unit . . . . . . . . . . . . . .
3
5
Operation . . . . . . . . . . . . . . . . .
9
5.1
Digital Operator Terminal . . . . . . . . . .
9
2
Functions . . . . . . . . . . . . . . . . .
4
5.2
Basic Settings . . . . . . . . . . . . . . . . . . .
10
5.3
2.1
Overload Shut–Down . . . . . . . . . . . . .
4
Reading the Load Population Recorder . . . . . . . . . . . . . .
10
2.2
Part–Load Switch . . . . . . . . . . . . . . . . .
4
2.3
Taring . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
2.4
Load Population Recorder (optional)
5
6
Installation . . . . . . . . . . . . . . . .
10
2.4.1
FEM Groups . . . . . . . . . . . . . . . . . . . . .
5
6.1
Housing and wiring diagrams . . . . . .
10
2.4.2
Definitions . . . . . . . . . . . . . . . . . . . . . . .
6
6.2
Regulations . . . . . . . . . . . . . . . . . . . . . .
15
2.5
Integrated Control Functions . . . . . . .
6
2.6
Frequency converter control system
6
2.7
Safety Functions . . . . . . . . . . . . . . . . .
6
7
Malfunctions . . . . . . . . . . . . . .
15
2.8
Accuracy . . . . . . . . . . . . . . . . . . . . . . . .
6
7.1
Causes and Remedies . . . . . . . . . . . .
15
7.2
Service . . . . . . . . . . . . . . . . . . . . . . . . . .
16
3
Components . . . . . . . . . . . . . .
7
3.1
LIS–SV evaluation unit . . . . . . . . . . . .
7
8
Disposal . . . . . . . . . . . . . . . . . .
16
3.2
Current Measurement Module . . . . .
7
3.3
LIS–FC Signal Converter . . . . . . . . . .
7
3.4
Load Signal Transmitter . . . . . . . . . . .
7
9
LIS – SV parameter list . . . . .
17
3.5
Load Indicator (OPTIONAL) . . . . . . .
8
3.5.1
Function of load indicator . . . . . . . . . .
8
10
Description of LIS – SV parameters . . . . . . .
20
4
Technical Data . . . . . . . . . . . .
8
4.1
Load Indicator System LIS–SV . . . . .
8
11
Declaration of conformity . .
25
Page 2
Data : 01.03.2016
1
General
The operating instructions must always be stored near the ABUS rope hoist and must be available to operating personnel at all times. Operating, maintenance and repair personnel must have read and understood the operating instructions before starting work.
1.1
System Description
The ABUS LIS–SV load indicator system is a compact universal load recording and evaluation system for hoists and cranes. The LIS–SV operates on the principle of microprocessor–controlled evaluation of signals from strain gauges installed on each hoist to be monitored in the form of measurement axles, measurement bolts or similar devices. The load calculated can be indicated using an ABUS type LAZ or GLZ load indicator. The basic LIS–SV module with integrated load population recorder also offers the optional feature of recording and evaluating the actual operating conditions of a crane system in accordance with FEM 9.755. As a standard feature, the maximum load of up to three hoists may be monitored. See also information on parameter 5.10 in Section 10. In addition, the system monitors the total carrying capacity of a crane system. The functions available include ”part load switch”, ”totalization and indication” and ”load population recorder” (optional). The unit can easily be adapted to a variety of load signal sources and is therefore a highly functional, universal unit. Special features: D overload shut–down function D load evaluation possible for three hoists D total load measurement and monitoring for three hoists D LAZ and/or GLZ load display (OPTIONAL) D load population recorder in accordance with FEM 9.755 (optional) D second shut - down point (adjustable in 2 % steps) D shutdown of main lifting speed on rapid load increase D Overload shut–down points can be set up to a maximum of 110 % of the rated load capacity of the hoist. D integrated digital operator terminal for adjustment of unit
AN120077.000_EN
D display of fault messages on operator terminal and load indicator D compact space–saving design D all connections made by plug–type connectors for easy maintenance D control function for external part - load relay
1.2
Use for the Intended Purpose
1.3
Notes on warranty
The ABUS LIS- SV is designed for use in the control systems of hoists of all types not subject to the risk of tipping- over. It is intended for installation in a closed housing and for use under the conditions listed in Section 4 below. Special investigations must be made concerning the suitability of the unit for use in other conditions and modes of operation. It may be necessary to obtain the manufacturer’s approval for any deviations.
ABUS assumes no liability for any loss or damage caused by use other than for the intended purpose or any work performed improperly or by unauthorized persons. ABUS assumes no liability as towards third parties. Attention! If you modify any components under your own responsibility, assemble components other than in accordance with the installation instructions and/or plans or use any components other than genuine ABUS components, ABUS will be released from any warranty obligations for the entire equipment. ABUS assumes no liability whatsoever for any damage to cranes or hoists which may be caused by the incorrect setting of the unit. It is recommended that repair and maintenance work should be carried out by the ABUS service department.
1.4
Replacement of unit
If a unit with load population recorder is replaced, the last value of the load population recorder must be read out and entered as the starting value for the new unit. In addition, a note must be made in the crane test book.
Page 3
2
Functions
General: For load recording and evaluation, the LIS–SV load indicator system needs a load signal transmitter (measurement axle, measurement bolt, etc.) installed on the hoist. For load evaluation on two or three hoists, the signals from the measurement axles of LIS- FC or SV units are converted into a frequency signal proportional to the load measured. This ensures interference- free transmission to the master LIS- SV. The load sensor receives a highly constant 10 V DC power supply from the LIS- SV or LIS- FC and returns a load- proportional voltage signal to the LIS- SV / LIS- FC. In the LIS–SV unit, the signal is amplified and evaluated by a microcontroller system. If the preset load limits are exceeded, hoist movement is stopped or other appropriate action is initiated using relay contacts. In addition, the load signal is processed for display on a load indicator and fed to the LAZ load indicator in the pendant control (and/or a large load display). The LIS–SV unit monitors both the individual load signals and the total load measured. Either the load measured by one of the three load measurement devices or the total load may be displayed.
2.1
b) Dynamic overload shut–down. If any dynamic peak exceeds 125 % of the rated value, the output relays for the two hoist speeds are immediately shut down. The control algorithm is specially programmed for hoists and ensures that the hoist is not shut down by dynamic load peaks below the limit. c) Shut–down on sudden load increase. If the load increases too rapidly, the relay for the main lifting speed is shut–down. The relay is only re–activated when the load has ceased to increase, provided that the maximum load has not been exceeded. This function prevents rope breakage as a result of lifting an excessive load with a loose rope at main lifting speed. Also, excessive force on the rope is prevented if the crane hook is suddenly blocked. Note: Even in the event of an overload shut - down, the load may be lowered at any time. When the load has been lowered (load below 90 % of static load threshold), the overload shut– down is reset.
Overload Shut–Down
The LIS–SV unit monitors up to three hoists for compliance with their maximum load capacity rating and the maximum load capacity of the entire system. Overload shutdown thresholds can be set between 0 and 110 % of rated load using the DBE operator terminal (see list of parameters in Section 9). The values given in this section are based on the standard setting of 110 %. The LIS–SV is equipped with two relays for enabling the main and precision lifting speed. If the overload threshold is exceeded, these relays shut the hoist down. At the same time, the load indicator display flashes at intervals of one second. If the unit is used for monitoring more than one hoist, the other hoists are also shut down if the overload threshold of one hoist is exceeded. The unit implements three types of overload shut– down function: a) Static overload shut–down. Static loads must not exceed 110 % of the rated value. The actual load value is averaged over the measurement time and compared with the threshold. This prevents prema-
Page 4
ture shut–down caused by dynamic load peaks. If the static load measured exceeds 110 % of the rated value, the two output relays are shut down.
Depending on the system configuration, lowering is only possible with individual or joint operation of the hoists.
2.2
Part–Load Switch
In some applications, another shut–down point below the rated load is required in addition to the overload shut–down. This may be the case if part of the hall structure is not designed for the entire load capacity of a crane system. The LIS- SE allows the user to set an additional shut down point (which can be adjusted via parameter 4.40 - 4.43). As soon as a signal is available at input EA of the unit, the relays for lifting movement are tripped when the set value is exceeded. The unit is then switched to the overload mode. A current transformer module with an additional switching relay may be used for more complex applications. The switching point for this relay may be set to any value between 0 and 110 % of rated load capacity using parameter P 4.5.
Data : 01.03.2016
2.3
Taring
The load indicated can be set to zero with a defined load on the hook (for example, the weight of load supports) using the tare button (TARA) which is normally incorporated in the pendant control. Each hoist selected and the total load may be tared separately. The tare function always applies to the load on the hoist currently selected. To tare the load, press the tare button until the display indicates 0.000. To delete a tare setting, press the tare button with no load on the hook for about 5 seconds. While the tare button is pressed, the current gross load is displayed. In the event of overloading, the tare value is deleted and the current gross load is indicated.
2.4
Load Population Recorder
(optional) If a load population recorder is integrated in the LIS–SV, the actual operating conditions of a hoist can be recorded. In addition to the total running time T, which is equivalent to the time during which the motor is switched on, the actual load on the hoist is recorded.
For this purpose, the unit evaluates the load measurements on a continuous basis. The LIS–SV unit calculates the actual use S, the load spectrum factor Km and the remaining service life of the hoist in accordance with FEM 9.755 from these values. The load spectrum factor is equivalent to the load population with which the hoist was operated.
2.4.1
FEM Groups
The EU machinery directive calls for precautions to be taken to prevent risks caused by fatigue and ageing on hoists and cranes. The following precautions have therefore been taken in order to achieve safe working periods (S.W.P.). Cranes and hoists are subdivided into various groups in accordance with FEM 9.511. The operator of a standard hoist is responsible for ensuring that the actual operating conditions of the hoist are recorded and documented in the test book at least once per year. In the course of regular inspection, the inspector must verify and determine whether the hoist is still being operated within its safe working period. The following table shows the theoretical service life D as a function of the FEM group and the load spectrum factor.
