At a glance:

General information

This section applies to anyone who lifts loads using the crane, performs work on the crane, or works nearby.

Read before starting work

Using this product manual

The following symbols are used in this product manual:

1. 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.

Instructions for the product manual

Read the product manual through carefully before starting work. Also be sure to observe additional product manuals for accessories and components.

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.

If the crane is sold on or hired out, always provide the product manual together with the crane.

Proper use

ABUControl is a modular crane control based on a central PLC and various CAN bus devices that communicate with each other via a CAN bus network. It is used for the control of an ABUS overhead travelling crane with one or several trolleys by using ABURemote radio remote control or an ABUCommander pendant control.

• ABUControl is a modular and interconnected crane control. All components of ABUControl are connected and aligned to each other. Individual CAN bus devices or other components may only be replaced by identical original spare parts.
• The ABUControl is only to be used with the ABUS-specific factory settings.
• Only use ABUControl on ABUS overhead travelling cranes. Do not connect any products from other manufacturers.
• Settings in KranOS may only be made by qualified personnel.

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.

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.

Warranty

• ABUS assumes no liability for damages that were caused by improper use, inadequately trained personnel, incorrect performance of work, nor for any changes, reconstruction or other modification of the crane or crane components which were 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.

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.

• Even after the emergency stop button has been pressed, life-threatening high voltages are still present in the crane control and in the trolley control.
• Before working on the crane, disconnect the power line and wait at least 15 minutes until the voltage has dissipated.

ABUControl

Description of the device

ABUControl consists of:

• Crane control
• Trolley control
• Absolute rotary encoder on the cable drum
• Load measuring system on the hoist

• Absolute rotary encoder on the hoist motor (optional)
• Distance sensor on the trolley or trolleys (optional)
• Distance sensor on the crane (optional)
• Additional motion restrictor (cross-type limit switch and/or reflective light barriers) (optional)
• LED matrix display
• Additional cross-type limit switches for building profile control (optional)
• Inclinometer on the trolley (optional

Overall view of the crane control:

The crane control set up varies according to the crane. The following figure can be used as a guide.

• 1: Fuse isolating link
• 2: Main contactor
• 3: Power pack
• 4: Field bus coupler for input and output signals
• 5: ABURemote receiver
• 6: Cable entry housing
• 7: CAN distributor
• 8: Frequency converter
• 9: Feed unit

Overall view of trolley control:

The trolley control set up varies according to the crane. The following figure can be used as a guide.

1 2 3 4 5

• 1: Trolley drive frequency converter
• 2: Hoist frequency converter
• 3: CAN distributor
• 4: PLC
• 5: Cable entry housing

Only with absolute rotary encoder "AWG"

Absolute rotary encoder "AWG" (on gear limit switch "GGS"):

• 1: Relay and pin multipoint connector for additional switching tasks (option)
• 2: Rotary switch for device address (option)
• 3: Button for resetting the device address
• 4: Circuit board
• 5: Switch for terminating resistor
• 6: Connection for CAN bus network and Modbus network

Only with "Kübler" absolute rotary encoder

"Kübler" absolute rotary encoder (on gear limit switch "GPK"):

• 1: CAN bus line
• 2: "Kübler" absolute rotary encoder

Performance features

ABUControl:

• ABUControl is a modular crane control based on proven electronic components from automation technology. The various modules on the crane are networked together and thus an intelligent control of crane functions is the result.
• ABUControl works with a PLC as the central computing unit. It evaluates the control commands from the radio remote control or pendant control as well as all responses from the absolute rotary encoders, motion restrictors (cross-type limit switches, light barriers, etc.) and other modules. Based on this, ABUControl controls the crane drives and hoist drives.
• The drive axles (crane travel and trolley travel) are equipped with frequency converters. These enable ABUControl to conveniently set the movement profiles. On request, the hoist can also be equipped with frequency converters in order to select and set the hoist profiles for the hoist.
• The hook position of the hoist and the lifting speed are recorded by an absolute rotary encoder. Through this, ABUControl knows how fast the hoist is turning. This enables some convenient additional functions (e.g. hoist synchronisation control). The highest and lowest hook positions are additionally recorded via an electromechanical gear limit switch.
• A crane with ABUControl is controlled by an ABURemote radio remote control. With this, some additional functions (e.g. sway control) can be conveniently operated from the transmitter. If the crane is controlled by a different radio remote control, certain functions (e.g. sway control) are unavailable or only available to a limited extent.
• Only with pendant control (option): The crane can also be controlled by a pendant control. Some functions of ABUControl (e.g. sway control) cannot be used with a pendant control or can only be used to a limited extent.
• Various ABUControl operating information is displayed on the LED matrix display. It also shows status and error messages from various crane components, which enables quick and simple troubleshooting.

• Only with double lifting speed (option): With this option, the lifting speed can be increased up to 200% (= doubled). This means that the crane can be worked faster. The maximum possible additional lifting speed (from 100%) is dependent on the load attached.
• Only with super-precision lifting (optional): This function is used for especially slow lifting and lowering with the hoist. This enables extremely exact positioning of the load. Super-precision lifting can be switched on and off at the transmitter or the pendant control.

With activated super-precision lifting in pole-switchable hoist drives, the frequency converter is switched from winding with fast lifting speed to winding with slow lifting speed.

For single-winding hoist drives that are not pole-switchable, (e.g. GM7000.2), the speed of the hoist motor is monitored by the frequency converter using a separate absolute rotary encoder, thus also enabling full torque at very slow lifting speeds so that the load can be held until a standstill is reached even without braking.

KranOS:

• KranOS is a graphic user interface where ABUControl is set.
• Crane operators and (trained) repair staff can access KranOS on a computer (e.g. laptop, tablet) and change settings and display operating data there.
• To access KranOS, no special software or app is necessary. The access occurs through a normal Internet browser.
• Access to KranOS (except the display of operating data) is protected by usernames with passwords. The various users have different user levels. The higher the user level, the more settings can be opened and changed.

The wiring and programming of ABUControl:

• ABUControl consists of a central memory-programmable control (PLC) and numerous CAN bus devices (e.g. absolute rotary encoder, frequency converter, etc.) that communicate with each other via a CAN bus network.
• ABUControl is constructed from modular standard industry components that can be simply and individually replaced when required. This means that if there is a fault, replacement of the entire control is not necessary. Selective individual components can be replaced.
• All ABUControl modules can be connected with one another by plug-in connections. Thus the modules can be quickly separated from each other.
• Every crane with ABUControl has a customer-specific configuration. The control thus knows the exact design of the respective crane and the optional version components.
• The CAN bus devices are programmed after replacement by the central PLC. This occurs either automatically or through the corresponding function in KranOS, depending on the device.
• After a replacement, the central PLC must be provided with the customer-specific programming via an SD card. In this way, the customer-specific data of the crane is retained.
• ABUControl is designed from the ground up with EMC compliance. Thus disruptions to other devices and industrial systems by electromagnetic waves are effectively prevented.
• Control signals at the outputs and inputs of the central PLC, the frequency converters and the field bus couplers can be tested with conventional measuring devices.
• In addition to the CAN bus network, several components are connected with each other via an Ethernet network. This includes a WLAN module, so that a WLAN network connection can be established from a laptop or tablet computer to the PLC. If further Ethernet network devices are used (e.g. radio data transmission module), all of these Ethernet devices are connected to an Ethernet switch as distributor.
• In addition to the CAN bus network, several components may be connected with each other via a Modbus network.

The trolley travel synchronisation control:

• When there is more than one trolley on the crane, ABUControl regulates the synchronous travel of all trolleys in joint operation. The trolleys therefore have the same travel speed and also the same acceleration time and braking time in joint operation within tight tolerances.
• The transport of a joint load is made even safer with the trolley travel synchronisation control.
• The trolley travel synchronisation control also functions if the trolleys have different sizes and (each considered separately) different maximum travel speeds.
• The trolley travel synchronisation control is possible for up to three trolleys per crane.

For tandem operation: The trolley travel synchronisation control is possible for up to two trolleys per crane on both cranes in tandem operation.

The hoist synchronisation control:

• When there is more than one hoist on the crane and frequency converters, ABUControl regulates the synchronous lifting and lowering in joint operation. The hoists therefore have the same lifting speed and also the same acceleration time and braking time in joint operation within tight tolerances.
• The transport of a joint load is made even safer with the hoist synchronisation control.
• The hoist synchronisation control also functions if the hoists have different sizes and (each considered separately) different maximum lifting speeds.
• The synchronisation control also balances different hoist loads from uneven load distribution. Thus an unevenly distributed load can also be synchronously lifted and lowered by all hoists.
• The hoist synchronisation control is possible for up to three hoists per crane.

For tandem operation: The hoist synchronisation control is possible for up to two hoists per crane on both cranes in tandem operation.

• For twin hoists: The synchronisation control is deactivated in the area of the brake phase before the highest hook position. This ensures that the wire rope is distributed evenly on both cable drums.

The movement profiles:

• For drives with frequency converters: ABUControl allows adjustment of the drive control. Thus, hoist drive and drive can be adjusted to individual usage in the acceleration and braking behaviour as well as in the maximum and minimum speed.
• The setting parameters are limited so that the crane can only be set within safe limits. Otherwise an acceleration that was too strong could e.g. strain the supporting structure (building) too much.
• You can switch between a step-less and a two-step movement profile in the KranOS movement profile control.
• Thus, various cranes within your movement profile can be adjusted to each other to achieve a similar behaviour.

The overload protection:

• ABUControl records the attached load on all hoists and adopts the overload protection of all individual hoists and the crane total load. Furthermore, it monitors the rotational direction and rotational speed of all hoists and safely switches off if there is an overspeed.
• ABUControl directly measures the attached load.
• A load measuring system is used for recording the load. It consists of a load sensor or a measurement bolt.
• The load measuring system serves primarily in detecting an overload on the crane and not in precisely weighing a suspended load. Also for load display in the transmitter or in the LED matrix display it is only used for displaying a rough estimate of the load. The load measuring system cannot be calibrated. The load measuring system has an accuracy of ±2 to 5% of the maximum load capacity of the crane.

Building profile using cross-type limit switch (variant):

• The building profile comprises all characteristics of a building that could influence the crane travel, trolley travel and lifting/lowering of the crane. This includes the beginning and end of the crane track, obstacles, blocked-off areas, crane flaps and the like.
• The ABUControl building profile control enables the adaptation and restriction of all crane axes depending on the building profile. For example, the speed can be reduced in front of obstacles or an intermediate stop can be inserted at specific positions. Furthermore, areas can be completely blocked for passing through or partial load ranges can also be set up in a building.
• If the crane is equipped with a building profile control, the switching points for the braking function or shut-down of the crane and trolley are also integrated in the building profile control.
• The cross-type limit switches are used for recording the position of crane and trolley.
• An absolute rotary encoder is used for recording the position of the hoist.
• A load measuring system is used for recording the load. It consists of a load sensor or a measurement bolt.

The building profile control via the crane position (variant):

• The building profile comprises all characteristics of a building that could influence the crane travel, trolley travel and lifting/lowering of the crane. This includes the beginning and end of the crane track, obstacles, blocked-off areas, crane flaps and the like.
• The ABUControl building profile control enables the adaptation and restriction of all crane axes depending on the building profile. For example, the speed can be reduced in front of obstacles or an intermediate stop can be inserted at specific positions. Furthermore, areas can be completely blocked for passing through or partial load ranges can also be set up in a building.
• If the crane is equipped with a building profile control, the switching points for the braking function or shut-down of the crane and trolley are also integrated in the building profile control.
• A absolute value measuring system is used for recording the position of crane and trolley. This can be implemented via laser distance sensors or a magnetic tape in the conductor system, for example.
• An absolute rotary encoder is used for recording the position of the hoist.
• A load measuring system is used for recording the load. It consists of a load sensor or a measurement bolt.
• The obstacles can be created, teached-in, edited or deleted in KranOS.
• An obstacle is defined and created as a cuboid with two corner points.

If an obstacle is more complex, it can be made up of several cuboids, each of which is positioned over the two corner points. It is important to note that the cuboids will overlap, as the measuring systems have a certain margin of error.

The sway control:

• The sway control significantly reduces the swinging movement of the load hook during trolley and crane travel.
• The sway control is based on mathematical calculations. The travel speeds of the crane and trolley, the hook position and the distance from the load hook to the load's centre of gravity (and thus also the length of the lifting tackle) are taken into consideration. The travel motors are then accelerated and braked by ABUControl in such a way that the travel movement counters the swinging movement and thus diminishes it.
• The sway control can be switched on and off via ABURemote. The value set for the distance from the load hook to the load's centre of gravity can be changed via ABURemote.
• The sway control can only reduce the swaying by acceleration and braking through mathematical calculations. Other influences such as wind, hitting an obstacle or similar, cannot be offset.
• The acceleration and braking distances of cranes and trolleys do not alter considerably through the sway control.
• The sway control initially functions only with a single hoist or on a crane with several trolleys in individual control, providing the unused trolley is in the parking position (load hook triggers top hoist limiter).

During the joint operation of several trolleys or in tandem operation, the sway control must be separately enabled.

The calculation of the sway control only functions correctly in joint operation of multiple trolleys or in tandem operation if the distances to the load's centre of gravity are the same on both hoists. For a uniform collective load, the hook position and the length of the lifting tackle added together must result in the same total length in each case. Otherwise, the sway control could actually increase the swaying of the load.

