This section describes the work steps that must be performed with ABUControl during the replacement of the wire rope on a wire rope hoist. The work steps that must be performed on the wire rope hoist are described in the wire rope hoist product manual.

The figures show the work process on the GM modular wire rope hoist. The procedure on the other wire rope hoists does not differ significantly.

For hoists with frequency converters: Move the load hook upwards until the top hoist limiter switching point is activated.

For hoists with contactor controls: Move the load hook so that the top hoist limiter switching point is NOT activated.

Measure, and note, the position of the load hook.

This makes adjusting the hoist limit switch after replacing the wire rope in many cases unnecessary.

To ensure the wire rope can be unwound from the cable drum using a motor, the hoist limit switch must be removed. Otherwise the cable drum will stop at the lowest hook position.

The figures show the gear limit switch "GPK". The procedure on the gear limit switch "GGS" does not differ significantly.

Open the hoist limit switch housing.

Unscrew and remove screws (2x).

Pull off the hoist limit switch.

Leave the shaft of the hoist limit switch in the same position, and do not turn it.

This makes adjusting the hoist limit switch after replacing the wire rope in many cases unnecessary.

If the shaft is accidentally twisted, the message "F_ _ 34 Wire rope change: Absolute rotary encoder 1 not removed.1“ or "F_ _ 33 Wire rope change: Absolute rotary encoder 2 not removed.1“.

Secure the hoist limit switch to ensure it does not fall down or hang from the connection cables.

So that the cable drum can be motor-driven, even though ABUControl does not receive a signal from the absolute rotary encoder (because the hoist limit switch is dismantled with the absolute rotary encoder), the wire rope change must be activated in ABUControl.

The wire rope change can be activated in the trolley control by coupling or by KranOS.

Either activate the wire rope change by coupling:

Open trolley control.

Search for prong terminal block -X104.

Remove the coupling from the parking position (upper pin multipoint connector).

Insert coupling on the upper pin multipoint connector.

●   The wire rope change is activated. The cable drum can now be motor-run without ABUControl receiving a signal from absolute rotary encoder.

●   All the wear values for calculating the maximum acceptable wear are deleted so that the calculation for the new wire rope can start over.

Or activate rope change via KranOS [1] [2]:

Log in to KranOS with user "Service" (user level ‚[1]) or "Abnahme" (commissioning) (user level [2]). See Connecting laptop or tablet computer with ABUControl, page  .

Select the desired hoist (e.g. Hoist 1) in the main menu.

●   The window for the requested hoist appears.

Click on the "Rope change cable drum 1" button.

●   The button's background turns green.

●   The wire rope change is activated. The cable drum can now be motor-run without ABUControl receiving a signal from absolute rotary encoder.

●   All the wear values for calculating the maximum acceptable wear are deleted so that the calculation for the new wire rope can start over.

Allow the wire rope to run off the cable drum using the motor.

Replacing wire rope. See the product manual for the wire rope hoist.

Move the load hooks to the position you noted previously.

Connect the hoist limit switch to the pins on the cable drum.

Screw the hoist limit switch tight.

Check the positions of the switching points.

As soon as the wire rope has been changed:

Remove the coupling from the lower pin multipoint connector on the prong terminal block -X104 and insert in the parking position (upper pin multipoint connector).

or

Click on the "Rope change cable drum 1" button.

●   The wire rope change is switched off.

●   The button's background is no longer green.

If the switching points have moved:

Normally, the adjustment of the hoist limit switch after replacing the wire rope can in many cases be omitted, since the position of the load hook was previously measured and then travelled to again. In special cases (e.g. if the wire rope is severely damaged or has been incorrectly rolled onto the cable drum), the switching points may need to be readjusted.

Reset switching points for the bottom hoist limiter, the top hoist limiter and the backup limiter.

See Setting switching points for backup limiter and top hoist limiter, page  .

See Setting switching point for the bottom hoist limiter.

Reference the absolute rotary encoder again. See Referencing the absolute rotary encoder.