Theoretical service life D, (h) FEM groups
1Dm M1
1Cm M2
1Bm M3
1Am M4
2m M5
3m M6
4m M7
5m M8
Line
load group / ropes|load factor
1
light 1 / L1 K = 0.5 (Km1 = 0.125 0.53)
800
1600
3200
6300
12500
25000
50000
100000
2
medium 2 / L2 0.5 < K < 0.63 (Km2 = 0.25 0.633)
400
800
1600
3200
6300
12500
25000
50000
3
heavy 3 / L3 0.63 < K < 0.8 (Km3 = 0.5 0.83)
200
400
800
1600
3200
6300
12500
25000
4
very heavy 4 / L4 0.8 < K < 1 (Km4 = 1 13)
100
200
400
800
1600
3200
6300
12500
Theoretical service life D (h)
When the theoretical service life D has elapsed, cranes and hoists connected to them may represent a risk to persons and machines. If a load population recorder is used, it is easier to determine the actual hours of use S, from which the remaining service life is calculated. In the case of standard hoists equipped with anLIS–SV with integrated load population recorder, the operating
AN120077.000_EN
conditions are recorded electronically. The inspector can have the actual hours of use S and other parameters displayed at any time (see Section 5.3). The FEM group is stored in the LIS–SV unit and can be displayed using the operator terminal. The group is indicated in hours at full load.
Page 5
2.4.2
Definitions
Theoretical service life The theoretical service life D is the calculated hours of service of a crane or a hoist over a period of about 10 years taking into consideration the group determined in accordance with FEM 9.511. Actual hours of use The actual hours of use S represent the effective use of the unit determined on the basis of operating hours and load populations. Total service life The total service life of a standard hoist is the period from initial commissioning through to final decommissioning of the hoist. Remaining service life The remaining service life or theoretical remaining service life of a hoist is the difference between the actual hours of use S and the theoretical service life D. When the theoretical service life has elapsed, the hoist must be overhauled.I Safe working period (SWP) The hoist is within its safe working period if S/D is less than or equal to 1.
2.5
Integrated Control Functions
In addition to overload protection functions, the LISSV features a number of integrated hoist control functions. D AC- 4 disable control In order to prolong the service life of the high lifting speed contactor, the LIS- SV unit prevents the contactor from being switched off until the set start - up delay of the motor has elapsed. This function significantly reduces contact erosion. D Braking with the motor acting as a generator Each time the hoist is braked from high speed, the LIS- SV unit ensures that the hoist is first braked by operating the motor as a generator at low speed before the brake is activated. This significantly extends the service life of the brake rotor. D Motor current monitoring function LIS- SV continuously monitors the current inputs. If an inadmissibly high motor current is detected, the unit immediately switches off main contactor K1. The motor circuit breakers installed in the electrical control system are therefore no longer required The main contactor is also switched off if a motor current is detected without a lifting or lowering control signal.
Page 6
Following a shut - down, the unit display flashes and the current measured is indicated. The unit is switched back on automatically after a delay of 2 minutes. To reset the unit before this delay has elapsed, proceed as follows: a. Switch off the power supply. b. Press the up and down buttons on the digital operator terminal at the same time.
2.6
Frequency converter control system
The integration of the individual components LIS- SV overload protection device and frequency converter for hoist motors results in a special control configuration. Further details are given in the special documentation ”Frequency converter for lifting with LIS- SV”.
2.7
Safety Functions
2.8
Accuracy
The LIS- SV is a microprocessor- controlled unit. In order to ensure the highest level of operational safety, the unit is equipped with an additional switching relay which only enables lifting or lowering if the correct mode of operation of the microprocessor is detected. The mode of operation is monitored by integrated logic which operates independently of the microprocessor. Before hoist motor starting is enabled, the system checks whether the switching relay is in rest position. If this is not the case, for example as a result of ”welding” of the relay contacts, the monitoring system positively prevents hoist start - up. As a further safety function, the system monitors whether the lifting or lowering signal is present at all times when the hoist motor is in operation. If the logic circuitry does not detect a control signal at any time, the hoist is automatically shut down by the safety circuit. The hoist is also shut down if the control signals for “lifting” and “lowering” are active at the same time.
The accuracy of the load measurement system is largely determined by the measurement error of the load signal transmitter. Normally, accuracies of the order of ±2- 5 %, of the rated load capacity of the hoist are reached.
Data : 01.03.2016
3
3.1
Components
LIS–SV evaluation unit
The LIS–SV unit (Fig. 1) is designed to evaluate the measurement axle signal of one hoist. The measurement axle is connected to terminals B+, B–, U+ and U– of the unit. B+ and B– supply a stabilized voltage of 10 V to the measurement axle. The load–proportional voltage signal at terminals U+ and U– is in the range from 0 to 20 mV. If the unit is used for monitoring two or three hoists, the load–proportional frequency signals from the LIS–FC units are connected to terminals F2–GND and F3–GND. The terminals for motor voltage evaluation are designated L1 to L3 and the current module terminals are designated I1 to I3. The functions of the isolated control inputs E1 to E7, EA are as follows: E1
E2
E3
E4
E5
E7
lowering control signal
x x
fast control signal Malfunction signals HW2
x
monitoring of fast lifting speed HW2
x
activation of second overload shut- down point
x x
taring control signal Equalization signal of synchronization control system
x
Current Measurement Module
The current module is selected on the basis of the rated current of the hoist motor in main lifting speed (see table).
AN120077.000_EN
Art.–No.
Adaptation factor
0
3
19683
115
I
8
9743
306
II
16
9744
613
III
23
9745
873
IV
36
9746
1381
V
60
9747
2344
VI
136
19682
5169
The marked conductors of the current terminal are connected to terminals I1, I2, I3 and GND of the SV unit. The maximum measuring range is: rated current x 1.35
3.3
LIS–FC Signal Converter
3.4
Load Signal Transmitter
The LIS–FC signal converter (Fig. 2) is used to extend the system for monitoring 2 or 3 hoists. It supplies a stabilized, short–circuit–proof voltage of 10 V at a maximum current of 100 mA at terminals B+ and B– for power supply to the load signal transmitter. The LIS–FC unit requires no adjustment and converts the millivolt signal of the transmitter (U+, U–) into a load–proportional frequency signal (F). The LIS–SV and LIS–FC units are coordinated using the operator terminal incorporated in the LIS–SV.
x
Output Q supplies a serial data protocol for the control of the ABUS load indicators LAZ (display in pendant control) and GLZ (large load display). The 5V power supply for the LAZ unit is provided by theLIS–SV unit. The GLZ unit has an integrated 24 V AC power supply. The integrated digital operator terminal DBE is used for reading and setting the variable parameters of the LIS– SV unit (see also Section 5.1).
3.2
Rated current [A]
EA
x
lifting control signal
Total load display
E6
Measuring range
Strain gauges with a voltage of 10 V and a sensitivity of 1- 2 mV/V may be used as load sensors. Any measurement bolts, tension straps and load cells in accordance with the technical data may be used. The LIS–SV allows the signal amplification to be adjusted to the sensitivity of the load signal transmitter used. Even if the sensitivity of the transmitter is not known, it is possible to calibrate the system using a known load. As the output signal of the transmitter is only of the order of a few millivolts, it must be connected to the LIS–SV or LIS–FC unit using a shielded cable. The cable should be as short as possible and must not be routed via any terminals. In addition, the connecting cable must not be installed directly next to a power cable.
Page 7
3.5
Load Indicator
(OPTIONAL) The LIS–SV is equipped with contacts for the connection of an ABUS load indicator. The load may be indicated by a four digit LAZ load display integrated in the pendant control or by a GLZ large load display. The load display is designed so that the load value can be clearly read even in poor visibility. The driver stage of the display is updated by the LIS– SV at intervals of one second, ensuring rapid indication of any load changes. A three–conductor cable, cross section 1 mm@, must be installed for the load indicator. The cable need not be shielded.
3.5.1
Function of load indicator
1. The load is continuously measured and indicated. 04.93 2. If the hoist is shut down as a result of overloading, the display flashes at one- second intervals. 16.57 3. In the case of mutual monitoring of two hoists, this symbol appears on the display in the event of a hoist failure as long as the up or down button on the pendant control is pressed: – – H2
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4
Technical Data
4.1
Load Indicator System LIS–SV
LIS – SV Power supply voltage A1,A2: Input voltage E1–E7; EA
17790
17791
17792
230VAC 10%
110VAC 10%
48VAC 10%
150–250VAC
90–120VAC
38–55VAC
Measuring range L1, L2, L3
0 – 627 V AC
Transformer output voltage I1, I2, I3
0 – 7,24 V AC
Power supply frequency
50 – 60 Hz
Switch contacts (3u,1a):
250 V AC, 8A
Power required
max. 15VA
Ambient temperature range
–20 to +55 C; no condensation
Output voltage for LAZ
5V, max. 250 mA
Indicator signal Q
Serial data protocol ± 12V
Power supply for transmitter B+, B–
10V; max. 100mA
Input voltage U+,U–
4.2
0 – 20mV
LIS–FC Signal Converter System
Power supply voltage A1, A2
48, 110, 230 VAC +/– 10%
Power supply frequency
50 – 60 Hz
Power required
ca 4,0 VA
Ambient temperature range
– 20 until +55 C
Power supply for transmitter B+, B–
10V; max. 100 mA
Input voltage U+, U–
0 – 25 mV
Output voltage F
+12V
Output frequency F
500Hz until 30 kHz
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Data : 01.03.2016
4.3
LAZ / GLZ Load Indicator Pendant control LAZ
Large load indicator GLZ
Power supply voltage
5VDC
24VAC
Digit size
10 mm (LED)
127 mm (LED)
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5
5.1
Operation
Digital Operator Terminal
The integrated digital operator terminal (DBE) with LED display and three–button keypad ( Fig. 1, items 1 to 4) is used for operating the unit and reading operating parameters. The unit is normally in the power down mode. This is indicated on the display (4) by a horizontal bar running from left to right. – If the unit detects a lift signal (E7), the display show steps running from bottom left to top right. – – – In the case of a lower signal (E2,) the steps run from top left to bottom right. – – – Following each operation of the hoist, the current reading of the operating hours meter is shown on the display for about 3 seconds. 15
16.57 If a load lower than the previous tared load is lifted, the display indicates - 0.00 instead of the operating hours. The system has 3 menu levels; access to level 3 is only available to ABUS personnel (a special CODE number is required). Menu level 2 is accessed by entering the PIN number “0055”. Menu level 1 us used solely for reading the values of the load population recorder and is only available if the load population recorder has been enabled. To reach this menu level, press the ENTER button for about 2 seconds and then enter the appropriate CODE number (see Section 5.3) If four incorrect attempts are made to enter a PIN or CODE number, the menu level concerned is entirely disabled and can only be enabled by ABUS. In this case, the display indicates
In the event of overloading, the display flashes and the current load is indicated.