The hook assistants (hook guidance and hook centring):

• The hook guidance allows the load hook to be moved by hand.
  Both the crane and the trolley travel in the direction the load hook is moved or pulled.
• The Hook centring function automatically positions the load hook vertically above the load "in lift" when the load is attached. This facilitates and speeds up positioning of the trolley vertically. This can reduce any diagonal pull.
• The hook guidance/hook centring function can be switched on and off using a quick-access button on the ABURemote radio control unit.
• The hook assistants work by precisely measuring the wire rope deflection. An inclinometer which measures the wire rope deflection is attached to the fixed point crosshead, the drum housing or the trolley frame. The inclinometer position can be adjusted in KranOS.
• To be able to use the function, perform a calibration run before startup multiple times from the lower to upper switch-off point.
  This determines the zero position of the inclinometer. The inclinometer calibration is activated in KranOS.
• The hook assistants only work with a single hoist or on a crane with several trolleys in individual control, provided the unused trolley is not selected and in the parking position (load hook triggers top hoist limiter).
• If the hook guidance/hook centring is active, position control cannot be activated, i.e. that the functions cannot be used at the same time.

Positioning control:

• Using the positioning control, you can move to pre-determined positions (manual or linear) or a follow route with up to 8 positions. Positions (manual or linear) can be created or modified in KranOS.

Positions of a route points cannot be created or changed in KranOS.

• The positioning control is switched on and off using ABURemote. Target positions can be selected and saved on the ABURemote transmitter. See "ABUS radio remote control ABURemote" product manual.
• The sway control status cannot be changed when PTP positioning control and teach-in PTP are activated. Access to the sway control function is locked in these modes (direct access buttons and menu).
• Switching between individual/together when PTP or teach-in PTP is activated causes an error and the procedure cannot be completed correctly.
• The super-fine lifting activity cannot be changed whilst PTP positioning mode and PTP teach-in are active

The anti-collision device:

• The anti-collision device on the crane and trolleys prevents two cranes (two trolleys) being able to hit each other at high speed or at low speed.
• The anti-collision device functions via a reflective light barrier or a distance sensor with laser beam depending on the application.
• The reflective light barriers and the distance sensors can react in a sensitive manner to the influences of dust, snow or particulates in the air. If the light beam is disrupted, the crane or trolley brakes and stops.

The tandem control:

• Two overhead travelling cranes with a joint load can be controlled simultaneously with just one transmitter by the tandem control.
• The tandem control works in combination with the synchronisation control. ABUControl controls the synchronous trolley travel and crane travel in tandem operation as well as the synchronous lifting (optional). Thus, the cranes have the same speed in the crane axes with narrow tolerances as well as the same acceleration time and braking time.
• The tandem control makes the transport of a joint load even safer.
• The tandem control also functions if the cranes have different maximum load capacities and (each considered separately) different maximum speeds.
• Loads that exceed the maximum load capacity of an individual crane in the crane installation can be lifted with the tandem control. As the load affects both cranes, the maximum load capacity of both cranes can be added together, both for cranes with identical maximum load capability and for those with different maximum load capacities. For unbalanced load distribution the total maximum load capacity is correspondingly lower.
• In tandem operation, the ABUControl controls of both cranes are wirelessly connected together and mutually transmit the normal operating modes via a radio data transmission module.
• In doing this, the corresponding parameters (e.g. "Acceleration time", "Braking time" and "Speed Maximum") are compared between the two cranes and, as far as possible, adapted so that the cranes are compatible. The travel profiles must be set identically for both cranes (e.g. "Step-less").
• Thus, for example, all travel limit switches on the crane and trolley, hoist limit switches and the overload protection are jointly evaluated. If the crane stops in one of the crane axes, the other crane also always stops in the same crane axis. The other crane axes can be moved farther without an intermediate stop.

The electronic track guidance system (option):

• The electronic track guidance system can reduce unbalanced loads as well as wear on the wheel flanges of the wheels. These occur when, for example, the trolley with load is in the load hook on the left or right end of the main girder and the crane travels.
• In addition, the distance of both wheels of an end carriage from the crane track is measured. If the crane runs unevenly (e.g. due to an unbalanced load), ABUControl evens this out again automatically, via a differential control of the drives of both end carriages.
• This means that the wear on the wheel flanges and the crane track can be significantly reduced.

Gear limit switch:

Bottom hoist limiter

• The wire rope hoist has a gear limit switch that functions as a mechanical hoist limit switch. It is directly coupled with the cable drum. It ensures that the load hook does not travel farther than the highest hook position or the lowest hook position.
• The upper switching point is called the "top hoist limiter" (middle adjusting screw); the lower switching point is called the "bottom hoist limiter" (left adjusting screw).
• Shortly before the load hook reaches the switching point of a hoist limiter, ABUControl slowly brakes the hoist motor. This method means that the switching points of the hoist limiter are only activated with a slow lifting speed.

• To additionally increase safety, the gear limit switch has another switching point. It is called the "Backup limiter" (right adjusting screw). It is located above the top hoist limiter and serves as an additional switching point when lifting.
• If the top hoist limiter should fail and the load hook then travels over the switching point of the top hoist limiter, ABUControl switches the entire crane off. The backup limiter has been set at the factory and is tamper-proof. The backup limiter has been set in the factory and sealed.

The gear limit switch without normal operative travel to the top hoist limiter:

• The top hoist limiter must not be travelled to during normal operation. If it is travelled to, the load hook stops at the switching point of the top hoist limiter. The backup limiter switching point is above the top hoist limiter switching point and can therefore not be activated in a normal case.
• If the hoist limit switch is incorrectly set or has a technical fault, the backup limiter may nevertheless be activated. The backup limiter must then be bridged so that the crane can be switched on again. In this case, contact your ABUS Service representative. See “ABUS Service”.

The gear limit switch with normal operative travel to the top hoist limiter:

• If the highest hook position must be travelled to in normal operation, the top hoist limiter is frequently activated and can fail because of this. In this case, the backup limiter ensures that the crane comes to a safe stop. So that the backup limiter can be regularly tested, the wire rope hoist has a toggle switch with which the top hoist limiter can be manually bridged and the crane can be manually switched on again after the test.

• 1: ABUControl begins the hoist drive brake phase shortly before the highest hook position. ABUControl individually calculates at which point the brake phase begins each time, depending on the current lifting speed. If the load hook travels upwards quickly, the brake phase begins earlier. If the load hook travels upwards slowly, the brake phase begins later.

In certain cases (e.g. with crossheads), a special hoist limit switch can be used. The start of the brake phase is then not individually calculated, but lies at a defined switching point.

• 2: Brake phase. How strong or gentle the brake phase is can be set in KranOS.
• 3: Switching point of the top hoist limiter. If it is activated, the load hooks stands still. Due to the individual beginning of the brake phase and the adjustable strength of the brake phase, the load hook only lifts with slow lifting speed shortly before reaching the top hoist limiter.
• 4: Switching point of the backup limiter. If it is activated, ABUControl switches the entire crane off.
• 5: Start of the brake phase, individually calculated each time, depending on the current lifting speed.
• 6: Brake phase.
• 7: Switching point of the bottom hoist limiter.

Discard prognosis

• The discard prognosis of ABUControl is used in calculating the maximum acceptable wear of the wire rope. It determines the wear of the wire rope and supports the examiner in the regular inspection by displaying the wire rope sections with the greatest wear.
• The main cause of wire rope wear on the wire rope hoist are the cyclic bendings. This is the number of bends that a particular wire rope section makes over the course of time over the individual reels on the bottom block and the deflection roller crosshead as well as on the cable drum.

Not only the number of cyclic bendings of a wire rope section but also the weight of the currently suspended load considerably influences whether or not broken wires will occur in the bent wire rope section during a cyclic bending.

• During running operation, ABUControl calculates the position at which the wire rope section is currently located. For wire rope sections running directly onto or off a reel, the suspended load is factored in and the corresponding wear for this rope section is saved (and used along with the other already saved values).
• The calculation of the maximum acceptable wear of the wire rope is no substitute for the regular inspection of the wire rope or for the inspection by the crane operator at the start of work. The intervals between the regular inspections are likewise not extended. Exterior damage (e.g. mechanical damage due to the wire rope sliding against an object) is also not taken into account.

Technical data

ABUControl can also be used at a reduced duty cycle and switching rate and also at an ambient temperature from +40 °C to +65 °C.

Operation at higher ambient temperatures:

1. For ambient temperatures of +40 °C to +65 °C, reduce the duty cycle according to the tables.

Operation at higher elevations:

At higher elevations, the crane will be less well cooled due to the reduced air pressure.

1. Reduce the duty cycle at higher elevations.

System requirements for computer

To be able to work with KranOS, a computer (e.g. laptop, tablet) is necessary. The device must fulfil the following system requirements:

• WLAN adapter (for establishing a wireless data connection with ABUControl)
• Standard Internet browser (for opening KranOS) with HTML5 support and JavaScript. The browser Google Chrome should preferably be used.
• The TCP/IP Internet protocol must be available at the WLAN adapter. The IP address should be obtained automatically (DHCP should be active). Both are usually the case.

Disposing of ABUControl components

If components of ABUControl are to be disposed of:

1. The entire control should be dismantled as much as is possible.
2. Observe local regulations concerning disposal and recycling.
3. Dispose of the individual parts sorted by material in an environmentally sound manner.

• Dispose of electronic components as scrap electronic parts.
• Dispose of cables and plug-in connections as scrap electronic parts.
• Dispose of steel sheet housing as waste metal.
• Plastic housing and plastic parts should be recycled as plastic waste.

Logging into and registering in KranOS

To change settings on ABUControl, a WLAN connection to ABUControl must be established with a WLAN-capable computer (laptop, tablet) for logging into KranOS.

Access to KranOS (except the display of operating data) is protected by usernames with passwords. The various users have different user levels. The higher the user level, the more settings can be opened and changed.

There are two user levels in ABU Control for KranOS access.

• User level [1] is "CUSTOMER" and includes read access. This allows access to diagnostic and display functions. This user level is therefore particularly relevant for the crane operator.
• User level [2] is "SERVICE" and includes authorisation to adjust the crane's settings. This makes this user level important for service work or maintenance.

The end user is responsible for the decision as to which persons or group of persons can be given knowledge of the usernames ("CUSTOMER" or "SERVICE") and the associated passwords.

Establishing WLAN connection

The figures show a WLAN connection to a PC with Windows 10. A WLAN connection is established differently for other operating systems on tablets, computers and smartphones.

1. Bring the laptop as close as possible to the crane, e.g. set it up directly beneath the crane.
2. Note the crane serial number of the crane that the connection should be established with.

The crane serial number is located, for example, on a sticker on the main girder.

1. If necessary: activate the WLAN adapter on the laptop.

Crane WLAN networkInput field for network key

1. Click on the symbol for the available WLAN networks in the system bar at the bottom right.
2. Select the WLAN network with the name (SSID) which corresponds to the crane serial number in the list of available WLAN networks and connect.

• Every crane has its own WLAN network.
• The network name (SSID) is identical with the crane serial number and is unique.

1. Enter the same character sequence for the network key again (with or without hyphens and/or blank spaces, exactly as it is on the network name (SSID)).

• The laptop will connect with the ABUControl WLAN.

Logging into KranOS

Address line with IP address for accessing KranOS

1. Open the browser on the computer.
2. Enter the address "192.168.1.1/abs" in the address line of the browser.

Enter "192.168.1.2/abs" for the second of two cranes in tandem operation.

1. Press the Enter button.

"Login" button

• The "Operating data" window appears.

The most important operating data of the crane can be read here. See "Reading operating data and load population recorder".

• The IP address and the crane serial number of the crane are displayed.

The IP address shown here is the IP address of the PLC. This is a different IP address than that for accessing KranOS in the browser.

1. Check the displayed IP address and crane serial number, and make certain that the connection with the right crane was established.

In case of doubt, switch to one of the crane axes in KranOS and check whether the corresponding motion is displayed in KranOS when the button is held depressed. See "Display status of crane axes".

1. Click the "Login" button.

Logging into KranOS

"Password" input field"User" input field

• The KranOS "Login" window appears.

1. Use capital letters and enter the username:

• Username for user level [1]: "CUSTOMER"
• Username for user level [2]: "SERVICE"

1. Enter password:

• Password for user level [1]: "CUSTOMER" (default password)

The default password for the "CUSTOMER" user can be changed after registration if required.

• Password for user level [2]: "SERVICE" (default password for first login)

The default password for the "SERVICE" user can be changed as required. It must also be changed after initial registration. See "Changing the password for KranOS".

1. Click "Login".

• The start window appears.

Note:

If there is no work on the KranOS for 30 minutes, the user is automatically logged out.

No connection to the PLC:

• If the connection to the PLC is lost, for example due to a damaged or disconnected cable, it is not possible to log in to KranOS.
• A warning appears: "PLC not accessible. Please check the connection. The values displayed here may be incorrect."

Connection between KranOS and PLC

The connection of KranOS and PLC is displayed in the start window.

• The description field "KranOS status" shows the status of the connection of KranOS to the PLC:

• Description field has a green background: Connection is established.
• Description field has a red background: Connection is interrupted. KranOS can be used, but the displayed values are possibly incorrect.

Reestablishing the connection:

1. Close the browser on the computer.
2. Reopen the browser.
3. Log in to KranOS again. See "Logging into KranOS".

Empty the browser cache on the computer:

The cache saves browser data from already visited websites. Normally this accelerates calling up websites. With KranOS however, this can lead to display problems. The cache should then be emptied.

