Operating the ABUS crane

The maximum load capacity is specified on the trolley and on the bottom block or hook assembly. The maximum load capacity of the crane is also given:

• For overhead travelling cranes: On the main girder
• For jib cranes: On the jib arm
• For HB cranes: On the crane girder

• For single-rail trolley tracks: On the trolley track

The maximum load capacity is specified on the trolley and on the bottom block or hook assembly. The maximum load capacity of the entire crane is also given on the crane itself:

• For overhead travelling cranes: On the main girder
• For jib cranes: On the jib arm
• For HB cranes: On the crane girder

• For single-rail trolley tracks: On the trolley track

Setting the load capacities

• If the maximum load capacity of the crane can be added together exactly from several trolleys, the load capacities of the respective trolleys are given with a “+”. The total is the maximum load capacity of the crane.

First 5 t trolleySecond 5 t trolley

20 t trolley10 t trolley5 t trolley

• If the maximum load capacity of the crane cannot be accurately added together from several trolleys, first the maximum load capacity of the crane is given, then the maximum load capacity of the trolleys, specified in brackets with a “/”.

Maximum load capacity of crane

Additional rules:

If the maximum load capacity of the crane corresponds exactly to that of the largest trolley, the maximum load capacity of the crane and the brackets are omitted.

Maximum load capacity of the crane and, at the same time, of the largest trolley

Maximum load capacity of the crane and, at the same time, of the largest trolley

• In this case as well, the maximum load capacity of the crane can be added together from several trolleys.

20 t trolley5 t trolley10 t trolley

This section only applies if the main girder (for overhead travelling cranes), the jib arm (for jib cranes), the crane girder (for HB cranes) or the trolley track (for single-rail trolley tracks) are divided into different areas with different maximum load capacities.

The maximum load capacities of the individual areas on the main girder (for overhead travelling cranes), the jib arm (for jib cranes), the crane girder (for HB cranes) or on the trolley track (for single-rail trolley tracks) are separated from each other by vertical lines. The respective maximum load capacity of the partial load range is given within the lines.

This section only applies if the crane has a warning device (e.g. horn or bell).

1. Inspect the entire wire rope for damage. The damage shown here or any similar damage should not be detectable on the wire rope.

Examples of damage:

The joining of the wire rope has opened. The inner strands of the wire rope are visible.

Loops have formed in the wire rope.

There is a kink in the wire rope. This results from violent external forces being applied to the wire rope.

The wire rope is flattened at one point. This results from the wire rope being pinched.

A bird cage has formed in the wire rope. This results from violent untwisting of the wire rope.

The wire rope has a corkscrew-type deformation.

1. Check the wire rope for detectable broken wires. If broken wires are found in the wire rope, do not work with the crane. Have a comprehensive wire rope test performed. See “General Product Manual for ABUS Cranes”.

• Is the chain lubricated with oil?

1. Inspect the entire chain for damage. The damage shown here or any similar damage should not be detectable on the chain.

Examples of damage:

Unlocking the emergency stop button

Emergency stop switch

1. Turn the emergency stop switch a quarter-turn clockwise.

1. The crane is ready for use.

Logging in

1. Switch on the transmitter of the radio remote control and log in to the receiver.

See the ABURemote product manual.

1. The crane is ready for use.

Once the transmitter is released:

1. The red signal lamp lights up.

Persons nearby thus know that a transmitter is logged in to the crane and the crane can move at any time.

Testing the slewing drive

Test the following before beginning work:

1. Press the ‘Slewing’ button completely.

1. The crane pivots in the corresponding direction.

1. Press the emergency stop switch.

1. The crane stops pivoting and slowly comes to a stop.
2. The slewing drive has no brake, therefore the crane slowly swings out.
3. The functional check of the slewing drive is now completed.

1. Switch the crane back on using the pendant control or radio remote control.

Checking hoist limiter

Test the following before beginning work:

1. Press the 'Lift' button halfway and move the load hook completely up with slow lifting speed.

1. At the highest hook position, the load hook halts.
2. The function of the top hoist limiter has now been tested.

Note:

When the top hoist limiter is tested at the start of each work shift, the wire rope is completely wound up. This distributes the wire rope evenly on both cable drums. Trouble-free operation is thereby assured.

If the wire rope is not regularly and evenly wound on both cable drums, it can happen that the wire rope is unevenly distributed, and thus the wire rope is completely wound up on one cable drum and not yet wound on the other one.

Checking the switching points

Test the following before beginning work:

1. Move the load hook until it reaches the set switching points.

1. The chain hoist no longer travels in the respective direction.

The chain hoist has a friction clutch. It prevents damage to the chain hoist if the load hook in the highest hook position knocks against the housing from below.

1. Therefore, also refrain from testing the friction clutch before performing work.

See the pendant control product manual.

See the ABURemote product manual.

This section applies only to cranes with ABUS Electrics 3 with two-stage travel drives and/or hoist drives (without ABULiner)...