95
[no]
Height: 112
4 5
75
2 6 1
100
3
1 “Enter”–button is used for selecting parameters and acknowledging values 2 “down“–button is used for displaying the previous parameter or for reducing numeric values and parameter settings. 3 “up“–button is used for displaying the following parameter or for increasing numeric values and parameter settings. 4 Display 5 digital operator terminal (DBE)
7
6 Unit interface Fig. 1
AN120077.000_EN
7 Connection of measurement bolt 100 Page 9
5.2
Basic Settings
5.3
Reading the Load Population Recorder
TheLIS–SV is adjusted at the factory. Any fine adjustments or new adjustments which may be necessary can be carried out in accordance with the adjustment instructions in Section 10 using a test load. Where possible, the test load should be equal to the rated load. If the test load is lower, there will be a significant deterioration in system accuracy. As a basic principle, the higher the test load, the higher the accuracy. It is recommended that a test load of at least 80 % of the rated load should be used. At this load, the specified accuracy can generally be ensured. The minimum load which can be used for setting is 40 % of the rated load capacity. If this load is used, it is not always possible to obtain the specified accuracy. If it is necessary to use a load of 40% to 80% for setting, this must be stated in the inspection report.
Menu level 1 The work required for enabling the load population recorder can only be performed by ABUS. If a valid code number “2223” is entered, the values stored and calculated by the load population recorder are displayed in sequence. To return to level 1, you must press the enter button (1, Fig. 1) for a little longer.
Fig. 2
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6
Installation Attention! Before commissioning the unit, it is essential to check whether the system has been wired up in accordance with the attached wiring diagrams.
The ABUS LIS–SV must only be installed by qualified electricians
Page 10
If the LIS–SV is retrofitted to an existing crane, inspection by an independent inspector may be necessary (see BGV D6, Section 25).
6.1
Housing and wiring diagrams
The dimensions required for the installation of the LIS–SV are given in Fig. 1 and Fig. 2.
Data : 01.03.2016
rot
gelb
blau
braun
gelb
weiß
grün
Standard
Fig. 3
AN120077.000_EN
Page 11
Total load monitoring
Fig. 4
Page 12
Data : 01.03.2016
Total load monitoring with display control / central contactor box
white
brown
yellow
white
brown
yellow
Trolley 2
green
Trolley 1
green
yellow
blue
red
load indication
Fig. 5
AN120077.000_EN
Page 13
Standard wiring diagram, LIS- SV with twin hoist
LIS- SV
LIS- SV
fast
LIS- SV
LIS- SV
LIS- SV
Fig. 6
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Data : 01.03.2016
6.2
Regulations
Safety warnings: You must not carry out any work inside the unit.
The load indicator system LIS–SV is in accordance with the following codes and standards: NSR 2014/35/EG
(low voltage)
EMV 2014/30/EG
(electromagnetic compatibility)
EN 61000- 6
Electromagnetic compatibility
Electrical installation work must be performed in accordance with the following general codes and standards:
In the event of a defect in an LIS–SV unit, please contact our service department. In order to avoid the risk of serious injury and severe damage, only persons qualified to work on electric power systems may work on the units. Before installing any commissioning the units, these persons must carefully read the operating instructions and observe the safety instructions.
IEC 60364- 5- 56 Requirements for the installation of power systems with rated voltages up to 1000V EN 60204- 32 Safety of machinery: Electrical equipment of machines; requirements for hoists. For special applications, other standards and regulations may also be applicable.
Attention! Any modifications to ABUS products and any parts installed in or on ABUS products which could impair the safety of the products must be approved by the manufacturer. ABUS will not be liable for any injury, loss or damage which may occur as a result of modifications which have not been approved or the use of products other than for the intended purpose. Note: ELECTROMAGNETIC COMPATIBILITY The unit has been designed in accordance with the EMC directive no. 2014/30/EC.
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7
7.1
Malfunctions
Causes and Remedies
TheLIS–SV displays the following error codes on the operator terminal or the load display. Err–Code
Explanation
Remedy
Errors following unit start - up Err 0
Total load not entered Check unit settings, parameters P 0.0, P 1.0 Rated load capacity of hoist 1 set to higher value than total load
Err 1
Unit not set for hoist 1
Check settings P 1.3, P 1.4
Err 2
Unit not set for hoist 2
Check settings P 2.3, P 2.4
Err 3
Unit not set for hoist 3
Check settings P 3.3, P 3.4
Err 4
Adaptation factor for current measurement not entered
Enter value under P 5.6
Errors in normal operation F1
Zero load frequency hoist 1 too low
F2
Zero load frequency hoist 2 too low
F3
Zero load frequency hoist 3 too low
AN120077.000_EN
Page 15
Err–Code
Explanation
Remedy
Errors on setting Err 6
Setting error: frequency at zero load 3 million switch operations 0.30 N·m
Max. start ---up speed
Cable cross section
31.03.2014
IP 65
Electrical/mechanical service life
Cable glands
A 120216.000_EN
---20° C to +70° C
3.0 A Ue= 230 V; Ie= 1.5 A 2x M20 0.14 --- 1 mm2 plastic 4 changeover contacts
Weight
235 g
Tightening torque/M5 fastening bolts
4 Nm
AN 310101
Original operating manual
Electrical connection
--- The contact numbers indicated in the wiring diagram start with 1 and increase from left to right (as can be seen on the 12---pole circuit board connector). --- The microswitches are numbered in ascending order starting with S1 on the left.
The cross---type limit switch may be connected using round or ribbon cables on both sides, as appropriate. The appropriate cable gland with M20 connecting thread must be used for the type of cable. If the cable does not have a pre-assembled switch, the 12-pole board connector must be connected according to the enclosed circuit diagram.
Safety advice Opening actuation of the cross-type limit switch meets Performance Level c, Category 1 of DIN EN ISO 13849-1.
You must make sure that the individual conductors of the connecting cable are properly installed inside the switch and are of the correct lengths.
The safety-related parts have been designed and constructed using proven components and safety principles as follows: --- The actuation system for initiating and implementing the necessary opening movement is positive-locking. --- The positive opening operation of the micro-switch does not depend on spring-loaded parts and thus complies with DIN EN 60947-5-1.
The cross---type limit switch must only be installed by a qualified electrician or other trained personnel. Additional notes: --- The switch position is clearly indicated by the position arrow on the switch and defined in the switch configuration table.
Wiring diagram
40--- 60 mm
--- S1
--- S2
12 14 11
1
40 mm
2
3
Switch Switch position
Switch position
--- S3
22 24 21
4
5
S1
--- S4
32 34 31
6
7
S2
42 44 41
8
9
S3
10
S4
Contacts
0
0
3,4
5,6
1
90
3,4
5,6
7,11
2
180
3,4
5,6
7,11
3
270
3,1
4
360
3,1
5
450
3,4
0
540
3,4
7,8
5,6
5,6
9,10 9,10 9,12
7,8
9,12
5,2
7,8
9,10
5,2
7,8
9,10
7,8
9,10
11 12
printed on:
Electrical parts list Order Number:
FX-16735993-0020
Assembly:
200347
Production ident no.:
5922688
Client: 185911
03.02.2017
FAIST Anlagenbau GmbH
ABUS mains power supply
Wiring diagrams: Prod-ID / CL op. mat. no.
CL
Quantity
Units u.o.m.
Part number Designation 1 Designation 3
1
5922688-70
1
1, pcs
.2
5933893-20
1
1, pcs
105838 Mains power supply Special 21431 Upper part end terminal AEK
.2
5933893-70
5
1, pcs
21422 Top part cable carrier ALK-S
.2
5933893-120
1
1, pcs
.2
5933893-160
1
22.000, mm
1
5922688-80
1
1, pcs
1
1
1, pcs
1
3
1, pcs
1
1
1, pcs
5922688-100
1
1, pcs
1
21430 Upper part of towing trolley Steel wheel with ball bearing 763 Flat cable 4G 6 7,2x22,3mm 71414 Terminal box 3x6+1PE T221 751 Housing T221 with mounting plate 124274 Cable clamp 2006 6 oA 0,5-10, mA 0,5-6, 41A 124276 Cable clamp 2006 6 PE oA 0,5-10, mA 0,5-6 77366 Isolating switch 63A fitted 160x250x165 (+45)
Designation 2 Designation 4 Festoon cable with square nut Steel roller with ball bearing AMK-S H07VVH6-F 1xM25r 1xM40f 200x120x 75 1-L / 1-L tension spring, gray, 7,5mm 1-L / 1-L green-yellow, 7,5mm K: 2x2xM40 V: 2xM40
Page 1 of
1
printed on:
Electrical parts list Order Number:
FX-16735993-0010
Assembly:
200201
Production ident no.:
5933713
Wiring diagrams:
500000E-004, 500000GB-004, 600167E-000, 600167GB-000
Technical data:
operating voltage: control voltage: span: Hoist type trolley 1: Load cap. trolley 1:
Serial number:
110-034551
CL
Prod-ID / CL op. mat. no.
.2
5933718-220
.2
5933718-240 -S31
Client: 185911
Single-girder travelling crane
Quantity
Units u.o.m.