1. In the "Google Chrome" browser: Press Ctrl + Shift + Del.

• The cache is emptied and the connection is re-established at the next opening of KranOS.

Operating KranOS

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "SERVICE" (user level ‚[2]) or "CUSTOMER" (user level [1]) must be logged in.

1. Log in to KranOS with user "CUSTOMER" (user level ‚[1]) or "SERVICE" (user level [2]). See "Logging into and registering in KranOS".

KranOS displays

After logging in:

"Back" button"User" menu

• Main menu:

The window associated with each crane axis (crane travel, trolley travel, hoist) can be selected here. Only crane axes that are actually available on the crane are displayed.

• "Settings" menu (three horizontal bars):

Three yellow bars: A menu with menu items that match the current window appears here.

Three black bars: No menu items are available for the current window.

• "Back" button (yellow arrow):

Here you can switch back to each previously displayed window.

• "User" menu (white figure):

A menu with menu items relevant to the logged in user appear here:

Change password: See "Changing the password for KranOS".

Logout: See "Logging out of KranOS".

In one of the windows:

Text field and input fieldButton (blue background)

• Selection field (white background): Here you can select a specified value from a list. See "Selecting value".
• Input field (white background): Numerical values can be entered here. See "Entering value".
• Description field (dark background): Numerical values are displayed here. They cannot be changed.
• Button (blue background): Buttons can be clicked on. They lead to another window or perform an action.

Main menu (crane axes)

• Main menu (crane axes) (blue or green background):
• Control signals (blue or green):

Terminal or device has a green background: there is voltage present or the motion restrictor has not been triggered.

Terminal or device has a blue background: there is no voltage present or the motion restrictor has been triggered.

• Button (red background): Buttons with safety-relevant functions (e.g. Bypass overload protection) have a red background as soon as they are switched on (active).

Opening and closing menus and menu items

To open the menus and menu items:

"Crane travel" menu item for crane axis

1. Click on the menu item for the desired crane axis in the main menu.

Only menu items for crane axes that are actually available on the crane are displayed (e.g. trolley 2).

Selected menu item (crane axis)"Settings" menu

• The selected menu item (crane axis) has a green background.
• The corresponding contents are displayed in the display area.
• If there are further menu items for the selected menu item (crane axis): The "Settings" menu is yellow.

Switching to another menu:

Other menu items (crane axes)

1. Click on one of the other menu items (crane axes) in the main menu.

• The newly selected menu item (crane axis) has a green background.
• The corresponding contents are displayed in the display area.

Main menu as selection field

• On smaller displays (e.g. with a smaller tablet computer), the main menu for the crane axes is shown as a selection field.

1. Click on the "Homepage" button.

If a different crane axis is called up instead of the homepage, this is shown on the button.

• The main menu is displayed with the crane axes.

1. Click on the menu item for the desired crane axis.

Opening settings:

"Settings" menu

1. Click on the "Settings" menu.

• A menu with menu items that match the current window appears here.

Switching back to the previous menu:

1. Click on the "Back" button.

• KranOS switches to the previously displayed menu item.

Switching back to the start window:

1. Depending on the window displayed: click on the "Back" button once or several times.

• The start window appears.

Entering value

Numerical values can be entered for some functions.

An input field with a white background is displayed in the window:

Input field with yellow border and green tickInput field with yellow border and red exclamation mark

1. Click input field.

• Arrow buttons appear for changing the values.
• The value range with the minimum and maximum permitted values is shown under the input field, if available.

1. Enter the desired value with the keyboard, or increase/reduce the value using the arrow buttons.

• If the new value lies within the permitted value range, a green tick appears next to the input field.
• If the new value lies outside the permitted value range, a red cross appears next to the input field. The input field background also becomes red.
• If the value was changed, a yellow border appears around the input field.

The value is not yet saved in ABUControl. See "Saving values in ABUControl".

Selecting value

For some functions, values (e.g. various settings) can be selected from a selection field.

Selection field

• A selection field with a small arrow pointing downwards is displayed in the display area.
• The currently selected value is displayed in the selection field.

1. Click on selection field.

• The possible values are displayed under the selection field.

1. Click on the desired value.

• The selected field is closed and the new value is adopted.
• If the value was changed, a yellow border appears around the input field.

The value is not yet saved in ABUControl. See "Saving values in ABUControl".

Saving values in ABUControl

After one or several values have been entered or selected within a window, the values must be transmitted to ABUControl.

Every time a window is opened, the currently set values are read from ABUControl and displayed. If values are input or selected but not saved, the next time the window is opened the original values that are still saved in ABUControl are displayed again.

After new values are input or selected:

Input field with yellow border

• If the value was changed, a yellow border appears around the input field or the selection field.

Changing additional values:

1. Press the TAB button to jump to the next input field or selection field.

There you can change additional values as described previously.

• The new values are not yet saved.

Saving values individually or all together:

1. Press the ENTER button.

or

Click on the "Write PLC" button.

• The message "Processing..." appears.
• A green tick appears in the centre of the screen.
• The new values are saved in ABUControl.

In some windows, several "Read PLC" and "Write PLC" buttons are available. The buttons are then applicable for the area that is summarised by colour (through different levels of grey).

If the values are not to be saved:

1. Click on the "Read PLC" button.

• The original values that are still saved in ABUControl are displayed again.

If one or more values are invalid when saving:

• If the new value lies outside the permitted value range, a red cross appears next to the input field. The input field background also becomes red.
• An error message is displayed.

What the error message looks like depends on the browser used.

• So long as only one value is invalid when saving, none of the values on the current page are saved.

A red cross appears in the centre of the screen:

• An error occurred when saving the values.

1. Reload the current page.
2. Enter the desired values again.
3. Click on the "Write PLC" button.

1. If the problem persists, re-establish the connection of KranOS and PLC. See "Connection between KranOS and PLC".

Logging out of KranOS

If there is no work on the KranOS for 30 minutes, the user is automatically logged out.

For manual logging out:

"User" menu"Logout" menu item

1. Click on "User" menu.

• The menu appears.

1. Click on the "Logout" menu item.

• The user is logged out.
• The "Operating data" window appears.

Changing the password for KranOS

The default password "SERVICE" for the user "SERVICE" (user level [2]) can be changed if necessary; it must also be changed after the first login. The default password "CUSTOMER" for the user "CUSTOMER" (user level [1]) can be changed if necessary.

The new password should be kept safe by the end user (e.g. in the service logbook in the crane or trolley panel) and should only be shared with the relevant group of people.

1. Log in to KranOS with user "CUSTOMER" (user level ‚[1]) or "SERVICE" (user level [2]). See "Logging into and registering in KranOS".

1. Click on "User" menu.

• The menu appears.

1. Click on the "Change password" menu item.

"New password" input field"Old password" input field

• The "Change password" window appears.

1. Enter the previous password in the "Old password" input field.
2. Enter the new password in the "New password" input field.
3. Reenter the new password in the "Repeat password" input field.
4. Click on the "Change password" button.

• The password has been changed.

Note:

Make a note of the new password in a suitable place (e.g. in the service logbook in the crane or trolley panel). The default "Service" password is no longer valid if the password has been changed. If you forget the new password, ABUS Service can reset the password. See "ABUS Service".

Note:

The first time you log in using the "SERVICE" account, the "Change Password" window will appear automatically, along with a message stating that the password must be changed.

You will not be able to access KranOS again until the password has been changed.

Setting the language

KranOS and the messages on the LED matrix display are shown in German by default. The language can be changed when you log in to KranOS.

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "CUSTOMER" (user level ‚[1]) or "SERVICE" (user level [2]) can be logged in. However, access is also possible without login (user level [0]€).

Setting language

1. Click on the "Language" button (globe).

• A list is displayed with the available languages.

1. Select the desired language.

• KranOS and the messages on the LED matrix display are switched to the selected language.

Overview of menus

Installing and connecting

This section applies to anyone who works on the crane prior to its use

The end user of the crane is responsible for the proper qualifications of the commissioning personnel.

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.

Installing the conductor system and absolute value measuring system

Connecting crane with ABUControl

Connecting the crane to the mains supply

1. Connect the power line in accordance with EN 60204.
2. Provide a permanent connection in accordance with DIN EN 50178, as the leakage current is large than 3.5 mA.

Selecting a fault current protection switch

If a fault current protection switch is to be used:

1. Use a type B fault current protection switch.

This is intended for operation with frequency converters and distinguishes between residual currents in different frequency ranges. This provides protection also for operation with frequency converters.

Assembling and disassembling cable entry housing

For cranes with short end carriages, the wiring and the cable entry housing are on the crane control in front of the high-tensile bolt. The cable entry housing must be removed in order to be able to tighten or loosen high-tensile bolts.

Removing cable entry housing

Cable entry housing

1. Open the crane control cover.
2. Press in the front four catches from the cable entry housing.
3. Tip the cable entry housing backwards (in the direction of the rear of the panel).

• The cable entry housing is removed from the panel.

1. Pull the cable entry housing forwards.

• The cable entry housing can hang loosely with the wiring on the crane control until the high-tensile bolts are tightened.

Attaching cable entry housing

Cable entry housing

1. Set the cable entry housing straight on the panel.
2. Press the cable entry housing into the panel.

• Latch in the catches (8x) with a clicking sound.

Guiding the connection cables into the cable entry housing

During assembly, the connection cables are placed through the cable entry housing into the panel and connected. All connection cables can be plugged in. The cable bushings in the cable entry housing serve as seals.

The cable bushing (rubber) is sufficient for thinner round cables. For thicker round cables and flat cables, a three-piece cable strain relief is used in addition to the cable bushing to fix the connection cable in place.

Opening cable entry housing

Cable entry housing

1. Lightly push the two clip fasteners at the top outwards.
2. At the same time, pull the upper part of the cover away from the housing.
3. Tilt the cover downwards until it is almost horizontal.

• The cover will be automatically released from the lower clip fasteners when it is tilted.

Tip:

If the cover cannot be tipped downwards due to space limitations, its upper and lower clip fasteners can also be pressed slightly outwards and the cover can then be simply taken off.

Preparing connection cable

Connection cable

1. Push the connection cable through the cable bushing until the connection cable can be guided up to the terminal block in the panel.

Depending on the line, the cable bushing has different openings (thick and thin round cables, flat cables) or is slotted.

1. Connect the cable locking latch to the connection cable from outside.

Plugging in connection cable

Connection cable with cable locking latchCable strain relief base unit

1. Put the cable strain relief base unit into the cable entry housing and latch it in.
2. Push the connection cable with the cable locking latch into the base unit and simultaneously guide the cable bushing (rubber) into the opening in the cable entry housing.
3. Connect the cable strain relief clamping bracket to the base unit.

Secure cable bushing

Opening for cable ties

1. Push the cable ties (not in the figure) into the opening on the cable strain relief.

• The cable tie is guided along the cable strain relief basic unit and comes out again at the other opening.

1. Put the cable ties together and hand-tighten them.

Installing cable duct

Cable strain relief base unitCable duct

1. Push the cable duct into the rail on the cable entry housing (below in the figure)

or

Push the cable duct into the rail between two cable strain relief base units (above in the figure).

1. Attach the connection cable onto the cable duct with cable ties.

Closing cable entry housing

Clip fastener

1. Place all four corners of the cover onto the housing.
2. Clip the cover into all four clip fasteners at the same time.

Setting switching point for the bottom hoist limiter

The wire rope hoist has a gear limit switch with three switching points. The backup limiter and the top hoist limiter are set at the factory. The bottom hoist limiter must be set on site.

Lowering the load hook to the lowest hook position

1. Lower the load hook to the desired lowest hook position.

• The load hook should not touch the floor of the building.
• The wire rope should not be slack.
• A certain minimum clearance must be maintained between the cable guide and the drum housing. This clearance is determined in the next work step.
• The hook path (distance between the highest hook position [= hook headroom, dimension C] and the lowest hook position) must not be greater than is specified on the type plate.

Only with wire rope hoists with one cable guide

Cable guide

1. Measure the distance 'F' between the cable guide and the drum housing and compare this with the table.

Wire rope hoist	Type	Reeving	Distance 'F'
GM 800	E, D, DA	4/1	42 ± 2
GM 1000	E, D, DA	4/1 2/1	56 ± 2
GM 2000	E, D, DA, DQA	4/1 2/1	59 ± 2.5
GM 3000	E, D, DA, DQA	4/1 2/1	73 ± 2.5
GM 5000	E, D, DA, DQA	4/1 2/1	87.5 ± 3
GM 5000	D	4/2	73 ± 2.5
GM 5000	Z	4/2 8/2	87.5 ± 3
GM 6000	E, D, DA, DQA	4/1 2/1	102 ± 3
GM 6000	Z	4/2 8/2	102 ± 3
GM 7000	D, DA, DQA	2/1 4/1 6/1	131 ± 4
GM 7000	D	4/2 8/2	87 ± 3
GM 7000	Z, ZA	4/2 6/2 8/2 10/2	131 ± 4

Only with wire rope hoists with two cable guides

Cable guide

1. Measure the distances 'F1' and 'F2' between the cable guides and the drum housing and compare these with the table.

Wire rope hoist	Distance 'F1'	Distance 'F2'
GM 5000 - D	80 ± 3	76 ± 3
GM 7000 - D	84 ± 3	87 ± 3

1. If necessary, raise the load hook until the distance 'F' or 'F1' or 'F2' is achieved.

Only with gear limit switch "GGS"

Detaching seal

Seal

1. Take off the housing cover of the hoist limit switch enclosure on the cable drum.
2. Press the seal apart in the centre with a screwdriver and remove it.