... and to cranes with ABUControl. With ABUControl, you can toggle at will in the ABUS KranOS movement profile control between a continuous and a two-stage movement profile.

Overview

The lifting speed and travel speed can be controlled in two levels (slow and fast).

Slower lifting/lowering/travel

1. Half-press the button (stage 1).

1. The crane lifts or lowers at a slower speed.

Fast lifting/lowering/travel

1. Press the button completely (stage 2).

1. The crane accelerates and lifts/lowers/travels at a faster speed.

Braking

1. Release the button halfway (back to stage 1).

1. The crane brakes and lifts/lowers/travels at low speed again.

Standstill

1. Release the button.

1. The crane brakes and comes to a standstill.

This section applies only to cranes with ABUS Electrics 3 with continuous acceleration of the travel drives and/or hoist drives (with ABULiner frequency converter)...

... and to cranes with ABUControl. With ABUControl, you can toggle at will in the ABUS KranOS movement profile control between a continuous and a two-stage movement profile.

Overview

The lifting speed and travel speed can be controlled continuously.

Slow lifting/lowering/travel

1. Half-press the button (stage 1).

1. The crane lifts/lowers/travels at the slowest speed.

Acceleration

1. Press the button completely (stage 2).

1. The crane accelerates.

Maintaining speed

1. Half-press the button again (stage 1).

1. The crane no longer accelerates and continues lifting/lowering/travelling at the current speed.

Braking

1. Release the button.

1. The crane brakes.

Maintaining speed

1. Half-press the button again.

1. The crane no longer brakes and continues lifting/lowering/travelling at the current speed.

Quick braking

1. Press the opposite button completely.

1. The crane brakes very quickly.

1. Pull or push on the load, the bottom block, the hook assembly, the lifting tackle or load lifting attachment to move the load.

Do not pull on the pendant control in order to move the load or the empty load hook.

1. Only pivot or move the load if it can be easily and safely stopped by hand.

The wire rope hoist has an overload protection feature. Depending on the type, the load of the fixed point crosshead is directly or indirectly measured, or the motor current of the hoist drive is recorded during lifting.

This allows the overload protection to measure the suspended load and ensures that the wire rope hoist cannot lift any load which exceeds the maximum load capacity.

In addition, the overload protection has a protective device to prevent lifting the load with a sudden jolt (sudden load increase).

If the wire rope hoist no longer lifts with the button pressed:

1. The overload protection has triggered. The crane is now loaded with over 110% of its maximum load capacity.
2. With load display: The load display flashes.
3. With horn: The horn sounds.

1. Release the ‘Lift’ button.
2. Press the ‘Lower’ button for at least 2 seconds and set down the load.

1. With ABUControl: For 10 seconds only slow lifting speed can be used for lowering. This prevents the crane from rocking with overload at fast lifting speed.

If the wire rope hoist briefly halts when lifting a load:

1. The overload protection has detected lifting with a sudden jolt (sudden load increase).
2. The wire rope hoist lifts for 3 seconds only at slow lifting speed.

1. Continue to hold the 'Lift' button completely pressed (stage 2).

1. After 3 seconds, the wire rope hoist accelerates again to the fast lifting speed.

If the wire rope hoist no longer lifts and lowers:

1. The crane is now loaded with over 130% of its maximum load capacity.
2. The wire rope hoist blocks lifting and lowering.

1. To set down the load, the overload protection must be temporarily bypassed.

See the ABUControl Product Manual.

In joint operation of two trolleys on a crane, the overload protection of both trolleys is jointly evaluated.

If the hoist of one of the trolleys is overloaded, the other trolley is stopped simultaneously.

If the overload protection of one of the hoists has triggered in individual operation:

1. The overloaded hoist can only be used to lower the load.

This enables a load slung on one or both hoists to be safely set down.

1. In addition, the other hoist can only be used for lifting.

This ensures that with a load which is slung on both hoists and has overloaded one of them, the load will not be lowered with the other hoist. That would further overload the already overloaded hoist.

By lifting a load (which is slung on both hoists) with the other hoist, the overloaded hoist can be relieved.

If the overload protection of one of the hoists has triggered in joint operation:

1. Only lowering is possible with both hoists.

This enables a load slung on both hoists to be safely set down.

If the overload protection for the total load has triggered in individual operation:

1. The overloaded hoist can only be used to lower the load.

This enables the load slung on one or both hoists to be safely set down.

In addition, the crane cannot be further overloaded.

1. The other hoist can be used neither for lifting nor lowering.

If the overload protection for the total load has triggered in joint operation:

1. Both hoists can only be lowered in joint operation.

This enables a load slung on both hoists to be safely set down.

This ensures that the crane cannot be further overloaded.

The chain hoist has a special overload protection (friction clutch). This ensures that the chain hoist cannot be used to lift loads that could cause direct mechanical damage to the chain hoist. It also prevents damage to the chain hoist if the load hook in the highest hook position knocks against the housing from below.

Nevertheless, do not exceed the maximum load capacity of the chain hoist!