FAIST Anlagenbau GmbH ELK
3/PE~50 Hz 400 V 230 V 7000 mm GM 3000.8000 L-202.41.6000.4 8000 kg
Part number Designation 1 Designation 3 Elektrik Seilzug VT
1
1, pcs
1
20
1
1, pcs
1
21
1
1, pcs
1
31
1
1, pcs
.2
5933718-430
.2
5933718-450 +SKA
5400 Gear limit switch 75.3 Lug 15° 86445 Pin multipoint connector lettering 6-4,PE,3-1 86447 Pin multipoint connector lettering 7-10 71377 Connector Elektrik Seilzug VT
1
1, pcs
1
25.01.2017
Designation 2 Designation 4 Endmontage GPK75.3-3 51/3B 75NE-399L 721 7-5,00 mainspring, light gray 721 4-5,00 mainspring, light gray Zwischenmontage
81611 Contactor control SKA 80.362K-E 380-500/230V 50Hz GM3000L Te LIS SGR 536 Q41= 2,5A Socket HUB SKA 18A Te 230V TS 50/60Hz 25.18 GE3Z.K43
.2
-K21, 22
2
1, pcs
.2
-K21, 22
1
1, pcs
.2
-K23
1
1, pcs
.2
-U32-X1
1
1, pcs
.2
-U32-X2
1
1, pcs
.2
-U32-X3
1
1, pcs
.2
-V21
1
1, pcs
14921 Contactor Te 230V 25A 4MNO1NO 1NC, LC1-DT40P7 230V 50/60Hz 71256 Mechanical locking Te LAD-9V2 for LC1-D09-D32 TeSys 75197 Contactor Te 230V 18A 1NO1NC LC1-D188P7 2MNO2MNC 230V 50/60Hz 74172 Bush multipoint connector 8413 5-7,62 coded 4-5, lettering 230V Screw, grey 19454 Bush multipoint connector 8113 11-5,08 lateral Screw, grey 19455 Bush multipoint connector 8113 19-5,00 lateral Screw, grey 310497 Rectifier GE3Z500-A
..3
1
1, pcs
123294 Housing 12,5 UT GN
99x114,5x12,5
..3
1
1, pcs
123295 Housing bottom part
ME 12,5 OT set
124264 Cable clamp 2002 2,5 oA 0,25-4, mA 0,25-2,5, 24A 124264 Cable clamp 2002 2,5 oA 0,25-4, mA 0,25-2,5, 24A 124266 Cable clamp 2002 2,5 PE oA 0,25-4, mA 0,25-2,5 Connection cable HUB TS 7B16+4B16 6902 Round cable ÖPVC-JZ 12G 2,5 ø14,7mm
1-L / 1-L tension spring, gray, 5,2mm 1-L / 1-L tension spring, gray, 5,2mm 1-L / 1-L green-yellow, 5,2mm -W21 12G2,5 3100mm
.2
-X1: 1-8
8
1, pcs
.2
-X20
2
1, pcs
.2
-X20
2
1, pcs
-W21
1
3.100, mm
1 .2
numbered
Page 1 of
6
Electrical parts list Order Number: CL
FX-16735993-0010
Prod-ID / CL op. mat. no.
Quantity
Client: 185911 Units u.o.m.
FAIST Anlagenbau GmbH
Part number Designation 1 Designation 3
.2
+KA-X21.1
1
1, pcs
.2
+KA-X21.2
1
1, pcs
.2
-K41, 42
2
1, pcs
.2
-K41, 42
1
.2
-K43
.2
Designation 2 Designation 4
86446 Bush multipoint connector lettering 1-3,PE,4-6 86815 Bush multipoint connector lettering 10-7 Socket KAF SKA 9A Te 230V TS
721 7-5,00 mainspring, light gray 721 4-5,00 mainspring, light gray 50/60Hz 09.09 1NC, LC1-D09P7
1, pcs
5267 Contactor Te 230V 9A 3MNO1NO 230V 50/60Hz 71256 Mechanical locking Te
1
1, pcs
75194
-X40
4
1, pcs
124264
.2
-X40
2
1, pcs
124266
.2
-K45
1
1, pcs
3916
.2
-X1:9-16(14-21)
8
1, pcs
124264
1
-Q41
1
1, pcs
123701
1
1
LAD-9V2 for LC1-D09-D32 TeSys Contactor Te 230V 9A 2MNO2MNC 1NO1NC, LC1-D098P7 230V 50/60Hz Cable clamp 2002 2,5 1-L / 1-L oA 0,25-4, mA 0,25-2,5, 24A tension spring, gray, 5,2mm Cable clamp 2002 2,5 PE 1-L / 1-L oA 0,25-4, mA 0,25-2,5 green-yellow, 5,2mm Time relay ZR 0,5-B 0,5s 24-240V, 0-60Hz Cable clamp 2002 2,5 1-L / 1-L oA 0,25-4, mA 0,25-2,5, 24A tension spring, gray, 5,2mm Motor circuit breaker 1,6-2,5A GV2-ME07 Connection cable KAF -W41 TS 7B16 Round cable ÖPVC-JZ 7G 1,5 ø9,1mm Bush multipoint connector lettering 1-3,PE,4-6 Connection cable KAF -W42 TS 7B16 Round cable ÖPVC-JZ 7G 1,5 ø9,1mm Bush multipoint connector lettering 1-3,PE,4-6 Socket outlet -X4 6S35 TS
7G1,5 1450mm
.2
-W41
1
1.450, mm
6753
.2
+KA-X41
1
1, pcs
86446
.2
-W42
1
1.350, mm
6753
.2
+KA-X42
1
1, pcs
86446
.2
-X4
1
1, pcs
5303 Add-on box 16p
500V
.2
-X4
1
1, pcs
5308 Pin insert 6S35 Lettering 1-6 Schnittstelle Steuerung SKA TS
500V 35A
1
1
1 .2
-X1:17(9,14,22)
1
1, pcs
.2
-X5
1
1, pcs
.2
-X5
1
1, pcs
-S31-X1
1
1, pcs
-W31
1
2.100, mm
577 Round cable ÖPVC-OZ 8X 1,0 ø9,5mm Currant transformer module 16A
-T32
1
1, pcs
9744 Current transformer module 16A
1 .2 1 .2 1 .2
124264 Cable clamp 2002 2,5 oA 0,25-4, mA 0,25-2,5, 24A 5303 Add-on box 16p 5310 Pin insert 16S16 Lettering 1-16 Pin base 8-pole -X31 HUG 18067 Bush multipoint connector 8-3, coded, lettering 1-8 Connection cable HUG -W31 TS
numbered 721 7-5,00 mainspring, light gray 7G1,5 1350mm numbered 721 7-5,00 mainspring, light gray
16S16 Krankatze 1-L / 1-L tension spring, gray, 5,2mm 500V 500V 16A
50 for printed circuit board Screw, grey 8x1,0 2100mm numbered TS
Page 2 of
6
Electrical parts list Order Number: CL
FX-16735993-0010
Prod-ID / CL op. mat. no.
Quantity
Client: 185911 Units u.o.m.
FAIST Anlagenbau GmbH
Part number Designation 1 Designation 3
Designation 4
.2
+SKA
1
1, pcs
71284 Steel housing M SGR 536
536x480x202
.2
+SKA
1
1, pcs
9350 Mounting plate SGR 536
492x446x2,5
1
1, pcs
1
1
1, pcs
7073 Bush multipoint connector
5933718-590 -S51
1
1, pcs
123029 Cross-type limit switch KHS
..3
.2
Designation 2
5933722-10 -U32
17790 Load indicator system LIS-SV
Cross-type limit switch KHS
1 .2
1
1
1, pcs
.2
6
1
1, pcs
.2
-X1
1
1, pcs
.2
-W_1
1
1.870, mm
1
5933713-440
1
5933713-480 +SKR
1
1, pcs
1 .2
-F1
1
1, pcs
.2
-F1
3
.2
-F1
.2
0-600V/230V/50-60Hz 733 4-2,50 6.41-2+ Ru8X1 L= 1,8m 6.41 TS -S51 40fl
27224 Housing cover 304600 . 18068 Bush multipoint connector 12-3 coded, lettering 1-12 577 Round cable ÖPVC-OZ 8X 1,0 ø9,5mm Elektrik Laufkran VT 108072 Contactor control Te 25A NEO SGV 600 -Q61= 6,3A Main fuse 25A gG NEO TS
,50 for printed circuit board Screw, grey numbered
SKR 80.36K 400/230V 50Hz
3-pole
1, pcs
2260 Fuse socket E18 Snap-on mounting 2994 Screw cap E18
3
1, pcs
2270 Fuse link E18 25A gG
400V
-F1
3
1, pcs
2948 Screw-in sleeve socket for
fuses E18 25A
-K1
1
1, pcs
6951 Contactor Te 230V 18A 3MNO1NO 1NC, LC1-D18P7 230V 50/60Hz Socket KRF SKR 9A Te 230V 50/60Hz 09.09 ZR
.2
-K61, 62
2
1, pcs
.2
-K61, 62
1
1, pcs
.2
-K63
1
1, pcs
.2
-K65
1
1, pcs
.2
-X61, 62
2
1, pcs
.2
-X61, 62
2
1, pcs
5312 Socket insert 10S16
1
-Q61
1
1, pcs
123703 Motor circuit breaker
Main contactor 18A Te 230V TS
1 .2 1
-U61
1
1, pcs
4127 Smooth switching relay SU-1 Power unit control TS
1 .2
-F10, 11
2
1, pcs
.2
-F10, 11
4
1, pcs
.2
-T1
1
1, pcs
1NC, LC1-D09P7
LAD-9V2 for LC1-D09-D32 TeSys 75194 Contactor Te 230V 9A 2MNO2MNC 1NO1NC, LC1-D098P7 230V 50/60Hz 3916 Time relay ZR 0,5-B 0,5s 24-240V, 0-60Hz 5302 Add-on box 10p 500V
Smooth switching relay -U61 TS
1 .2
5267 Contactor Te 230V 9A 3MNO1NO 230V 50/60Hz 71256 Mechanical locking Te
50/60Hz
124286 Safety clamp 281 - 6,3x32 oA 0,5-10, mA 0,5-6, 10A 14881 Fine wire fuse 6,3x32 1,0A-T 5259 Control transformer 100VA STT 0,1
500V 16A 4,0-6,3A GV2-ME10 SU-1 380-415V 50/60Hz 380-415V 50/60Hz 100VA 400/230V cylindrical fuse 1-L / L-1 tension spring, gray, 7,5mm 500V 400/230V, ±5% Si 0,5A Quick fastening device
Page 3 of
6
Electrical parts list Order Number: CL
FX-16735993-0010
Prod-ID / CL op. mat. no.
Quantity
Client: 185911 Units u.o.m.