Setting bottom hoist limiter

The bottom hoist limiter is set with the left adjusting screw.

White pointer of cam ringOrange pointer

1. Remove the adjusting key. It is fastened on two mounts on the gear limit switch.

Alternatively, a hexagon wrench key size 3.0 (ideally with rotary plate) can be used.

An electrically operated screwdriver may NOT be used.

1. Press the adjusting key into the adjusting screw. Press it into the adjusting screw with light pressure.
2. If necessary: Turn the adjusting screw until the white pointer of the cam ring lies to the right of the orange pointer. It should be neither to the left of the orange pointer nor exactly on it.

The middle white arrow shows the exact position of the switching point; the two white arrows to the left and right of it indicate the start and end of the switching phase (switching hysteresis).

1. If necessary: Turn the adjusting screw until the white pointer of the cam ring lies to the right of the orange pointer. Continue turning until the white pointer lies exactly on the orange pointer and a clicking sound is audible.

• Turning to the right shifts the switching point downward.
• Turning to the left shifts the switching point upward.

1. The switching point for the lowest hook position is now set. At this switching point the load hook stops during normal operation after it has previously braked. The braking distance is automatically determined by ABUControl in the next step.

Only with gear limit switch "GPK"

Setting bottom hoist limiter

The bottom hoist limiter is set with the foremost adjusting screw.

MicroswitchControl cam

1. Turn the foremost adjusting screw until the control cam is on the right of the Microswitch. It must not be on the left of the Microswitch or exactly on it.
2. Turn the adjusting screw to the left until the control cam presses in an anti-clockwise direction against the Microswitch and an audible click is heard.

1. The switching point for the lowest hook position is now set. At this switching point the load hook stops during normal operation after it has previously braked. The braking distance is automatically determined by ABUControl in the next step.

• The lowest hook position of the load hook has now been determined.

Determining braking distance

In normal operation, the load hook brakes at a slow lifting speed before it stops at the lowest hook position.

The braking distance is also determined automatically by ABUControl.

1. Raise the load hook without load a few metres upwards.
2. Lower the load hook with fast lifting speed downwards.

• The load hook stops at the lowest hook position.

Depending on how the switching point was changed, it may be that the load hook with fast lifting speed moves to the switching point and then suddenly stops there or that the load hook brakes earlier than is necessary and a long stretch moves only at slow lifting speed.

If the load hook has to travel a long way at slow lifting speed, the end position of the brake phase can be changed manually. See "Temporarily changing the end position of the brake phase of the hoist drive".

• ABUControl saves the new switching point of the lowest hook position and now calculates the necessary braking distance automatically.

During the next travel to the switching point:

• The load hook brakes (depending on the current lifting speed) shortly before the lowest hook position at slow lifting speed.
• The load hook only still travels with slow lifting speed immediately before the switching point.
• The load hook stops at the switching point.

Checking the setting

1. Raise the load hook.
2. Lower the load hook at both slow and fast lifting speed and check whether it halts at the lowest hook position.

Only with gear limit switch "GGS"

Sealing the adjusting screws

Seal

1. Insert the seal on the adjusting screw and press it in.

Installing, setting and teaching-in distance sensor

With trolley travel distance sensors: The trolleys measure their distance from the end of the main girder in each case with a distance sensor laser beam. With this measurement, the braking function and shut-down can be implemented (instead of by the usual cross-type limit switch) and also the anti-collision device (instead of by the usual reflective light barriers) through the resulting calculated position of both trolleys. In the joint operation of both trolleys, the constant distance between the trolleys is also calculated and correspondingly controlled.

With crane travel distance sensor: The cranes measure their distance from another crane on the same run (or from both of the other cranes on the same run) via the distance sensor laser beam. This enables the braking function and the shut-down to the other crane/s on the same run to be implemented (instead of by the usual reflective light barriers). This also enables the constant distance to be controlled in tandem operation. The braking function and shut-down at the end of the crane track is implemented via the cross-type limit switch.

Reflective light barriers or one-way light barriers are generally used when there is a crane distancing system due to structural reasons or a load-dependent crane distancing system. Cross-type limit switches are generally used for building profile controls or an absolute value measuring system.

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "Service" (user level [2]) must be logged in.

Overview: Distance sensor and reflector

• With crane travel distance sensor: The distance sensor of the crane and the reflector for the distance sensor of another crane on the same run are fastened on a shared mount on the end carriage. On the other crane on the same run, the placement of distance sensor and reflector are accordingly interchanged. The light beams of the distance sensors are not allowed to cross each other.

• With trolley travel distance sensor on the wire rope hoist GM modular: The distance sensor is pushed laterally onto a mount in the cover of the cable drum. The reflector is taped onto the end carriage of the crane as adhesive foil or fastened on a square tube.
• With trolley travel distance sensor on the wire rope hoist GM compact: The distance sensor is installed on the trolley frame with a magnetic mount. The reflector is taped onto the end carriage of the crane as adhesive foil or fastened on a square tube.

Installing distance sensor

The distance sensor is either fastened with a mount on a square tube on the end carriage or attached to the wire rope hoist with a magnetic mount.

Only with distance sensor on square tube

Installing the mount for the light barriers

Threaded bracket

1. Attach the mount on the end carriage.
2. Bolt the mount onto the threaded bracket.

Threaded bracket	Tightening torque
M8	25 Nm
M10	50 Nm
M12	75 Nm

1. Slide on the two pipe clamps and secure them.
2. Push the square tube in the pipe clamps and screw tight.

AdapterMounting plate

1. Push the entire mount onto the square tube.
2. Screw in the mount using M8 rib nuts (4x) and tighten by hand.
3. Push the distance sensor into the adapter on the mounting plate and tighten the screws.

Only with distance sensor on magnetic mount

1. Select the appropriate size and type from the following drawings.
2. Read the dimensions A and B from the following tables.

Magnetic mount

Assembly position of the magnetic mount on wire rope hoist E

Size	Dimension A	Dimension B
800 4/1	130	100
1000 2/1	130	130
1000 4/1	130	130
2000 2/1	130	130
2000 4/1	130	160
3000 2/1	130	160
3000 4/1	130	160
5000 2/1	130	160
5000 4/1	130	200
6000 2/1	130	160

Assembly position of the magnetic mount on wire rope hoist S. Observe dimension C and fasten the distance sensor as centred as possible on the rope drive.

Size	Dimension A
800 4/1	140
1000 4/1	180
2000 4/1	180
3000 2/1	180
3000 4/1	245

Assembly position of the magnetic mount on wire rope hoist U. Observe the different positions for the left and right distance sensor.

Size	Dimension A	Dimension B	Dimension C	Dimension D
5000 4/1	330	350	310	660
6000 2/1	325	640	285	560
6000 4/1	400	320	370	595
7000 2/1	360	420	450	550

Assembly position of the magnetic mount on wire rope hoist D.

Size	Dimension A	Dimension B
800 4/1	210	60
1000 4/1	200	50
2000 2/1	200	50
2000 4/1	200	50
3000 2/1	225	50
3000 4/1	225	50
5000 2/1	200	50
5000 4/1	130	50
5000 4/2	200	50
5000 6/1	130	50
6000 2/1	200	45
6000 4/1	170	50
6000 6/1	200	50
7000 2/1	190	50
7000 4/1	190	50
7000 4/2	190	50
7000 6/1	190	60
7000 8/2	190	50

Assembly position of the magnetic mount on wire rope hoist DA.

Size	Dimension A	Dimension C
800 4/1	540	30
1000 4/1	250	35
2000 2/1	520	55
2000 4/1	520	55
3000 2/1	470	50
3000 4/1	550	60
5000 2/1	550	45
5000 4/1	610	55
6000 2/1	565	50
6000 4/1	700	55
7000 2/1	590	70
7000 4/1	390	170
7000 6/1	350	200

Assembly position of the magnetic mount on wire rope hoist DQA. Observe dimension C and fasten the distance sensor as centred as possible on the rope drive.

Size	Track	Dimension C
2000	1400	100
3000	1400	85
2000	1600	100
3000	1600	85
5000	1600	75
6000	1600	80
2000	2000	95
3000	2000	85
5000	2000	75
6000	2000	85
2000	2500	100
3000	2500	80
5000	2500	75
6000	2500	85
7000	2500	100
7000	3000	100
7000	3500	100

Assembly position of the magnetic mount on wire rope hoist Z.

Size	Dimension B
5000 4/2	535
5000 8/2	580
6000 4/2	565
6000 8/2	570
7000 4/2	725
7000 6/2	850
7000 8/2	660
7000 10/2	300
7000 12/2	470

Assembly position of the magnetic mount on wire rope hoist ZA.

Size	Dimension A	Dimension C
5000 8/2	315	355
6000 8/2	315	200
7000 6/2	440	500
7000 8/2	420	482
7000 10/2	500	570

1. Attach the magnetic mount to the wire rope hoist.

The position specified refers to the point on the distance sensor at which the laser beam emerges from it.

Depending on the installation situation, the position for the magnetic mount may already be marked.

Only with wire rope hoist GM modular

Drum side

1. Pull off the cover from the drum side.

Angle plate

1. Push the angle plate with the slit laterally into the cover.
2. Place the cover on the wire rope hoist.
3. Push the distance sensor into the adapter on the mounting plate and tighten the screws.

Installing reflector

1. During tandem control: Put the cranes at maximum distance.
2. During the joint operation of two trolleys: Put trolleys at maximum distance.

Only with reflectors on a square tube

Threaded bracket

1. Bolt the mount onto the threaded bracket.

Threaded bracket	Tightening torque
M8	25 Nm
M10	50 Nm
M12	75 Nm

1. Slide on the two pipe clamps and secure them.

Square tube

1. Push the square tube in the pipe clamps.
2. Push the reflector onto the square tube.
3. Move the reflector so that the laser point is as close to centred as possible.

The more precise adjustment is done later on the distance sensor.

1. Screw on the pipe clamps and reflector using M8 rib nuts (4x) and tighten by hand.

Setting distance sensor

Only with mount

Fillister-head screw M6x20

1. Adjust the distance sensor with M6x20 fillister-head screws (3x) so that the laser point is exactly on the centre of the reflector.

1. If the distance sensor receives the laser beam reflected from the reflector, the LEDs on the distance sensor light up.
2. If the distance sensor does not receive the laser beam, one of the LEDs flashes.

Only with magnetic mount

Adjust the distance sensor with the rough and fine adjustment screws so that the laser point is exactly in the centre of the reflector.

1. Release the fillister-head screw in the elongated hole for the rough adjustment and tilt the distance sensor.
2. If necessary, release the fillister-head screw for the fine adjustment and fine-adjust the distance sensor with the short, crosswise-lying fillister-head screw.

1. If the distance sensor receives the laser beam reflected from the reflector, the LEDs on the distance sensor light up.
2. If the distance sensor does not receive the laser beam, one of the LEDs flashes.

1. Tighten the long fillister-head screws (2x).

1. Travel along the entire traversing range with the crane (or the trolley) and check whether the laser beam meets the reflector at every position and does not drift laterally or upwards/downwards.

Opening the distance sensor settings

1. Log in to KranOS with user "Service" (user level [2]). See "Logging into and registering in KranOS".
2. Select the desired trolley drive or crane travel drive (e.g. trolley travel 1 or crane travel) in the main menu.

• The window for the requested drive appears.

1. Click on the "Crane travel distance sensors" (or "Trolley travel distance sensors") menu item in the "Settings" menu (three horizontal bars).

Teaching-in distance sensor

Now the distance sensor will be taught in. For this purpose, the crane/trolley is travelled to the desired position and the distance sensor value determined for this position is saved in ABUControl.

"Teach-in mode" button

1. Click on "Teach-in mode" button.

• The button's background turns green.
• "Teach-in mode" is switched on.
• The notice "Overriding limit switch" is displayed.

It is possible that switching points for braking function and shut-down already saved will now be ignored.

Thus, the trolley (the crane) can be moved to any new positions.

• A message appears for which switching point (braking function or shut-down) is to be travelled to.

1. Travel the trolley (the crane) to the corresponding position.

The distance sensor must be at least 0.35 m away from the reflector.

1. In the column for the switching point which is to be learnt: Click on the "Write PLC" button.

• The measured value for the current position is displayed in the description field.

The displayed value is a measured value without measurement unit, which is used to calculate the position later.

1. Repeat the process for all further switching points.

After the switching points have been saved:

• The teach-in mode ends automatically.
• The limit switch bridging turns off automatically.

Calibrating the load measuring system with an increased test load

The load measuring system continuously determines the current load on the load hook. This value is necessary for many crane functions, especially for the overload protection.

The load measuring system must be calibrated once with an increased test load in order for the attached load to be evaluated.

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "Service" (user level [2]) must be logged in.

Requirements for the calibration:

• A test load is necessary for the calibration.
• The dimensions of the test load must be known exactly.
• The dimensions of the test load should if possible correspond to the maximum load capacity of the crane or the trolley, or it should lie as close as possible to the maximum load capacity of the crane or the trolley.

For the dynamic test of the maximum load capacity of the crane a test load of 110% of the maximum load capacity of the crane is usually used. In general, this can also be used for the calibration.

A load above the maximum load capacity of the crane may only be lifted by a qualified person for the test before the first commissioning of crane installations.

ABUControl blocks the lifting function for loads over 110% of the maximum load capacity of the crane. The load can no longer be lifted and can only be set down instead.

Opening hoist calibration

1. Log in to KranOS with user "Service" (user level [2]). See "Logging into and registering in KranOS".
2. Select the desired hoist (e.g. hoist 1) in the main menu.

• The window for the requested hoist appears.

1. Click on the "Hoist calibration" menu item in the "Settings" menu (three horizontal bars).

Selecting load measuring channels

The area in the left of the "Hoist calibration" window is used for the calibration with an increased test load. Whereas the "Calibrating load sensor" button is only needed if the fixed point crosshead or the load sensor was replaced.

Test load input field"Calibrating load sensor" button

• The "Hoist calibration" window appears.
• The currently measured value is displayed and constantly updated in the "Load sensor actual value" field.

The current values in the "Proportional value" and "Load sensor actual value" lines are measured values without measurement units, which are later used to calculate the load.

Calibrating zero load

1. If necessary: Take the load and lifting tackle out of the load hook.
2. Lift/lower the empty load hook so that it hangs relatively far up, e.g. about a metre under the highest hook position.

This ensures the weight of the unwound wire rope is not included in the measurement.

Measured proportional value

• Click on the "Accept calibration value" button in the "Calibration at zero load" column.
• The current value is saved as the "zero load" and displayed in the "Proportional value" field in the column "Calibration at zero load".

Calibrating test load

"Test load" input field

1. Click on the "Test load" input field in the "Calibration at test load" column.
2. Input the test load dimensions.

• The input value is accepted.

1. Observe the applicable occupational health and safety regulations and lift the test load.
2. Wait until the test load hangs calmly in the load hook.
3. Click on the "Accept calibration value" button in the "Calibration at test load" column.

• The value determined at the current test load is saved. The value displayed in the "Proportional value" field in the "Calibration at test load" column refers to the crane's rated load. If the crane has been calibrated with a test load that is lower than the rated load, the value displayed in the "Proportional value" field is extrapolated to the rated load. The value displayed in the "Proportional load" field is then higher than the value in the "Actual load sensor value" field.

Bridging overload protection

For testing, a static test with 1.25 times the weight of the maximum load capacity of the crane and a dynamic test with 1.1 times the weight of the maximum load capacity of the crane must be carried out before the first commissioning.

The overload protection of the crane must also be bridged.

If a load weighing more than 110% of the maximum load capacity is lifted:

• The overload protection of the crane triggers.
• The load cannot be lifted any further.
• The load hook can only be lowered.

If the overload protection is bridged after having been triggered at a load more than 110%:

• The load can now be lifted further.
• If the load reduces to under 100% of the maximum load capacity, the load can again be directly lifted and lowered without bridging the overload protection.

Bridging overload protection

Bridging overload protection by coupling:

Prong terminal block ‑X103

1. Open trolley control.
2. Search for prong terminal block ‑X103.
3. Connect the double-pole coupling with jumper into the prong terminal block.

A suitable coupling with jumper can be found in the documentation folder/test log book of the crane.

• The overload protection is now bridged.

With LED matrix display: The message "F0021: Overload protection bridged" is shown.

• After 15 minutes: The overload protection is automatically switched on again.

With LED matrix display: The message "F0022: Overload protection bridged: Time exceeded" is shown.

If the overload protection is to be bridged again, the coupling must first be removed and then plugged in again.

If the coupling has a jumper inserted and ABUControl is restarted, the overload protection is not automatically bridged. Instead, the message "F0023: Overload protection: remove bridging" is displayed.

The overload protection is only bridged if the coupling is inserted with a jumper with the crane switched on.

Bridging overload protection by KranOS:

1. Log in to KranOS with user "Service" (user level [2]). See "Logging into and registering in KranOS".
2. Select the desired hoist (e.g. hoist 1) in the main menu.

• The window for the requested hoist appears.

1. Click the button "Bypass overload protection".

• The button's background turns red.
• The overload protection is now bridged.
• After 15 minutes: The overload protection is automatically switched on again.

If the overload protection is to be bridged again afterwards, the button must be clicked again.

Reactivating overload protection

As soon as the static and dynamic tests have ended:

1. Remove the coupling from the prong terminal block-X103.

or

Click the button "Bypass overload protection".

• The overload protection is switched on again.
• The button's background is no longer red.

1. Press the emergency stop button and unlock again.

or

Press the horn.

• The fault message is thus activated on ABUControl.

Installing light barrier for signal transmission for load-dependent crane distancing system

For a load-dependent crane distancing system, it must be known in both controls (in the crane and the other crane on the same run) whether the set load has fallen below or been exceeded on the other crane. This information is transmitted between the cranes via a light barrier. Each crane has light barriers for signal transmission; one as a transmitter and one as a receiver.

• The light barriers for transmitting the release signal are installed on opposite ends of the end carriages of the cranes.
• One transmitter and one receiver is installed on each crane.
• The transmitter is installed above and the receiver below on a crane. It is the other way around on the other crane.

Installing the mount for the light barriers

Threaded bracket

1. Attach the mount to opposite ends of the end carriages.
2. Bolt the mount onto the threaded bracket.

1. Slide on the two pipe clamps and secure them.

Only with vertically arranged light barriers

Mount for the light barriers

1. Push the mount for the light barriers (2x) into the pipe clamps.
2. Align the mounts and hand-tighten the pipe clamps.

Installing the light barriers

Light barriers

1. Push light barriers into the mounts.
2. Screw the light barriers until hand-tight.
3. Route the light barrier connection cables to the crane panel and secure with cable clips.

Only with horizontally arranged light barriers

If there is little space due to the lower installation height of the crane over the main girder, the light barriers can be installed side-by-side with additional mounts rather than above one another.

Mount for the light barriers

1. Push the mount for the light barriers (4x) into the pipe clamps.
2. Align the mounts and hand-tighten the pipe clamps.

Installing the light barriers

Light barriers

1. Push light barriers into the mounts.
2. Screw the light barriers until hand-tight.
3. Route the light barrier connection cables to the crane panel and secure with cable clips.

Only with light barriers on the end carriage

Light barriersMount for the light barriers

1. Place the mount for the light barriers on the holes on the end carriage.
2. Screw in the mount for the light barriers with the M8x20 rib screws.
3. Push light barriers into the mounts.
4. Screw the light barriers until hand-tight.
5. Route the light barrier connection cables to the crane panel and secure with cable clips.

Aligning light barriers

Green LED: operating voltageYellow LED (only on the receiver): visual contact to the transmitter exists

1. Align both light barriers on the crane and the other crane on the same run exactly to one another with the self-locking nuts. The yellow LED must light up on the receiver.

• Green LED (on transmitter and receiver): operating voltage present.
• Yellow LED (only on the receiver): visual contact to the transmitter exists.

1. As soon as the crane can be traversed: Run the entire crane track in various distances with the crane and the other crane on the same run and check whether the alignment of the light barriers are correct (the yellow LED on the receiver (visual contact exists) must light up in the entire traversing range). If necessary, realign the light barriers.

Due to deviations in the position of the crane track, the alignment of the light barriers can differ from each other.

Mounting the magnetic base antenna for the radio data transmission module

In tandem operation, the ABUControl controls of both cranes are wirelessly connected together and mutually transmit the normal operating modes via a radio data transmission module.

The magnetic base antennas of the radio data transmission modules must be positioned on the trolleys depending on the on-site conditions.

On cranes with tandem control:

The magnetic base antennas of the radio data transmission modules are connected, the connection cables laid and guided out of the panel or prepared for this.

Trolley frameMagnetic base antenna

• Mount the magnetic base antennas on the two trolleys in such a way that there is visual contact between them.
• Depending on the type of crane and trolley, the height of the main girder and the on-site conditions, the magnetic base antenna can, for example, be mounted on the trolley frame or on the end carriage on the other side of the trolley frame so that it points toward the partner crane. The connection cable of the magnetic base antenna is long enough for this and can be guided through the existing installation channels.
• If necessary, guide the connection cable of the magnetic base antenna out of the panel. See "Guiding the connection cables into the cable entry housing".
• Attach the magnetic base antenna so that nothing becomes caught during crane travel or trolley travel.

Installing and connecting the inclinometer

With the hook guidance/hook centring function (optional), the deflection of the wire rope is measured using an inclinometer.

To do this, first the inclinometer must be fitted then a calibration run must be carried out to save the wire rope's zero position. See "Calibrating the inclinometer". The orientation of the inclinometer must then be stated in KranOS.

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "Service" (user level [2]) must be logged in.

Preparing the wire rope angle follower

Only with inclinometer for wire rope hoist D with reeving 4/2 or 8/2 and for wire rope hoist Z

On a type D wire rope hoist with a 4/2 or 8/2 reeving, or on a type Z wire rope hoist, a multi-part wire rope angle follower is fitted, which is secured around the wire rope. The inclinometer, which measures the wire rope's angle of inclination, is mounted on the wire rope angle follower. The rope can pass through the wire rope angle follower. In order to secure the wire rope angle follower around the wire rope, it must first be dismantled so that the two halves can be assembled around the wire rope.

If the cable hoist is being removed from the crane, installed, transported by crane or forklift, or mounted on a lorry, the wire rope angle follower must be removed to prevent it from being damaged.

1. Remove the cylindrical pins (2x)

1. Undo the rounded head screws K4x17 (2x).

1. Pull the semi-circular brackets on the wire rope angle follower apart.

Installing the inclinometer

Only with for wire rope hoist with fixed point crosshead

In wire rope hoists with a fixed point crosshead, the inclinometer is secured to the cable pocket using a clamping device.

PlateRope socket

1. Clamp the bracket, plate and counter-bracket to the wire rope pocket using M4x16 fillister-head screws (3x).
2. Screw the M4x16 fillister-head screws (3) into the press-fit nuts on the counter-bracket. 5 Nm.

Press-fit nutInclinometer

1. Screw the inclinometer to the plate using fillister-head screws M4x16 (2x). 5 Nm.

On the back of the plate there are press-fit nuts into which the fillister-head screws are screwed.

Only with wire rope hoist D with reeving 4/2 or 8/2 and form GM 5000

On the D GM 5000 wire rope hoist with a 4/2 or 8/2 reeving, the weld-on plate is welded from the inside to the side wall of the bracket for the deflection roller crosshead, to which the wire rope angle follower is attached.

Rib screw M6x12Weld-on plate

1. Screw the bracket to the weld-on plate on the inside of the side panel using M6x12 rib screws (2x). 19 Nm.

Hexagon head screw M6x25Bracket

1. Insert the M6x25 hexagon head screw with washer through the cross-suspension on the support arm and through the bracket.
2. Slide the M6 nut with the washer onto the M6x25 hexagon head screw and tighten it. 10 Nm.

Semi-circular brackets with support arm

1. Screw the previously removed semi-circular bracket to the installed semi-circular bracket with support arm using K4x17 rounded head screws (2x). 1 Nm.

1. Push the cylindrical pins (2x) all the way into the semi-circular brackets using the locking mechanism.

InclinometerPlate

1. Secure the inclinometer to the wire rope angle follower plate using M4x12 hexagon head screws (2) and locking washers (2). 3 Nm.

Only with wire rope hoist D with reeving 4/2 or 8/2 and form GM 7000

On the D GM 7000 type wire rope hoist with a 4/2 or 8/2 reeving, the weld-on plate is welded from the outside to the side wall of the bracket for the deflection roller crosshead, to which the wire rope angle follower is attached.

Rib screws M6x12Weld-on plate

1. Screw the bracket to the weld-on plate on the outside of the side panel using M6x12 rib screws (2x). 19 Nm.

Hexagon head screw M6x25Bracket

1. Insert the M6x25 hexagon head screw with washer through the cross-suspension on the support arm and through the bracket.
2. Slide the M6 nut with the washer onto the M6x25 hexagon head screw and tighten it. 10 Nm.

Semi-circular brackets with support arm

1. Secure the semi-circular bracket to the semi-circular bracket with the support arm using K4x17 rounded head screws (2x). 1 Nm.

1. Push the cylindrical pins (2x) all the way into the semi-circular brackets using the locking mechanism.

InclinometerPlate

1. Secure the inclinometer to the wire rope angle follower plate using M4x12 hexagon head screws (2) and locking washers (2). 10 Nm.

Only with wire rope hoist Z

On the type Z wire rope hoist, a weld-on plate is attached to the underside of the trolley frame, to which the wire rope angle follower is secured.

Weld-on plate

1. Secure the bracket to the weld-on plate using M6x12 rib screws (2x). 19 Nm.

Hexagon head screw M6x25Washer

1. Insert the M6x25 hexagon head screw with washer through the cross-suspension on the support arm and through the bracket.

Washer

1. Slide the M6 nut with the washer onto the M6x25 hexagon head screw and tighten it. 10 Nm.

Semi-circular brackets

1. Secure the semi-circular bracket to the semi-circular bracket with the support arm using K4x17 rounded head screws. 1 Nm.

1. Push the cylindrical pins (2x) all the way into the semi-circular brackets using the locking mechanism.

Inner hexagon head screw M4x12Locking washer

1. Secure the inclinometer to the wire rope angle follower plate using M4x12 hexagon head screws (2) and locking washers (2). 3 Nm.

Connecting the inclinometer

1. Route the wire rope angle sensor connector to the absolute encoder and plug it in.

Calibrating the inclinometer

To use the hook guidance and hook centring, the inclinometer must be calibrated. To do this, a calibration run must be carried out to save the wire rope's zero position. The hook guidance and hook centring are only available once calibration has been successfully completed.