FAIST Anlagenbau GmbH
Part number Designation 1 Designation 3
.2
-T1-F12
2
1, pcs
Designation 4 250V
Socket outlet -X0 6S35 TS
1 .2
-X0
1
1, pcs
310338 Add-on box 16p
500V
.2
-X0
1
1, pcs
500V 35A
.2
-X1
18
1, pcs
.2
-X1:0
1
1, pcs
5308 Pin insert 6S35 Lettering 1-6 124264 Cable clamp 2002 2,5 oA 0,25-4, mA 0,25-2,5, 24A 300957 Earth terminal KN 4-25²
1-L / 1-L tension spring, gray, 5,2mm 11-3, 60mm
.2
-X1:0
1
1, pcs
300959 Adapter KN
Top hat rail
.2
-X2
1
1, pcs
3930 Add-on box 24p
500V
.2
-X2
1
1, pcs
4172 Socket insert 24S16
500V 16A
.2
-X4
1
1, pcs
5303 Add-on box 16p
500V
.2
-X4
1
1, pcs
5314 Socket insert 6S35
500V 35A
.2
-X5
1
1, pcs
5303 Add-on box 16p
500V
.2
-X5
1
1, pcs
5313 Socket insert 16S16
500V 16A
.2
-X12
3
1, pcs
.2
-X32
4
1, pcs
.2
-X71: 1-4
4
1, pcs
.2
+SKR, SKA
1
1, pcs
124264 Cable clamp 2002 2,5 oA 0,25-4, mA 0,25-2,5, 24A 124264 Cable clamp 2002 2,5 oA 0,25-4, mA 0,25-2,5, 24A 124264 Cable clamp 2002 2,5 oA 0,25-4, mA 0,25-2,5, 24A 5333 Steel housing SGV 600
.2
+SKR, SKA
1
1, pcs
5318 Mounting plate SGV 600
.2
+SKR
1
1, pcs
71268 Flange plate M FP13-1
168x266x1,5
.2
+SKR
1
1, pcs
71271 Flange plate M FP17-1
168x266x1,5
5933713-500 +KSZ
1
1, pcs
109178 Festoon cable for trolley DS
Socket outlet -X2 24B16 TS
1
Socket outlet -X4 6B35 TS
1
Socket outlet -X5 16B16 TS
1
1
3920 Fine wire fuse 5,0x20 0,5A-T
Designation 2
1-L / 1-L tension spring, gray, 5,2mm 1-L / 1-L tension spring, gray, 5,2mm 1-L / 1-L tension spring, gray, 5,2mm 600x270x190 570x250x2,5
Connector system S
.2
5933724-20
2
1, pcs
21421 Top part cable carrier ALK-K
Plastic rollers bushed bearing
.2
5933724-80
1
1, pcs
21431 Upper part end terminal AEK
with square nut
.2
5933724-130
1
1, pcs
.2
5933724-180 -W4
1
9.600, mm
.2
5933724-190 -W5.1
1
9.600, mm
.2
5933724-220 +SKR-X4
1
1, pcs
21430 Upper part of towing trolley Steel wheel with ball bearing 761 Flat cable 4G 2,5 5,8x17,9mm 304084 Flat cable 12G 1 2,6x25,5mm 79015 Connector housing 16p M32s
.2
5933724-230 +SKR-X4
1
1, pcs
.2
5933724-260 +SKA-X4
1
1, pcs
.2
5933724-270 +SKA-X4
1
1, pcs
.2
5933724-310 +SKR-X5
1
1, pcs
5308 Pin insert 6S35 Lettering 1-6 79015 Connector housing 16p M32s 5314 Socket insert 6S35 79016 Connector housing 16p M40s
AMK-S H07VVH6-F LIFY2YKFFL-JZ Ribbon cable 500V 500V 35A 500V 500V 35A 500V
Page 4 of
6
Electrical parts list Order Number: CL
FX-16735993-0010
Prod-ID / CL op. mat. no.
Quantity
Client: 185911 Units u.o.m.
FAIST Anlagenbau GmbH
Part number Designation 1 Designation 3
.2
5933724-320 +SKR-X5
1
1, pcs
.2
5933724-360 +SKA-X5
1
1, pcs
.2
5933724-370 +SKA-X5
1
1, pcs
5310 Pin insert 16S16 Lettering 1-16 79016 Connector housing 16p M40s 5313 Socket insert 16S16
Designation 2 Designation 4 500V 16A 500V 500V 16A
.2
5933725-20
3
1, pcs
21421 Top part cable carrier ALK-K
Plastic rollers bushed bearing
.2
5933725-70
1
1, pcs
21431 Upper part end terminal AEK
with square nut
.2
5933725-120 1
1
1, pcs
.2
5933725-140 8
1
1, pcs
21421 Top part cable carrier ALK-K
Plastic rollers bushed bearing
.2
5933725-150 9
1
1, pcs
21422 Top part cable carrier ALK-S
Steel roller with ball bearing
.2
5933725-210 -W2.1
1
10.400, mm
.2
5933725-230 +SKR-X2
1
1, pcs
.2
5933725-240 +SKR-X2
1
1, pcs
1
5933713-520 -W61, -W62
1
1, pcs
.2
5933726-10 W61
1
2.700, mm
.2
5933726-20 W62
1
9.650, mm
.2
5933726-30
.2
5933726-40 +SKR-X61
1
1, pcs
.2
5933726-50 +SKR-X61
1
1, pcs
.2
5933726-90 +SKR-X61
1
1, pcs
.2
5933726-100 +SKR-X62
1
1, pcs
.2
5933726-110 +SKR-X62
1
1, pcs
.2
5933726-150 +SKR-X62
1
1, pcs
1
5933713-540 +HT-S1
1
1, pcs
1
5933713-550 -W3
1
1, pcs
-W3
1
4.309, mm
1 1
5933713-560
1
5933713-570 -S71
1
1, pcs
4775 Control carrier support
304083 Flat cable 12X 1 2,6x25,5mm 79022 Connector housing 24p M40s High housing 4171 Pin insert 24S16 Lettering 1-24 106398 Connection cable KRF 2 Mot 6753 Round cable ÖPVC-JZ 7G 1,5 ø9,1mm 6753 Round cable ÖPVC-JZ 7G 1,5 ø9,1mm Connector parts KRF 10S16 7G1,5² 7B16 79002 Connector housing 10p M20s
numbered numbered 2 Mot 20r KG10R/6R 500V
500V 16A
721 7-5,00 mainspring, light gray 500V
721 7-5,00 mainspring, light gray B24
70358 Control cable SC15X1 L=4250mm BJS24/15-SC15X1-BJB24/15 35971 Control cable 15X1 OZ without ø9,4mm Crane travel limit switch Braking function 123032 Cross-type limit switch KHS
1
1, pcs
.2
6
1
1, pcs
304600 .
1
1, pcs
1
1, pcs
123955 Connection cable slewing motor L=10000mm 18068 Bush multipoint connector 12-3 coded, lettering 1-12
-X1
10S16- 7G1,5- 7B16
108834 Pin insert 10K16 Lettering 1-10 86446 Bush multipoint connector lettering 1-3,PE,4-6 70278 Pendant control HT611S-N222K-
1
.2
500V 16A
500V 16A
.2
1
LIFY2YKFFL-OZ Ribbon cable 500V
108834 Pin insert 10K16 Lettering 1-10 86446 Bush multipoint connector lettering 1-3,PE,4-6 79002 Connector housing 10p M20s
Cross-type limit switch KHS
1
16/24-pole
sheath numbered, stranded -S71 TS KHS6.4 L= 10,0m M20 6.41-2+ Ru8X1 L=10,0m 6.41 TS -S51 40fl
27224 Housing cover
KHS P12p-8X1 ,50 for printed circuit board Screw, grey Page 5 of
6
Electrical parts list Order Number: CL
FX-16735993-0010
Prod-ID / CL op. mat. no.
Quantity
Client: 185911 Units u.o.m.