Notes:

• Before the inclinometer can be calibrated, the absolute rotary encoder must be referenced. See "Referencing the absolute rotary encoder".
• To ensure accurate calibration, the load hook must hang vertically throughout the calibration run. The best way to achieve this is to attach a load to the load hook. In the case of small load hooks and those fitted with a spring-loaded cable drum, a load must always be attached during the calibration run to ensure that the load hook hangs vertically.
• The inclinometer must be recalibrated after every dismantling (e.g. when changing the wire rope) or when replacing the inclinometer.

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "Service" (user level [2]) must be logged in.

1. Log in to KranOS with user "Service" (user level [2]). See "Logging into and registering in KranOS".
2. Select the desired hoist (e.g. hoist 1) in the main menu.

• The window for the requested hoist appears.

1. Click on the "Hoist profile parameter" menu item in the "Settings" menu (three horizontal bars).

• The "Hoist profile parameter" window appears.

1. Click on the "Inclinometer parameter" menu item in the "Settings" menu (three horizontal bars).

• The "Inclinometer parameter" window appears.

"Calibrating inclinometer" button

1. Lower the load hook all the way down.
2. If possible and applicable: attach the load.
3. Click the "Calibrating inclinometer" button.
4. Raise and lower the load hook along its full travel until 100% is displayed in the "Calibration progress" field.

During the calibration run, the trolley and the crane must not be moved, as this would cause the load hook to swing. This would compromise the calibration. Do not move the load hook in any other way during the calibration run either.

The fields "Calibration quality in the trolley travel direction" and "Calibration quality in the crane travel direction" show how good the result of the calibration run is.

1. Check the correct setting of the inclinometer. See "Setting the inclinometer position".

Setting the inclinometer position

To ensure that the hook assistants can measure the rope deflection correctly, the alignment of the rope angle sensor must be set correctly in KranOS.

Before the alignment of the inclinometer can be set, the inclinometer must be calibrated. See "Calibrating the inclinometer"..

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "Service" (user level [2]) must be logged in.

1. Log in to KranOS with user "Service" (user level [2]). See "Logging into and registering in KranOS".
2. Click on the "Movement profile" menu item in the "Settings" menu (three horizontal bars).

• The "Movement profile" window appears.

"Inclinometer rotated by 90°" buttonInclinometer orientation drop-down menu

1. Use the drop-down menu to select the orientation of the rope angle sensor for the relevant hoist.
2. If necessary, use the 'Inclinometer rotated by 90°' switch to select the installation orientation of the inclinometer.

• The button's background turns blue.

1. Click on the "Write PLC" button.

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.

Read before starting work

Test 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 requirements 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.

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

The qualified person inspecting the crane is responsible for the type and scope of the test.

Overview: testing crane with ABUControl

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.

Additionally, at least the following points must be inspected:

1. Read out the operating data and the load population recorder for further calculation of the remaining service life. See "Reading operating data and load population recorder".
2. During normal operative travel of the top hoist limiter: test backup limiter. See "Testing backup limiter".
3. Inspect the wire rope with the aid of the discard prognosis. See "Inspecting wire rope with the aid of the discard prognosis" and "Displaying parameters for maximum acceptable wear and data of the rope drive".
4. Check the overload protection. See "Check the overload protection".

Reading operating data and load population recorder

ABUControl determines numerous operating data in ongoing operation and displays an overview of these. The operating data, especially the operating hours counter and load population recorder, are important for regular inspection.

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "CUSTOMER" (user level ‚[1]) or "SERVICE" (user level [2]) can be logged in. However, access is also possible without login (user level [0]€).

Opening operating data

Without login:

1. Establish WLAN connection.
2. Open KranOS in the browser. See "Logging into and registering in KranOS".

• The "Operating data" window appears.

For the logged in user:

1. In the start window: Click on the "Operating data" menu item in the "Settings" menu (three horizontal bars).

• The window with the operating data appears.

Note:

If the crane serial number stored in the PLC does not match the crane serial number in KranOS, a message will appear indicating the conflict.

Reading operating data

"Operating hours" field"Reversing motions" field

1. Read the corresponding value from the line for the desired crane axis.

• "Operating hours": time that the drive or drives of the respective crane axis were in motion.
• "Motions": Number of motions of the respective crane axis. In each case, a motion is counted if the corresponding drive accelerates from a standstill.
• "Inching counter": Number of short motions. The number is increased by one when the corresponding drive accelerates from a standstill and runs only for up to 2 seconds. At the same time, the "Motions" description field increases by one.
• "Reversing motions": Number of reverse motions. The number is increased by one when the corresponding drive accelerates from a given motion direction directly into the opposite direction within 2 seconds. At the same time, the "Motions" description field increases by one.

Reading the load population recorder

"Consumed value" field"Overload counter" field

• "Consumed value": calculated full-load hours of the hoist.
• "Nominal value": maximum permitted full-load hours of the hoist.
• "Overload counter": Number of lifting motions with overload. The number always increases by 1 if the hoist lifts a load that is over the maximum load capacity of the crane. At the same time, the "Motions" description field also increases by 1.

For further information about the evaluation of the remaining service life: See "General product manual for ABUS cranes".

Notes:

• The displayed values are updated as the "Operating data" window is displayed. Thus you can observe in which operating situation the displayed values are increased.
• The values are saved in ABUControl. If the PLC is replaced, the values must be manually transferred.

Testing backup limiter

Only with normal operative travel to the top hoist limiter

This section only applies if the top hoist limiter may be travelled to during normal operation.

The top hoist limiter may be intentionally triggered during the normal course of work. The top hoist limiter must be tested upon switching on the crane.

If the top hoist limiter is damaged through normal use, an additional backup limiter handles the shutdown. This backup limiter must be checked within the course of regular inspection.

Moving the load hook to the correct position

1. Move the load hook out of the limit switch range (up or down).

The load hook may not be within the limit switch range prior to the test.

Testing backup limiter

'Top' position

1. Turn the toggle switch to the 'top' position and hold.
2. Raise the load hook up slowly.

1. The load hook moves up.
2. Due to the activated toggle switch, the load hook does not stop as usual at the switching point of the top hoist limiter, it moves onwards instead.
3. The backup limiter is activated.
4. The main contactor switches off.
5. The backup limiter has now been checked.

If the main contactor did not switch off:

1. There is a problem with the crane circuitry or individual components. The crane may no longer be operated.

1. Shut down the crane.
2. Contact ABUS Service. See “ABUS Service”.

Switching the crane on again

'Bottom' position

1. Turn the toggle switch to the 'bottom' position and hold.

1. The main contactor is bridged.
2. The crane switches back on.

1. Move the load hook out of the limit switch range.

Inspecting wire rope with the aid of the discard prognosis

The wire rope test is made easier and more reliable through ABUControl, which displays wire rope sections for which pronounced wear has been calculated.

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "CUSTOMER" (user level ‚[1]) or "SERVICE" (user level [2]) must be logged in.

Calling up "Maximum acceptable wear"

1. Login to KranOs with user "CUSTOMER" (user lever [1]) or "SERVICE" (user level [2]). See "Logging into and registering in KranOS".
2. Select the desired hoist (e.g. Hoist 1) in the main menu.

• The window for the requested hoist appears.

1. Click on the "Wear maximum acceptable wear" menu item in the "Settings" menu (three horizontal bars).

Reading the calculations for the maximum acceptable wear

"Rope position" column"Wear length" column

• The window "Maximum acceptable wear" appears.
• The table shows one or more wire rope sections (one wire rope section per line) for which ABUControl has calculated pronounced wear.

• The "Rope position" column indicates where the respective wire rope section is located. The length is measured from the fixed point to the start of the respective wire rope section.
• The "Wear length" column shows the length of the respective wire rope section exhibiting pronounced wear. This is measured from the start of the position given in the "Rope position" column.

• The "Total length wear area" field shows the wire rope section from the table that has been calculated as the wire rope section with highest wear.
• The "Maximum wear" field indicates the degree of wear on the wire rope section with highest wear.

1. Start the inspection of the wire rope at the displayed rope positions.

All displayed wire rope sections should be checked in succession. This is where broken wires are expected to appear first.

Inspecting the wire rope

On all displayed wire rope sections with pronounced wear:

Distance from the fixed point up to the start of the wire rope section ("Wire length" field)

1. Lower the load hook as far down as possible.

This facilitates the measuring of the wire rope.

1. Measure the distance of the "Rope position" from the fixed point of the wire rope hoist.

This is the point at which the pronounced wear begins on the wire rope section.

The wire rope section with highest wear is usually located in the first fall, but it can also lie in other falls depending on usage of the crane. In this case, measure the distance of the "Rope position" starting from the fixed point of the wire rope hoist and around the reel on the bottom block.

1. Measure the "Total length wear area" from the start of the wire rope section.

• This is the area where the wire rope section with the greatest wear is located. This is where broken wires are expected to appear first.

1. Start the wire rope test here.

See also "General Product Manual for ABUS Cranes", section "Inspecting the wire rope".

If it is determined that the maximum acceptable wear has not yet been reached at this point:

1. Inspect the entire remaining wire rope.

Only with wire rope hoists with a twin hoist or with a true vertical lift hoist

This section applies only to wire rope hoists with a twin hoist (not one but both wire rope ends are each wound onto their own cable drum) and wire rope hoists with a True Vertical Lift hoist (not one but both wire rope ends are wound together onto a shared cable drum).

Checking both halves of the wire rope

Compensating sheave

These wire rope hoists wind the wire rope at both ends. The middle wire rope piece remains nearly motionless on the compensating sheave of the wire rope hoist or the bottom block. The compensating sheave functions as a fixed point and the two wire rope halves are considered two individual wire ropes.

The wear calculated by ABUControl applies to the first as well as the second wire rope half. Due to the symmetrical arrangement, the same wear is assumed for both wire rope halves.

1. Inspect the wire rope half both to the left of the compensating sheave and to the right of the compensating sheave. The compensating sheave is considered a fixed point.

Checking the wire rope on the compensating sheave

ABUControl considers the wire rope on the compensating sheave as a fixed point.

However, due to swinging of the load and marginal variations in rotation of the two cable drums, wear also occurs on the wire rope on the compensating sheave.

Compensating sheave

1. Inspect the wire rope piece on the compensating sheave (middle deflection roller at top on the the wire rope hoist or on the bottom block) especially carefully in addition to the rest of the wire rope.

Replacing the wire rope

If the wire rope has reached its maximum acceptable wear:

1. Replace the wire rope. See "Replacing the wire rope" as well as the product manual of the wire rope hoist.

Displaying parameters for maximum acceptable wear and data of the rope drive

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "CUSTOMER" (user level ‚[1]) or "SERVICE" (user level [2]) must be logged in.

Calling up "Maximum acceptable wear parameter"

1. Login to KranOs with user "CUSTOMER" (user lever [1]) or "SERVICE" (user level [2]). See "Logging into and registering in KranOS".
2. Select the desired hoist (e.g. Hoist 1) in the main menu.

• The window for the requested hoist appears.

1. Click on the "Hoist profile parameter" menu item in the "Settings" menu (three horizontal bars).

• The "Hoist profile parameter" window appears.

1. Click on the "Maximum acceptable wear parameter" menu item in the "Settings" menu (three horizontal bars).

• The window "Maximum acceptable wear parameter" appears.

1. Read off the desired parameters:

• "Number of falls": Number of falls of the wire rope running between the bottom block and the trolley frame.

• "Wire rope for cable drum":

1: One rope end is wound onto the cable drum, the other rope end is fastened to the fixed point.

2: Both rope ends are wound onto the cable drum (wire rope hoist with True Vertical Lift hoist, reeving D4/2)

• "No. of cable drums": Number of cable drums per wire rope hoist

1: Wire rope hoist for single girder travelling cranes (type E, S, U) or for double girder travelling cranes (type D, DA, DQA)

2: Twin hoist (type Z, ZA)

• "Wire rope nominal diameter": Diameter of the wire rope on the cable drum
• "Nominal diameter of rope coil": Diameter of a single revolution (= turn) of the wire rope on the cable drum (cable drum diameter + wire rope diameter)
• "Diameter of upper deflection roller": Diameter of the upper deflection roller + wire rope diameter
• "Diameter of bottom deflection roller": Diameter of the bottom deflection roller + wire rope diameter
• "Cable drum axis to bottom block": Distance between the axis of the cable drum and the axis of the deflection roller(s) of the bottom block
• "Fixed point to upper deflection roller": Distance from the fixed point to the axis of the upper deflection roller
• "Cable drum to upper deflection roller": Distance from the axis of the cable drum to the axis of the upper deflection roller.
• "Wire rope identifier": ABUS wire rope identifier (A100=100, A101=101, A102=102, A103=103, A104=104, A105=105, A106=106)
• "Rope correction summand": internal value for the calculation
• "Rope correction factor": internal value for the calculation
• "Rope correction summand offset": internal value for the calculation
• "Rope correction factor offset": internal value for the calculation
• "Efficiency of rope drive": internal value for the calculation
• "Wire length": length of the entire wire rope
• "Nominal wire strength": strength of the wire rope
• "Rope factors": internal values for calculation

Check the overload protection

The overload protection must be checked within the scope of the regular inspection, and in the case of an overload, switch off the lifting motion.

Prerequisites for the test of the overload protection:

• This work step requires a test load.
• The dimensions of the test load must be known exactly.
• The dimensions of the test load should if possible correspond to the maximum load capacity of the crane or the trolley, or it should lie as close as possible to the maximum load capacity of the crane or the trolley.

Because the overload protection reacts at an overload of 110%, the factor for measuring the overload can be temporarily reduced in KranOS. This enables the overload protection to also be triggered with a test load that lies under 110% of the maximum load capacity of the crane.