FAIST Anlagenbau GmbH
Part number Designation 1 Designation 3
.2 1
-W_1
1
10.070, mm
1
1, pcs
1
5933713-770
1
5933713-780
2
1, pcs
1
1
1, pcs
1
1
1, pcs
Designation 2 Designation 4
577 Round cable ÖPVC-OZ 8X 1,0 ø9,5mm 82281 Switching lug KHS-EK straight
numbered
Switching lug limit switch TS to be fitted to runway 30/32 21406 Switching lug KHS-30/32 To be fitted on C-rail 30/32 79016 Connector housing 16p M40s
straight 10x400
5314 Socket insert 6S35
6x240
straight 8x400 500V 500V 35A
Page 6 of
6
drawn with ELCAD (R)
Copyright by ABUS - Germany
Ausgabe: English
- wiring diagram of the crane fabr.-nr./customer:
/
functions:
standard with LIS-SE/SV operating voltage: 3/PE ~___Hz, ___V (clockwise rotating field);
drawing-nr. sheet kind of plan 500000-004 500000-004 500000-004 500000-004 500000-004 500000-004 500000-004 500000-004 500000-004 500000-004 500000-004
1 2 3 4 5 6 7 8 9 10 11
2SL 2SL 2SL 2SL 2SL 3KL 3KL 3KL 3KL 5IS 5IS
=A1 =A2 trolley left crane backward c 004 b 003 a 002 revision
08.09.11 21.09.04 25.08.00 date
crane 1 crane 2 trolley right crane forward
GG GG GG drawn
designation
wiring diagram/main power wiring diagram/control current wiring diagram/main power wiring diagram/control current wiring diagram/control current terminalplan/ terminalplan/ terminalplan/ terminalplan/ installation plan/ installation plan/
unit characteristic
date 20.04.2000 drawn G.Görzen proof. W.Dick symbol-file: LK12
control voltage: 1~___Hz, ___V notes
power supply/crane drive emergency stop/crane drive lifting gear/trolley drive lifting gear trolley drive +SKR-X0,+SKR-X1,+SKR-X2,+SKR-X4 +SKR-X5,+SKR-X32,+SKR-X61,+SKR-X62 +SKA-X1,+SKA-X4,+SKA-X4.1,+SKA-X5, +SKA-X20 +SKA-X40 crane trolley
located +FKA +FKR +HSZ +HT +HW +KA
+KA1 +KA2 +KB +KR +KSZ +KSZ1 +KSZ2
inverter on hoist inverter on crane bridge main power supply push button pendant wall of the building trolley
trolley 1 trolley 2 crane track crane bridge + end truck trolley power supply trolley power supply trolley 1 trolley power supply trolley 2 register
origin: 500000
replacement for:
replacement by:
+SGM +SKA +SKA1 +SKA2 +SKB +SKR +VFS
hoisting limit sw. box trolley panel trolley panel 1 trolley panel 2 crane track panel crane bridge panel sliding control parts list
unit
500000-004
location 1IH
net:
sheet
00
from
11
drawn with ELCAD (R)
3
4
5
6
-Q61 -K1 /2.2
7
8 -X4 1 2 3 PE
1 3 5
1L1 /3.1 1L2 /3.1 1L3 /3.1 1PE
1
2
2
1
+KSZ-W4 PE 3
Copyright by ABUS - Germany
/3.1
2 4 6 I>> I>> I>>
1 3 5
2 4 6
-F10
-F1
/2.5
-F11 ___ +5%
-T1
-K61
0
___
1 3 5
/2.6
0
/2.5
2 4 6
-K63
1 3 5
-K62
R1 R3
2 4 6
1 3
-K63 /2.6
R2 R4
2 4
-F12 box mounting-plate -X1 0 PE-S
-X1 1 -X1 16 L01 L02
-W1.2 1
2
3
PE
+KR
-W61 1
2
-V61
3
~ ~
main power supply 3/PE~___Hz; ___V clockwise rotating field GG GG GG drawn
date 20.04.2000 drawn G.Görzen proof. W.Dick symbol-file: LK12
L02
1U 1V 1W -M1
/2.1
L01
8Y 2Y
08.09.11 21.09.04 25.08.00 date
-X62 1 2 3
control voltage ___V, ___Hz
4
5
6
PE
-W62 1
2
4 5 6 PE
7 8 4 5 6 PE
BR BR
~ ~ 8Y 2Y
1U 1V 1W -M1
-M61
bridge drive 1
power supply/crane drive origin: 500000
replacement for:500000
replacement by:
4
5
6
PE
- +
-X62 1 2 3 9 10
-Y1 2U M 2V 3~ 2W 8/2P
wiring diagram/main power
-V62
3
- +
-X61 1 2 3 9 10
/2.1
2) option c 004 b 003 a 002 revision
4 5 6 PE
PE
L1 L2 L3 PE
Disconnecting from ctrical net via plug, not in time of elecrical loading
3
-X61 1 2 3
7 8 4 5 6 PE
BR BR
-Y1 2U M 2V 3~ 2W 8/2P
-M62
bridge drive 2 parts list
unit
500000-004
location
+SKR
2SL
2
B1 B2
SU-1
smooth switching 2)
-X1 17
-X0 1 4 2 5 3 6 PE -W1.1 1
-U61
1 2
sheet
1
from
11
/1.3
drawn with ELCAD (R)
1 L01 ___V, ___Hz
2
3
-X2 1 emergency stop 2
horn -X2 12 14
4
5
15 16 PE
6
9
7
-X5 1
8
fast 11
10
+KSZ-W5 1
Copyright by ABUS - Germany
1L01
/4.1
-X5 2 +KSZ-W5 2
+SKA
-X5 2 -X1 2 -W31 1
-X1 1 .1 1
-X1 4
lifting 2 -X1 2
-S71
-W31 2
6
8
-W71 1
-W71 3
-W71 5
-X1 3 .1 11
-X1 9 .4 41
crane travel forward 12 limit switch +KR -X1 4
-X1 3
-W71 2
backward 42
.2
5 21
-K62 5
13
6 7
10
.3
7
-W71 6 -W71 7
7
14
8
-W74 4
-X1 9 -X1 10
-W75 3
-K61 5
13
8
12
-X5 3
L013
-X1 12
-X5 3
-K1
A1
-H11
+KR
A1
-K61
-W11 2
-K62
A2
A1
2 t
-K63
A2
0
1 A1 A2
-X1 13 main contactor 1 /1.1 3 /1.1 5 /1.1 13 /4.5 21
c 004 b 003 a 002 revision
-K65
0,5sec.
-W11 1
A2
L02
08.09.11 21.09.04 25.08.00 date
GG GG GG drawn
-X1 2
-X1 3
-W74 1
-W75 1
/4.4
+KSZ-W5 3
/1.3
-W75 4
11 14
5 4
+KR
11
/4.4
3 4
-B75
14
-W71 8
-U32
5 4
+KR
31
backward 32
3 4
-B74
forward 22
-W71 4
-X1 5
-W74 3
2 4 6 14 22
date 20.04.2000 drawn G.Görzen proof. W.Dick symbol-file: LK12
horn 2)
forward 1 /1.5 3 /1.5 5 /1.5 13 7
2 4 6 14
backward 1 /1.6 3 /1.6 5 /1.6 13 7
2 4 6 14
wiring diagram/control current
fast 1 /1.6 R1 /1.5 R3 /1.5 3 /1.6
emergency stop/crane drive origin: 500000
replacement for:
replacement by:
2 R2 R4 4
1
-B74 +KR
3 5
4
-W74 2
2
1
-B75 7
+KR
3 5
4
-W75 2
2
7
-X1 14 -X1 15 -X5 11 light barrier forward 2) light barrier backward 2)
parts list
unit
500000-004
+KSZ-W5 11
security switch +SGM
location
+SKR
2SL
-S31
sheet
2
1L02
/4.1
2) option
from
11
Copyright by ABUS - Germany
1L1 1L2 /1.8 1L3 /1.8 1PE /1.8
/1.8
1
drawn with ELCAD (R)
2 -X4.1 1
-X4 1 2 3 PE
3
-X4.1 2 3 4 5 6
4
5
6
7
8
3)
-Q41 3
current transformer
-K21 /4.4
current control
-K22 /4.5
2 4 6
-K23 /4.5
R1 R3 R2 R4
-K21 7-K22 /4.4
8
7
/4.5
control see /4.4
2 4 6
1 3 5
-K41 /5.2
2 4 6
1 3
-K23 /4.5
8
I>> I>> I>>
4
I1 I2 I3 GND LIS-SE/SV L1 L2 L3
-U32
1 3 5
3
2
2
1
1
-T32
1 3 5
1 3 5
/5.3
2 4 6
-K43 /5.4
2 4
-K42
R1 R3
1 3 5 2 4 6
-K43 /5.4
R2 R4
1 3 2 4
mounting-plate 5 6
~ ~ 1 2
+ 3 4
-X20 1
+KA
-W21.1 1
box
-X20 2
2
3
-X21 1 2 3
9
10
7
8
(6) (7)
(4) (5)
9 10
7 8
12Y 2Y
BR BR
1U 1V 1W -M1
-Y1 2U M 2V 3~ 2W 12/2P
-M21
-W21.1 4
3 PE 5
6
-X40 1
PE
-W41 1
(-W21.2 1) (2) (3)
08.09.11 21.09.04 25.08.00 date
GG GG GG drawn
date 20.04.2000 drawn G.Görzen proof. W.Dick symbol-file: LK12
2
-V41
3
~ ~
4 5 6 PE
8Y 2Y
1U 1V 1W -M1
(n) ab GM3000H
4
6
PE
-W42 1
4 6 PE 2
7 8 4 5 6 PE
BR BR
-M41
replacement for:
replacement by:
5
6
PE
7 8 4 5 6 PE
BR BR
8Y 2Y
1U 1V 1W -M1
4
- +
-X42 1 2 3 9 10
trolley drive motor 1
lifting gear/trolley drive
-V42
3
~ ~
-Y1 2U M 2V 3~ 2W 8/2P
wiring diagram/main power
origin: 500000
5
2
- +
-X41 1 2 3 9 10
hoist motor c 004 b 003 a 002 revision
3 5 PE
-Y1 2U M 2V 3~ 2W 8/2P
-M42
2) option 3) only with cross section > 2,5mm² location
trolley drive motor 2 parts list
unit
500000-004
+SKA
2SL
-V21
1 2 ~ ~
sheet
3
from
11
4
5
6
7
8
fast -X2 13
+SKR
-X2 3
-K1 /2.2
-X5 4
-X5 5
+KSZ-W5 4
+KSZ-W5 5
-X5 4
-X5 5
4 13
-X2 17 18 19 20
6
7
6
7
+KSZ-W32 1
2)
-W31 5
-X1 3 .2 1
-X1 5 .3 1
lifting 2 -X1 4
lowering 2 -X1 6
-S31
hoisting limit sw. +SGM
-W31 4
-U32
-W31 6
-X1 5 -X1 6
+ - F
control see: 4
+KA-B32 transmitter
E4 E5
E7
22
11
23
12 14
A1
-K22
A2
EA A1 A2 E1
current transformer /3.3
load indicator 7
/2.2
E2
/2.2
1L01
2L01
E6 overload device 21
A1
-K23
A2
A2
1L02
-X5 11 1 /3.2 3 /3.2 5 /3.2 7 /3.3
08.09.11 21.09.04 25.08.00 date
GG GG GG drawn
date 20.04.2000 drawn G.Görzen proof. W.Dick symbol-file: LK12
2 4 6 8
lowering 1 /3.3 3 /3.3 5 /3.3 7 /3.3
2 4 6 8
1 /3.4 R1 /3.2 R3 /3.2 3 /3.4
2 R2 R4 4
wiring diagram/control current
lifting gear origin: 500000
replacement for:
replacement by:
/5.1
fast
parts list
2) option 3) only with LIS-SV location
unit
500000-004
+SKA
2SL
lifting
c 004 b 003 a 002 revision
LIS-SE/SV
Δl
A1
-K21 /2.8
4
L013
-U32
1L02
3
B+ B- U+ U-
-X1 8 3)
/2.2
2
E3 +5V Q GND
-W32 green
-X1 7
21 22 23 24
-X32 1 2 3 4 7
-W31 3
/5.1
tare LAZ
5
14 6
-X1 4
1L01
+12 -12 F1 GND
-X5 1
3
white
2
yellow
1L01
drawn with ELCAD (R)
brown
/2.8
1
B+ BU+ U-
Copyright by ABUS - Germany
sheet
4
from
11
Copyright by ABUS - Germany
/4.8
1L01
drawn with ELCAD (R)
1
2
3
4
5
6
7
fast
+SKR
-X2 6
7
-X5 8
9
PE
10
9
PE
10
-X5 8
9
PE
10
-X1 9
-X1 11
-W51 1
-W51 3
+KSZ-W5 8
-S51
trolley travel limit switch +KA
-X1 3 .1 11
.4
13 -W51 5
9 41
left 42
-X1 4
10
-W51 2
-X1 1 L01
8
right 12
.2
5 21
-K42 3
right 22 6 7 .3 31
-W51 4
-X1 10
8
-X1 12
-W51 6 -W51 7
2
8
14
-X1 14 -X1 15
-K41
left 32
13
13 14
-W51 8
-X1 16
-K45
0,5sec.