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "SERVICE" (user level [2]) must be logged in.

Calling up parameters for the hoist profile

1. Log in to KranOS with user "SERVICE" (user level [2]). See "Logging into and registering in KranOS".
2. Select the desired hoist (e.g. Hoist 1) in the main menu.

• The window for the requested hoist appears.

1. Click on the "Hoist profile parameter" menu item in the "Settings" menu (three horizontal bars).

Reducing the "Overload factor"

• The "Hoist profile parameter" window appears.

1. In the "Overload factor" field, enter a factor through which the present test load will become an overload.
2. Click on the "Write PLC" button.

Lifting the test load

1. Observe the applicable occupational health and safety regulations and lift the test load.
2. The overload protection must trigger.

• The display on the LED matrix display flashes.

1. Set down the test load.

Resetting the overload protection

1. Switch off the crane at the circuit isolator or mains switch.
2. Wait 60 s.
3. Switching the crane on again

• ABUControl will restart.
• The overload factor will be reset again.

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.

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.

Instructions regarding safety when performing maintenance work

Observe the following safety information for all maintenance work on the crane with ABUControl:

• Switch off the mains switch. Secure the switch to ensure it cannot be turned back on accidentally.
• Open the fuse isolating link in the crane panel. Secure the fuse isolating link with a padlock so that it cannot be accidentally closed again.
• Use suitable lifting platforms and fall protection equipment.
• Adequately cordon off the operating range around the lifting platform.
• Switch off other cranes on the same crane track or cranes that are above or below the crane to be serviced. Secure the switches to ensure they cannot be turned back on accidentally. Other cranes could otherwise overturn the lifting platform or hit the crane to be 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 crane control and in the trolley control.

These safety instructions apply particularly to the crane with ABUControl:

• Before working on the crane, disconnect the power line and wait at least 15 minutes until the voltage in the immediate circuits and the frequency converter has dissipated.
• Do not open the frequency converter housing.

Switching off the crane

Switching off crane with fuse isolating link

The fuse isolating link in the crane control fulfils the function of the circuit isolator. The entire crane can thus be disconnected from the current to the greatest possible extent.

This is primarily useful if the entire crane installation cannot be switched off with a general mains switch.

Product safety sign on the cover of the crane control for switching off the crane.

1. Open crane control
2. Observe the applicable occupational health and safety regulations and turn the fuse isolating link on the handle downwards.
3. Secure fuse isolating link with padlock so that it cannot be accidentally closed again.
4. Wait for 15 minutes while the voltage is dissipated.

• The crane is de-energised from the fuse isolating link onward. Voltage is still present up to the fuse isolating link. In special power circuits (e.g. for load lifting attachments), voltage may also still be present even if the fuse isolating link is open.

Changing fuses

Fuse link

1. Open out the fuse isolating link.
2. Replace the fuse link.
3. Close up the fuse isolating link.

Setting switching points for backup limiter and top hoist limiter

The wire rope hoist has a gear limit switch with three switching points.

The switching points for the top hoist limiter and the backup limiter placed above it are set and sealed at the factory.

If required, (e.g. if the load hook cannot be run right up to the top due to a crosshead), after changing the wire rope or after repairs, the switching point for the top hoist limiter may need to be reset.

Determining switching points

Switching point
Backup limiter C1

• The hook headroom (dimension C) is principally the highest position that the load hook may travel to without damaging the wire rope. A certain safety buffer is factored into this.
• The hook headroom (dimension C) is always the distance between the lower edge of the wheel on the wire rope hoist and the inner edge of the load hook.
• The hook headroom (dimension C) always refers to a standard series load hook. In the case of larger or smaller load hooks, see the wire rope data sheet for details of the hook headroom.
• The switching point for the backup limiter is designated as C1 and lies slightly above the hook headroom. This is the absolute uppermost position up to which the load hook may move without damaging the wire rope.
• The switching point for the top hoist limiter is designated as C2 and lies slightly below the hook headroom.
• Both switching points (C1 and C2) each have two alternative reference edges: A1 and A2 (distance between one of the edges on the wire rope hoist that are easily accessible from below and the axis of the deflection roller on the bottom block), as well as B1 and B2 (distance between one of the edges on the wire rope hoist that are easily accessible from below and the and the upper edge of the bottom block). These additional dimensions can be used as an alternative to the hook headroom and can make measuring easier. They are also independent of the load hook size and can thus be used with smaller or larger load hooks.

1. Select the appropriate reference edge on the wire rope hoist and on the bottom block from the following drawing.
2. Read the dimensions C1 and C2, or alternatively A1 and A2 or B1 and B2, from the following table.

Reference edges on the wire rope hoist according to type:

Reference edges on the bottom block:

Hook headroomBackup limiter switching point

Fundamentally:

• 146 rotations of the adjusting screw completely rotate the control cam on the gear limit switch 360° once.
• How many millimetres of hook path correspond to one rotation of the adjusting screw is specified in the following table.
• Rotating the adjusting screw to the right moves the switching point downwards, rotating the adjusting screw to the left moves the switching point upwards.
• How many millimetres of hook path the load hook travels in the dead range of the Microswitch (switching hysteresis) is specified in the following table.

* The specified values apply for the GM 1000 compact and for the GM 1000 modular. The values are identical for both designs.

Travelling to the backup limiter switching point

The backup limiter switching point may only be adjusted by a qualified person for service purposes.

Dimensions A1, B1, C1

1. Bypass top hoist limiter manually, so that the backup limiter can be travelled to.
2. Raise the load hook up to dimension A1, B1 or C1.

Only with gear limit switch "GGS"

Detaching seals

Seals

1. Open the housing cover of the hoist limit switch enclosure on the cable drum.
2. Press the seals apart in the centre with a screwdriver and remove them.

Setting backup limiter The backup limiter is set with the right adjusting screw. White pointer of cam ringOrange pointer Remove the adjusting key. It is fastened on two mounts on the gear limit switch. Alternatively, a hexagon wrench key size 3.0 (ideally with rotary plate) can be used. An electrically operated screwdriver may NOT be used. Press the adjusting key into the adjusting screw. Press it into the adjusting screw with light pressure. If necessary: Turn the adjusting screw until the white pointer of the cam ring lies to the left of the orange pointer. It should be neither to the right of the orange pointer nor exactly on it. The middle white arrow shows the exact position of the switching point; the two white arrows to the left and right of it indicate the start and end of the switching phase (switching hysteresis). If necessary: Turn the adjusting screw until the white pointer of the cam ring rotates clockwise. Continue turning until the white pointer lies exactly on the orange pointer and a clicking sound is audible. Turning to the right shifts the switching point downward. Turning to the left shifts the switching point upward.

The switching point for the backup limiter is now set. ABUControl switches off the main conductor of the crane at this switching point. This switching point is only activated if the top hoist limiter has not switched (e.g. because it is faulty). Turn the adjusting screw three-quarters of a turn to the left. The microswitch switches again; the main contactor switches back on. Lower the load hook slightly. Turn the adjusting screw three-quarters of a turn back to the right. Travelling to the switching point of the top hoist limiter Move the load hook up to dimension A2, B2 or C2.

Setting top hoist limiter The top hoist limiter is set with the middle adjusting screw. White pointer of cam ringOrange pointer Remove the adjusting key. It is fastened on two mounts on the gear limit switch. Alternatively, a hexagon wrench key size 3.0 (ideally with rotary plate) can be used. An electrically operated screwdriver may NOT be used. Press the adjusting key into the adjusting screw. Press it into the adjusting screw with light pressure. If necessary: Turn the adjusting screw until the white pointer of the cam ring lies to the left of the orange pointer. It should be neither to the right of the orange pointer nor exactly on it. The middle white arrow shows the exact position of the switching point; the two white arrows to the left and right of it indicate the start and end of the switching phase (switching hysteresis). If necessary: Turn the adjusting screw until the white pointer of the cam ring rotates clockwise. Continue turning until the white pointer lies exactly on the orange pointer and a clicking sound is audible. Turning to the right shifts the switching point downward. Turning to the left shifts the switching point upward.

The switching point for the highest hook position is now set. At this switching point the load hook stops during normal operation after it has previously braked. The braking distance is automatically determined by ABUControl in the next step.

Only with "Kübler" gear limit switch

Setting backup limiter

The backup limiter is set with the backmost adjusting screw.

Control camMicroswitch

1. If necessary: Turn the adjusting screw until the control cam is to the left of the Microswitch. It should not be either directly on or to the right of the microswitch.
2. Turn the adjusting screw to the right until the control cam presses in a clockwise direction against the Microswitch and an audible click is heard.

1. ABUControl switches off.
2. The switching point for the backup limiter is now set.

ABUControl switches off the main conductor of the crane at this switching point. This switching point is only activated if the top hoist limiter has not switched (e.g. because it is faulty).

1. Turn the adjusting screw three-quarters of a turn to the left.

1. The Microswitch switches again, ABUControl switches on again.

1. Lower the load hook slightly.
2. Turn the adjusting screw three-quarters of a turn back to the right.

Travelling to the switching point of the top hoist limiter

1. Move the load hook up to dimension A2, B2 or C2.

Setting top hoist limiter

The top hoist limiter is set with the adjusting screw second from the back.

Adjusting screw

1. If necessary: Turn the adjusting screw until the control cam is to the left of the Microswitch. It should not be either directly on or to the right of the microswitch.
2. Turn the adjusting screw to the right until the control cam presses in a clockwise direction against the Microswitch and an audible click is heard.

1. The switching point for the highest hook position is now set. At this switching point the load hook stops during normal operation after it has previously braked. The braking distance is automatically determined by ABUControl in the next step.

Determining braking distance

In normal operation, the load hook brakes at a slow lifting speed before it stops at the highest hook position.

The braking distance is also determined automatically by ABUControl.

1. Raise the load hook without load a few metres downwards.
2. Lower the load hook with fast lifting speed upwards.

• At the highest hook position, the load hook halts.

Depending on how the switching point was changed, it may be that the load hook with fast lifting speed moves to the switching point and then suddenly stops there or that the load hook brakes earlier than is necessary and a long stretch moves only at slow lifting speed.

If the load hook has to travel a long way at slow lifting speed, the end position of the brake phase can be changed manually. See "Temporarily changing the end position of the brake phase of the hoist drive".

• ABUControl saves the new switching point of the highest hook position automatically and now calculates the necessary braking distance automatically.

During the next travel to the switching point:

• The load hook brakes (depending on the current lifting speed) shortly before the highest hook position at slow lifting speed.
• The load hook only still travels with slow lifting speed immediately before the switching point.
• The load hook stops at the switching point.

Checking the setting

1. Lower the load hook.

• Lift the load hook at both slow and fast lifting speed and check whether it halts at the correct point.

Only with gear limit switch "GGS"

Sealing the adjusting screws

Seals

1. Insert seals (2x) onto the adjusting screws and press them in.

Temporarily changing the end position of the brake phase of the hoist drive

In normal operation, ABUControl begins the brake phase of the hoist drive shortly before the switching point of the top/bottom hoist limiter. ABUControl individually calculates at which point the brake phase begins each time, depending on the current lifting speed. If the load hook travels upwards quickly, the brake phase begins earlier. If the load hook travels upwards slowly, the brake phase begins later.

Immediately before the hoist limiter switching point, the load hook only travels at slow lifting speed and continues to travels at slow lifting speed until the switching point is activated and the load hook stops. Normally, this is only a short stretch (a few centimetres).

However, if the switching point on the hoist limit switch is changed, for example, ABUControl does not yet recognise the resulting new end position and the new beginning of the brake phase. Due to this, it can happen that the load hook travels very far (if the switching point was significantly changed) only at slow lifting speed.

In such cases, the point to which the load hook only travels at slow lifting speed (end of the brake phase) can be temporarily changed. As soon as the switching point of the hoist limiter is activated, this manual change can however be overwritten so that the brake phase ends immediately before the hoist limiter switching point.

The process described here only changes (in KranOS) the end position of the brake phase of ABUControl temporarily. The hoist limiter switching point is not changed because of this.

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "Service" (user level [2]) must be logged in.

Opening the hoist limiter settings

1. Log in to KranOS with user "Service" (user level [2]). See "Logging into and registering in KranOS".
2. Select the desired hoist (e.g. hoist 1) in the main menu.

• The window for the requested hoist appears.

1. Click on the "Hoist calibration" menu item in the "Settings" menu (three horizontal bars).

Setting the wire length

Input field for wire length, "Hoist limiter Top drive 1"Input field for wire length, "Hoist limiter Bottom drive 1"

• The "Hoist calibration" window appears.

1. In the input fields of the wire length, enter at which ones the load hook is to stop (the brake phase ends).

or

Move the load hook to the desired position and click on the "Actual value" button under the respective input field.

• The wire length (length of the uncoiled wire between cable drum and fixed point) is entered in the input fields. The hook position is not input!
• The wire length must be input separately for drive 1 and 2 (at twin hoist).

1. Click on the "Write PLC" button.

• The set values are saved.

During lifting and lowering:

• ABUControl begins the brake phase of the hoist drive shortly before the set values. The point at which the brake phase begins is calculated by ABUControl individually each time, depending on the current lifting speed.

During the next travel to the top/bottom hoist limiter switching point:

• The previous setting is overwritten.
• Now ABUControl brakes the hoist drive again, so that the load hook moves immediately before the hoist limiter switching point only with slow lifting speed.