/4.8
-K42
A2
1L02
c 004 b 003 a 002 revision
08.09.11 21.09.04 25.08.00 date
GG GG GG drawn
date 20.04.2000 drawn G.Görzen proof. W.Dick symbol-file: LK12
-K43
A2
right 1 /3.5 3 /3.5 5 /3.5 13 5
A1
t
A2
left
2 4 6 14
1 /3.6 3 /3.6 5 /3.6 13 5
0
2 A1
-X1 17 L02
fast 2 4 6 14
1 /3.6 R1 /3.5 R3 /3.5 3 /3.6
2 R2 R4 4
wiring diagram/control current
trolley drive origin: 500000
replacement for:
replacement by:
parts list
unit
500000-004
location
+SKA
2SL
A1
-K41
1
sheet
5
2) option
from
11
target blip extern
c 004 b 003 a 002 revision 2) option
08.09.11 21.09.04 25.08.00 date GG GG GG drawn date 20.04.2000 drawn G.Görzen proof. W.Dick symbol-file: LK12 origin: 500000 replacement for: replacement by:
0
-T1
+SKA-X4 +SKA-X4 +SKA-X4 +SKA-X4
3 4 9 10 5 6 7 8
+KR-S71-X1 +KR-S71-X1 +KR-S71-X1 +KR-S71-X1 +KR-S71-X1 +KR-S71-X1 +KR-S71-X1 +KR-S71-X1 +KR-H11 +KR-H11
2) crane travel lm.sw. " " " " " " " horn 2) "
1 2 3 PE
1 2 3 4 5 6 7 8 1 2
PE
1 2 3 PE
1 2 3 PE
terminalplan/
+SKR-X0,+SKR-X1,+SKR-X2,+SKR-X4 parts list
500000-004
1 2 3 PE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PE
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 2 3 4 5 6 PE
-X4
-X2
L02
PE-S L01
-X1
/1.1 /1.1 /1.2 /1.1 /1.2 /1.2 /1.2
unit
/1.8 /1.8 /1.8 /1.8
Σ4 terminals
/2.2 /2.2 /4.4 /4.5 /4.5 /5.2 /5.3 /5.4 /2.5 /2.5 /2.6 /2.2 /4.2 /2.3 /2.3 /2.3 /4.7 /4.7 /4.7 /4.7 /4.7 /4.7 /4.7 /4.8 /2.3
Σ25 terminals
/1.2 /1.3 /2.7 /2.8 /2.5 /2.5 /2.5 /2.5 /2.6 /2.7 /2.7 /2.6 /2.3 /2.3 /2.7 /2.8 /1.3 /1.3
Σ18 terminals
connection
PE ___
-Z-SGV -T1-F12
operating material -characteristic
mounting-plate control circuit sec.
terminal number 1 2 3
flat cab. 4G__ round cab. 4G__ round cab. 4G__ round cab. 4G1,5 round cab. 8X1
L1 L2 L3 L1 L2 L3 PE PE
terminal commentary terminal jumper terminal no.
+HSZ-W0 +HSZ-W0 " +HSZ-W0 " +HSZ-W0 " +HSZ-W0 " +HSZ-W0 " +HSZ-W0 " +HSZ-W0 "
-K1 -K1 -K1 -Z-SGV
2 4 6 PE mounting-plate
1 2 3 4
A2 forward
-K61
-X32 -X32 -X32 -X32
4 12
-X5 -X1
A2 backward 11 A2 main contactor
-K62 -X5 -K1 PE-SSP
1 L01 2 5 13 7 8 9 10 4 6 13
1 9 A1 forward 10 A1 backward 13 14 13 14 14
-X5 -X2 -K61 -X2 -K62 -K62 -K62 -K61 -K61 -X2
-X1 -X5 -X5 -K1 -X5 -X5 -X5 -X5 -X1 -X1 -K62
PE 1
1 main fuse 3 " 5 " 1 " 3 " 5 " 0 PE-S
equipment commentary
-X0 -X2
-F1 -F1 -F1 -F1 -F1 -F1 -X1
terminal number
3KL
cable no. operating material -characteristic
main power supply 3/PE~___Hz; ___V clockwise rotating field
+KSZ-W4 -W1.1 -W1.2 -W11 -W71 page/path
Σ7 terminals
cable no.
-X0
target blip intern
equipment commentary
terminal block
Copyright by ABUS - Germany drawn with ELCAD (R)
location
+SKR
sheet
6
from
11
c 004 b 003 a 002 revision
operating material -characteristic
2) option
08.09.11 21.09.04 25.08.00 date GG GG GG drawn date 20.04.2000 drawn G.Görzen proof. W.Dick symbol-file: LK12 origin: 500000 replacement for: replacement by:
bridge drive 1 " " " " " "
+KR-X62 +KR-X62 +KR-X62 +KR-X62 +KR-X62 +KR-X62 +KR-X62
+KR-X61 +KR-X61 +KR-X61 +KR-X61 +KR-X61 +KR-X61 +KR-X61
bridge drive 1 " " " " " "
terminal number
+SKA-U32 +SKA-U32 +SKA-U32 +SKA-U32
1 2 3 4 5 6 PE
1 2 3 4 5 6 PE
E3 +5V Q GND
1 2 3 4 5 6 PE
1 2 3 4 5 6 PE
1 2 3 4
flat cab. 12G1 flat cab. 12X1 round cab. 7G1,5 round cab. 7G1,5 1 2 3 4 5 6 7 8 9 10 11 PE
1 2 3 4 5 6 PE
1 2 3 4 5 6 PE
1 2 3 4
1 2 3 4 5 6 7 8 9 10 11 PE
terminal commentary terminal jumper terminal no.
terminalplan/
+SKR-X5,+SKR-X32,+SKR-X61,+SKR-X62 parts list
500000-004 3KL
target blip extern
-X62
-X61
-X32
connection
LIS-SE/SV " " "
cable no. /1.7 /1.7 /1.7 /1.8 /1.8 /1.8 /1.8
Σ7 terminals
/1.5 /1.5 /1.5 /1.6 /1.6 /1.6 /1.6
Σ7 terminals
/4.7 /4.7 /4.7 /4.8
Σ4 terminals
/2.8 /2.2 /2.2 /4.2 /4.4 /4.5 /4.5 /5.2 /5.3 /5.4 /2.8 /5.4
-K63 -K61 -U61 -K63 -K63 -K63 -Z-SGV
-K63 -K63 -U61 -U61 -U61 -K62 -Z-SGV
-X2 -X2 -X2 -X2
-X1 -X2 -K1 -X2 -X2 -K1 -X2 -X2 -X2 -X2 -X1
operating material -characteristic
1 2 3 4 5 6 7 8 9 10 11 PE
equipment commentary
R2 2 2 smooth switching 2 2) R3 4 PE mounting-plate
1 R2 2 smooth switching B1 2) " B2 " 4 PE mounting-plate
21 22 23 24
3 2 A1 main contactor 13 3 14 5 6 7 8 15
terminal number
+SKA-X5 +SKA-X5 +SKA-X5 +SKA-X5 +SKA-X5 +SKA-X5 +SKA-X5 +SKA-X5 +SKA-X5 +SKA-X5 +SKA-X5 +SKA-X5
+KSZ-W5 +KSZ-W32 -W61 -W62 page/path
Σ12 terminals
cable no.
-X5
target blip intern
equipment commentary
terminal block
Copyright by ABUS - Germany drawn with ELCAD (R)
unit location
+SKR
sheet
7
from
11
c 004 b 003 a 002 revision 2) option
08.09.11 21.09.04 25.08.00 date GG GG GG drawn date 20.04.2000 drawn G.Görzen proof. W.Dick symbol-file: LK12 origin: 500000 replacement for: replacement by:
terminalplan/ hoist motor " " " " " " " " " "
3
-X4
+SKA-X1,+SKA-X4,+SKA-X4.1,+SKA-X5, +SKA-X20 +KA-X21 +KA-X21 +KA-X21 +KA-X21 +KA-X21 +KA-X21 +KA-X21 +KA-X21 +KA-X21 +KA-X21 +KA-X21
2 3 9 10 7 8 5 6 1 4 PE
1 2 3 4 5 6 7 8 9 10 11 PE
2
-X4
+SKR-X5 +SKR-X5 +SKR-X5 +SKR-X5 +SKR-X5 +SKR-X5 +SKR-X5 +SKR-X5 +SKR-X5 +SKR-X5 +SKR-X5 +SKR-X5
1
1 2 3 PE
+SKR-X4 +SKR-X4 +SKR-X4 +SKR-X4
-X4
5 6 3 4 9 10 5 6 7 8
+SGM-S31-X1 +SGM-S31-X1 +KA-S51-X1 +KA-S51-X1 +KA-S51-X1 +KA-S51-X1 +KA-S51-X1 +KA-S51-X1 +KA-S51-X1 +KA-S51-X1
terminal number
hoisting limit sw. " 2) trolley travel lm.sw. " " " " " " "
operating material -characteristic 1 2 3 4 5 6 7 8
5 6
1 2 3 4
2 3 9 10 7 8 5 6 1 4 PE
1 2 3 4 5 6 7 8 9 10 11 PE
1 2 3 PE
flat cab. 4G__ flat cab. 12G1 round cab. 12G1,5 round cab. 8X1 round cab. 8X1
+SGM-S31-X1 +SGM-S31-X1 +SGM-S31-X1 +SGM-S31-X1
terminal commentary terminal jumper terminal no. 1 2 3
1 2 3 4 5 6 7 8 9 10 11 PE
1 2 3 4 5 6
1 2 3 PE
parts list
PE
-X20
-X5
-X4.1
-X4
L02
L01
connection
500000-004 3KL
target blip extern 1 2 3 4
cable no. /3.2 /3.2 /3.3 /3.3 /3.3 /3.3 /3.4 /3.4 /3.2 /3.4 /3.4
Σ11 terminals
/4.1 /2.2 /2.2 /4.2 /4.4 /4.5 /4.5 /5.2 /5.3 /5.4 /4.1 /5.4
Σ12 terminals
/3.2 /3.3 /3.2 /3.3 /3.2 /3.3
Σ6 terminals
/3.1 /3.1 /3.1 /3.1
Σ4 terminals
/5.8 /2.2 /2.2 /4.4 /4.4 /4.4 /4.5 /4.5 /5.2 /5.2 /5.3 /5.3 /5.4 /5.5 /5.5 /5.4 /5.8
R2 R4 1 lifting gear 2 " 3 " 4 " 2 4 2 2 PE mounting-plate
4 7 E7 overload 9 device 11 13 A2 lifting
-X1 -X1 -U32 -X1 -X1 -K42 -K21
-K23 -K23 -V21 -V21 -V21 -V21 -K23 -K23 -K21 -K22 -Z-SGR
1 L01 2 14
1 1 3 3 5 5
-X1 -X1 -U32
-K22 -Q41 -K22 -Q41 -K22 -Q41
right
left
overload device overload device right
equipment commentary
1 3 5 PE mounting-plate
E6 6 E2 8 A1 9 A1 13 14 13 14 A2
-U32 -X5 -U32 -X5 -K41 -X5 -K42 -K42 -K42 -K41 -K41 -K41
-X4.1 -X4.1 -X4.1 -Z-SGR
1 2 11 5
-X5 -X5 -U32 -X5
operating material -characteristic
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
terminal number
security switch " hoisting limit sw. "
+KSZ-W4 +KSZ-W5 -W21.1 -W31 -W51 page/path
Σ17 terminals
cable no.
-X1
target blip intern
equipment commentary
terminal block
Copyright by ABUS - Germany drawn with ELCAD (R)
unit location
+SKA
sheet
8
from
11
08.09.11 21.09.04 25.08.00 date
GG GG GG drawn
PE mounting-plate
4 -K42
-Z-SGR
R2 R4 2 4 R2 R4 2 4 2
PE PE 6
1
1 1 2 6 3 4 PE 5 6
2 3 4 5 2 3 4 5
PE
Σ14 terminals
date 20.04.2000 drawn G.Görzen proof. W.Dick symbol-file: LK12
terminalplan/
+SKA-X40 origin: 500000
replacement for:
replacement by:
parts list
unit
500000-004
location
+SKA
3KL
2) option c 004 b 003 a 002 revision
1 2 1 2 1 2
operating material -characteristic
motor motor motor motor motor motor
terminal number
2 3 4 5 2 3 4 5 1 1 6 6 PE PE
round cab. 7G1,5 round cab. 7G1,5
motor 2
target blip extern
terminal commentary terminal jumper terminal no.
+KA-X41 +KA-X41 +KA-X41 +KA-X41 +KA-X42 +KA-X42 +KA-X42 +KA-X42 +KA-X41 +KA-X42 +KA-X41 +KA-X42 +KA-X41 +KA-X42
cable no.
connection
motor 1
-W41 -W42
page/path
-X40
terminal block
cable no.
operating material -characteristic
equipment commentary
target blip intern
/3.5 /3.5 /3.6 /3.6 /3.7 /3.7 /3.8 /3.8 /3.5 /3.7 /3.6 /3.8 /3.6 /3.8
terminal number
-K43 -K43 -K43 -K43 -K43 -K43 -K43 -K43 -K41
drawn with ELCAD (R)
trolley drive " " " trolley drive " " " trolley drive trolley drive trolley drive trolley drive trolley drive trolley drive
equipment commentary
Copyright by ABUS - Germany
sheet
9
from
11
Copyright by ABUS - Germany
drawn with ELCAD (R)
1
2
3
4
5
6
7
8
crane bridge panel
+SKR
-X4
+KSZ-W4
-X5
+KSZ-W5
-W1.1, -W1.2 -X0
W4 W5
+KSZ-W32
-X1
-X1
-X32
/11.1 /11.1
-X2 2)
-X1
W32
/11.1
-X61
-X62
control -W11
-W74, -W75
-W71
-W61
-W62
main power supply
crane bridge
+KR
-X62
-M61 bridge drive 1
-M62 bridge drive 2
-S71
-B74 -B75
2)
2)
crane travel limit switch
light barrier
-H11 2)
11 c 004 b 003 a 002 revision
08.09.11 21.09.04 25.08.00 date
GG GG GG drawn
date 20.04.2000 drawn G.Görzen proof. W.Dick symbol-file: LK12
installation plan/
crane origin: 500000
replacement for:
replacement by:
horn
parts list
unit
500000-004
location
+SKR
5IS
-X61
sheet
10
2) option
from
11
Copyright by ABUS - Germany
drawn with ELCAD (R)
1
2
3
4
5
6
7
8
trolley panel
hoisting limit sw. box
+SKA
/10.8 /10.8 /10.8
W4 W5 W32
+KSZ-W4
-X4
+KSZ-W5
-X5
+SGM
-X1
-W31
+KSZ-W32 2)
-X1
-S31
hoisting limit sw.
-U32
-X20
-X40
-X40
-X1
-W51
-W42
-W41
-W21.2
-W32
-W21.1
LIS-SE/SV
2) trolley
+KA
3)
-M21
hoist motor
transmitter
-X41
-X21.2
-X42
-M41
-M42 2)
trolley drive motor 1 trolley drive motor 2
11 c 004 b 003 a 002 revision
08.09.11 21.09.04 25.08.00 date
GG GG GG drawn
date 20.04.2000 drawn G.Görzen proof. W.Dick symbol-file: LK12
installation plan/
trolley origin: 500000
replacement for:
-S51
replacement by:
trolley travel limit switch
parts list
2) option 3) only with LIS-SV location
unit
500000-004
+SKA
5IS
-B32
-X21.1
sheet
11
from
11
drawn with ELCAD (R)
3
4
5
6
2)
-S1
11
lifting 12
4
14
11
31
-X2 1
+VFS-X2 ion-box trolley
+VFS-W2.1 1
28.2
11
right 12
41
42
-S41 012
6
5
14
-S42 012
44
31
left 32
4
1a 1b
21
22
24
6
5
34
2
3
11
forward 12
41
42
-S61 012
8
14
44
4
-S62 012
31
22
24
8
backward 32
34
2
3
7
5
6
7
8
9
10
11
2
3
4
5
6
7
8
9
10
11
2
3
4
5
6
7
8
9
10
11
4
5
6
7
8
9
10
11
4
5
6
7
8
9
10
11
3
44
4
4
2
41
42
3
+VFS-W2.1 3
1
21
7
2
+VFS-W2.1 2
+SKR-X2 1
4
3
28.1
29
26 control cable-W3 1
24
34
2
-X2 1
22
4
lowering 32
1a 1b
emergency stop 12
-S22 012
1a 1b
21
3
31.2
OFF-ON 4 1
button pendant
-S21 012
L011
31.1
27
-S1
3 2
32
28.3
-S1.1
8
33.3
30
7
33.2
2
33.1
1
31.3
Copyright by ABUS - Germany
push button pendant
-S1
trolley 1-1+2-2
1b
1a
1b
1a
1b
11
21
-S11
11
-S71
11
preselection 14 12 trolley 2
-X2 12 control cable-W3 12
+VFS-X2 junction-box trolley
-X2 12
22 24 3
5
4
horn 12 14 3
2
-S71
bridge 12 14 over-ride control 3 2 /travel limit switch
3 2
1a
1b
1a
1b
1a
1b
1a
1b
1a
1b
-S27
11
-S85
11
-S81
11
-S82
11
-S32
11
Super 12 14 4 1 precision hoist 3
2
crane light
12 14 load-lifting attachment 12 14 load-lifting attachment 12 14 3
2
3
2
3
14
15
16
17
18
19
20
13
14
15
16
17
18
19
20
13
14
15
16
17
18
19
20
2
3
4
5
6
7
8
14
15
16
17
18
19
20
+ п -
tare 12 14
2
13
-P32
load indicator
3
blue
-S12
1a
yellow
L011
red
8
2
-X2 21
22
23
24
22
23
24
22
23
24
9
10
11
12
21
22
23
24
21
-X2 21
+VFS-W2.1 12 +VFS-W2.2 1
+SKR-X2 12
13
Optionen (siehe Baugruppe)
revision
date
date 14.05.2014 drawn G.Görzen proof. S.Karthaus drawn symbol-file:
plan of wiring up/
origin: 600167
replacement for:
replacement by:
push button pendant HT 611/1011S-N222K/S-B
parts list
unit
600167-000
location
+HT
2SL
c b a
sheet
1
2) option
from
2
Copyright by ABUS - Germany
drawn with ELCAD (R)
1
2
3
view -A- by BJ24 -A-
plug-in connector -X2 connection control cable
1
16 17
4
15 5
12
3
-A-
11
6 1 2 10 18 7 9 24 8 19 20 21 22 23
plug-in connector -X2 connection control cable
24 = position pin
-S1
2
6
7
view -A- by BJ24
14 13 4
5
1
3
17
5
14 13 4
3
12 11
6 1 2 10 18 7 9 24 8 19 20 21 22 23
24 = position pin
-S1
2
option
16
15
8
option
3
4
-S21
4
-S21
5
-S22
5
-S22
-S42
6
7
-S41
-S42
6
7
-S41
-S62
8
9
-S61
-S62
8
9
-S61
10
11 option
by -N222S
12
13
by -N222S
revision
date
date 14.05.2014 drawn G.Görzen proof. S.Karthaus drawn symbol-file: LK12
wiring diagram/
origin: 600167
replacement for:
replacement by:
push button pendant HT611S-N222K/S push button pendant HT1011-N222K/S
parts list
unit
600167-000
location 2SL
c b a
sheet
2
from
2