Switching between radio remote control and pendant control

If the crane is additionally equipped for radio remote control with a mobile control with pendant control, the pendant control can be used as necessary (e.g. when the radio transmitter is not available).

This requires that several bush multipoint connectors be reconnected in the crane panel.

Note:

When using a pendant control, a continuous movement profile is automatically activated. This cannot be changed in KranOS. The movement profile set in KranOS applies only to operation via the radio remote control.

Detaching the coupling from the receiver

Bush multipoint connector X2

1. Open the crane panel.
2. Find bush multipoint connector X2.
3. Detach bush multipoint connector.

Inserting coupler plug from pendant control

The bush multipoint connectors from the pendant control have already been guided into the crane panel and laid ready there.

Bush multipoint connector X2 12

1. Insert bush multipoint connector from pendant control:

• Bush multipoint connector X2.11 (terminal 1 to 5)
• Bush multipoint connector X2.12 (terminal 6 to 15)
• Bush multipoint connector X2.13 (terminal 16 to 27. Depending on the crane equipment, only individual terminals may be available and not all those described here)
• Bush multipoint connector X2.14 (terminal 28 to 38. Depending on the crane equipment, only individual terminals may be available and not all those described here, or the bush multipoint connector may be entirely omitted)

Replacing the wire rope

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.

Preparing for wire rope replacement

1. Move the load hook under the upper limit switch range. The switching point of the top hoist limiter must NOT be pressed.
2. 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.

Only for ABUControl with contactor control or for twin hoist

In order for the wire rope to 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.

Removing the hoist limit switch

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

Hoist limit switchPins on the cable drum

1. Open the hoist limit switch housing.
2. Unscrew and remove screws (2x).
3. Pull off the hoist limit switch.
4. 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" or "F_ _ 33 Wire rope change: Absolute rotary encoder 2 not removed" is displayed.

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

Activating the wire rope change on ABUControl

The wire rope changeover on ABUControl must be activated using a plug-in coupler in the trolley control panel or in KranOS. This is also necessary if the hoist limit switch has been removed (only required for contactor control or twin hoists), so that the cable drum can be driven by the motor.

Either activate the wire rope change by coupling:

Pin multipoint connector for parking

1. Open trolley control.
2. Search for prong terminal block ‑X104.
3. Remove the coupling from the parking position (upper pin multipoint connector).
4. 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.
• The message "F_ _ 28: Wire rope change activated" is displayed.
• All the wear values for calculating the maximum acceptable wear are deleted so that the calculation for the new wire rope can start over.
• The speed of crane travel and trolley travel is limited to the slow travel speed.
• When the crane travel and trolley travel are moving, the horn sounds every second.

Or activate rope change via KranOS:

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "Service" (user level [2]) must be logged in.

1. Log in to KranOS with user "Service" (user level [2]). See "Logging into and registering in KranOS".
2. Select the desired hoist (e.g. hoist 1) in the main menu.

• The window for the requested hoist appears.

1. 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.
• The message "F_ _ 28: Wire rope change activated" is displayed.
• All the wear values for calculating the maximum acceptable wear are deleted so that the calculation for the new wire rope can start over.
• The speed of crane travel and trolley travel is limited to the slow travel speed.
• When the crane travel and trolley travel are moving, the horn sounds every second.

Replacing the wire rope

1. Allow the wire rope to run off the cable drum using the motor.
2. Replacing wire rope. See the product manual for the wire rope hoist.

Switching off the wire rope change

As soon as the wire rope has been changed:

1. 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.

1. To acknowledge the message "F_ _ 28: Wire rope change activated", press the emergency stop button or horn.

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.

1. 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".

See "Setting switching point for the bottom hoist limiter".

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

If an inclinometer is fitted:

If an inclinometer is fitted, the wire rope angle follower must be calibrated. See "Calibrating the inclinometer".

Basic calibration of the load sensor

If the fixed point crosshead with load sensor or a single load sensor on the fixed point crosshead is replaced, the load sensor must undergo the basic calibration again. This calibration is a basic procedure has nothing to do with the calibration of the load measuring system with an increased test load, rather it represents the basic reference point for all load measurements. The load sensor must be completely free of load for this basic calibration. The wire rope and bottom block are also not permitted to affect the load sensor and must therefore be removed for the basic calibration.

After the basic calibration of the load sensor, the zero load must also be recalibrated and the load measuring system must additionally be recalibrated with an increased test load.

For a load measuring system with measurement bolt, the measurement bolt does not require a basic calibration. However, the calibration of the load measuring system with an increased test load is also necessary with a measurement bolt.

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "Service" (user level [2]) must be logged in.

Opening hoist calibration

1. Log in to KranOS with user "Service" (user level [2]). See "Logging into and registering in KranOS".
2. Select the desired hoist (e.g. hoist 1) in the main menu.

• The window for the requested hoist appears.

1. Click on the "Hoist calibration" menu item in the "Settings" menu (three horizontal bars).

Basic calibration of the load sensor

The area in the right of the "Hoist calibration" window is used for the basic calibration. This work step is necessary if the fixed point crosshead or the load sensor was exchanged.

The load sensor must be completely free of load. The wire rope and bottom block are not permitted to affect the load sensor. The rope socket must therefore be removed from the fixed point crosshead. The fixed point crosshead may not be jammed or subjected to other mechanical tension.

• The "Hoist calibration" window appears.

1. Click the "Calibrating load sensor" button.

• A confirmation prompt appears.

1. Click the "Perform calibration" button.

• The "Calibrating load sensor" button is greyed out.
• The calibration mode is activated.

1. Switch off the crane at the circuit isolator or mains switch.
2. Wait 60 s.
3. Switch the crane on again.

• ABUControl will restart.
• The load sensor will additionally be calibrated during the restart.

Calibrating the load measuring system with an increased test load

After the basic calibration of the load sensor, the zero load must also be recalibrated and the load measuring system must additionally be recalibrated with an increased test load.

1. Calibrate the load measuring system again with an increased test load. See "Calibrating the load measuring system with an increased test load".

Display status of crane axes

Information about the current status of all crane axes (crane travel, trolley travel, hoist) can be displayed in KranOS.

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "CUSTOMER" (user level ‚[1]) or "SERVICE" (user level [2]) must be logged in.

Displaying the crane axis

1. Log in to KranOS with user "CUSTOMER" (user level ‚[1]) or "SERVICE" (user level [2]). See "Logging into and registering in KranOS".
2. Select the desired crane axis (e.g. crane travel) in the main menu.

• The window for the corresponding crane axis appears.

The windows differ from each other depending on the crane axis.

Crane travel:

Crane travel frequency converters -TA61 and -TA62Crane travel limit switch -B71

• Crane travel limit switch (-B71): The crane travel limit switch switch position is displayed here.

Green background: travel limit switch not triggered
Blue background: travel limit switch triggered.

The crane travel limit switches are used for a braking function and shut-down. In the direction of the crane track end, cross-type limit switches (-B71) are used; in the direction of another crane on the same run, reflective light barriers are used (instead of -B71, -B711 and -B712 as well as -B713 and -B714 are used).

• Additional crane travel limit switches (‑B72): In addition to ‑B71, each crane travel limit switch may be provided in duplicate for each switching point and direction of travel in order to enhance the safety of the system.

• Crane travel frequency converters (-TA61 and TA62): The status of the crane travel frequency converter is displayed here:

"Ready": The frequency converter is ready for operation.

"Running": The frequency converter is active so that the drive rotates.

"Target speed": Speed at which the drive is expected to rotate.

"Actual speed": Speed at which the drive rotates.

For cranes without electronic track guidance system, a joint frequency converter (-TA61) is used for both crane travel drives. For an electronic track guidance system or a 4-wheel crane travel drive, an additional frequency converter -TA62 is displayed.

• Cross-type limit switch for building profile control (‑B76 / ‑B77): The current switch position of the cross-type limit switch that is used for the building profile control is displayed here. Through the combination of both cross-type limit switches, each with six switching statuses, up to 36 positions can be recorded.

• Reflective light barriers for crane distancing system (-B73): The switching statuses of the reflective light barriers of the crane distancing system are displayed here.

With the crane distancing system, the crane brakes at low speed (braking function) or remains completely still (shut-down), once a set distance to another crane on the same run falls below the target.

For each switching point and every travel direction one reflective light barrier is used. ABUControl monitors the normally closed contact (NC) and the normally open contact (NO) or all reflective light barriers simultaneously.

Switching contact 1 is used for the shut-down forwards, switching contact 2 is used for the braking function forwards, switching contact 3 is used for the braking function backwards and switching contact 4 is used for the shut-down backwards.

The crane distancing system is frequently used to prevent cranes e.g. from exceeding a certain distance due to static reasons. The crane distancing system can also be jointly used with the anti-collision device (see crane travel limit switch -B71).

• Additional reflective light barriers for crane distancing system (-B74): In addition to -B73 every reflective light barrier can be available in duplicate for every switching point and every travel direction to increase system security.

• Light barrier for signal transmission for load-dependent crane distancing system (-B78):

If the crane distancing system is run load-dependently, the crane is decelerated and stopped as soon as a set distance to another crane on the same run is fallen short of and a load above a set value is simultaneously moved.

So that both controls in the crane and the other crane on the same run are known, whether the set load has just fallen below or been exceeded on the other crane, this information is transmitted with a light barrier between both cranes. Each crane has light barriers for signal transmission of the release signal, one as a transmitter and one as a receiver.

Which signal is currently present at the receiver is displayed here. Area 1 shows the release signal in the forwards direction. Area 3 shows the release signal in the backwards direction.

NC has a blue background, NO has a green background: The set load is fallen short of. The crane does not receive a release signal from the other crane on the same run.
NC has a green background, NO has a blue background: The set load has been exceeded. The crane receives a release signal from the other crane on the same run.

The load can be set in the advanced parameters. See "Setting advanced travel profile parameters (crane travel profile, trolley travel profile)".

Trolley travel:

Trolley travel frequency converter -TA41Trolley travel limit switch -B51

• Trolley travel limit switch (-B51): The switching position of the trolley travel limit switch is displayed here.

Green background: travel limit switch not triggered
Blue background: travel limit switch triggered.

• Trolley travel frequency converters (-TA41): The status of the trolley travel frequency converter is displayed here:

"Ready": The frequency converter is ready for operation.

"Running": The frequency converter is active so that the drive rotates.

"Target speed": Speed at which the drive is expected to rotate.

"Actual speed": Speed at which the drive rotates.

Cross-type limit switch for building profile control (‑B56 / ‑B57): The current switch position of the cross-type limit switch that is used for the building profile control is displayed here. Through the combination of both cross-type limit switches, each with six switching statuses, up to 36 positions can be recorded.

Hoist:

Hoist frequency converter ‑1TA21 and ‑2TA21Hoist limit switch -B31 and -B32

• Hoist limit switch (-B31): The hoist limit switch switching is displayed here.

Green background: hoist limit switch not triggered
Blue background: hoist limit switch triggered.

An additional hoist limit switch -B32 is used at a twin hoist for the second cable drum.

For hoists with contactor controls: The current switch position is only displayed while the hoist lifts or lowers. If the hoist is stopped, the switching points have a blue background.

• Hoist frequency converter (-1TA21): The status of the hoist frequency converter is displayed here:

"Ready": The frequency converter is ready for operation.

"Running": The frequency converter is active so that the drive rotates.

"Target speed": Speed at which the drive is expected to rotate.

"Actual speed": Speed at which the drive rotates.

An additional frequency converter ‑2TA21 is displayed at a twin hoist for the second cable drum.

Load display: The load measuring system measurement results are displayed here:

"Load capacity": Maximum load capacity of the hoist.

"Individual load": Currently measured load on the hoist.

"Total load": Total load on all hoists or on all cranes.

"Overload counter": Number of lifting motions with overload. The number always increases by 1 if the hoist lifts a load that is over the maximum load capacity of the crane.

• Button: The service work functions can be switched on here:

"Bypass overload protection": See "Bridging overload protection".

"Rope change cable drum": See "Replacing the wire rope".

Selecting movement profiles

Different movement profiles can be selected for the movements of all three crane axes (crane travel, trolley travel, lift/lower). The basic motion behaviour can be defined through this.

For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "Service" (user level [2]) must be logged in.

Opening selection for movement profile

1. Log in to KranOS with user "Service" (user level [2]). See "Logging into and registering in KranOS".
2. In the start window: Click on the "Movement profile" menu item in the "Settings" menu (three horizontal bars).

Selecting movement profile

Selection fields for movement profiles

• The "Movement profile" window appears.
• The current settings are displayed.

1. Select the desired movement profile in the crane axis:

• Step-less: The drive can be accelerated into the second level up to a maximum value with a two-step button or joystick as long as the button is held down. If the button or joystick switches back into the first level, the drive maintains the current speed. If the button or joystick is released, the speed is reduced.
• Two-step: The drive can be accelerated to a permanently set slow travel speed in the first level and to a permanently set fast travel speed in the second level with a two-step button or joystick.
• Linear analogue value: The drive can be continuously accelerated and braked with a proportional joystick. The further the joystick is activated, the faster the drive rotates. The relationship between the joystick and drive is linear.

Analogue value S curve: As before. The relationship between the joystick and drive is in the form of an S curve. This means that relatively a lot of motion is necessary on the joystick in the range around the zero point of the joystick (drive stationary), and relatively less on the upper and lower stop points of the joystick. Thus the crane can be very precisely controlled, particularly during slower movements.

1. Click on the "Write PLC" button.

Setting individual control for ABURemote transmitters