If the load hook no longer moves, but the chain hoist is still running:

1. The friction clutch has engaged.

1. Release the ‘Lift’ button.
2. Press the ‘Lower’ button and set down the load.

The LIS-SE has an inching counter. It ensures that the wire rope hoist is not used too long in inching operation (button pressed repeatedly in quick succession).

If the wire rope hoist no longer lifts after repeated brief presses of the button:

1. The inching counter has triggered. The wire rope hoist has been raised 16 times in inching operation.

1. Lower the load hook for 5 seconds at slow or fast lifting speed.

1. The inching counter is reset. The wire rope hoist can be normally operated again.

The crane (or trolley) has a braking function. The braking function prevents the crane (or trolley) from impacting the safety buffer, an obstacle or another crane (another trolley) at high speed.

If the crane (or trolley) runs at high speed:

1. The crane (or trolley) brakes at the switching point for the braking function:

• The crane brakes a small distance before the end of the crane track.
• The crane brakes a small distance before another crane on the same run.
• The trolley brakes a small distance before the end of the main girder.
• The trolley brakes a small distance before the other trolley.

1. The crane (or trolley) continues running at low speed.

1. Continue running the crane (or trolley), if necessary, at low speed.
2. Run the crane (or trolley), if necessary, in the opposite direction out of the limit switch range.

The crane (or trolley) has a travel limit switch with braking and shut-down functions. The braking function prevents the crane (or trolley) from impacting the safety buffer, an obstacle or another crane (another trolley) at high speed. The shut-down function additionally prevents the crane (or trolley) from an impact at low speed.

If the crane (or trolley) runs into the limit switch range of the braking function:

1. The crane (or trolley) brakes at the switching point for the shut-down function and stops.

• The crane brakes just before the end of the crane track.
• The crane brakes just before another crane on the same run.
• The trolley brakes just before the end of the main girder.
• The trolley brakes just before the other trolley.

1. The crane (or trolley) is at the outermost limit of the traversing range and cannot go any further.

1. Run the crane (or trolley), if necessary, in the opposite direction out of the limit switch range.
2. With anti-collision device: Or continue running another crane (another trolley) on the same run and thus enlarge the traversing range of the crane (or trolley) again.

The wire rope hoist has a gear limit switch that functions as a mechanical hoist limiter. 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.

• 1: Switching point of the top hoist limiter. If this is triggered, the hoist motor stops.
• 2: Switching point of the bottom hoist limiter. If this is triggered, the hoist motor stops.
• 3. To additionally increase safety, the gear limit switch has another switching point. It is called “backup limiter”. It is located above the top hoist limiter and serves as an additional switching point when lifting.

If the top hoist limiter is no longer working (e.g. through faulty contactors, inversely poled rotary field...) and the load hook thus moves above the switching point of the top hoist limiter, the backup limiter switches off the main contactor and thus the whole crane.

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.

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.

The braking behaviour differs from the sequences described here. See the ABULiner product manual.

However, the operation by the crane operator does not essentially differ from the sequences described here.

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.

1. Do not intentionally trigger the top hoist limiter.

The top hoist limiter may not be intentionally triggered during the normal course of work.

1. The load hook stops directly at the highest / lowest hook position.

1. Move the load hook in the opposite direction out of the limit switch range.

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. Trigger the top hoist limiter as required.

The top hoist limiter may be intentionally triggered during the normal course of work. If the top hoist limiter suddenly stops functioning, the load hook stops at the switching point of the backup limiter. The switching point of the backup limiter lies a small distance above the top hoist limiter.

1. The load hook stops directly at the highest / lowest hook position.

1. Move the load hook in the opposite direction out of the limit switch range.

The chain hoist is equipped with an adjustable friction clutch. This serves as an emergency stop device.

1. Do not intentionally run through the upper or lower end of the hook path.

The friction clutch must not be deliberately triggered during the normal course of work.

1. The friction clutch is triggered directly at the highest / lowest hook position. The load hook stops, the hoist motor continues running.

1. Move the load hook in the opposite direction out of the end of the hook path.

Note

The friction clutch on the chain hoist GMC cannot be adjusted!

An upper and a lower switching point can be set with the mechanical hoist limit switch. When the load hook reaches one of the switching points, the chain hoist brakes and halts.

The switching points may be triggered during normal operation. If the microswitches of the hoist limit switch wear out due to regular use, the friction clutch of the chain hoist serves as an emergency end stop device.

An upper and a lower switching point can be set with the electronic hoist limit switch. When the load hook reaches one of the switching points, the chain hoist brakes and halts.

Setting the intermediate switching point:

With the intermediate switching point function, any hook position between the upper and lower switching point can be moved to during normal operation.

See the product manual for the chain hoist.

Moving to the intermediate switching point:

The rotary switch is only required to set the intermediate switching point.

1. In normal operation, the chain hoist brakes as soon as the load hook approaches the intermediate switching point and halts there.

The function is optimised for moving to the intermediate switching point at fast lifting speed. At slow lifting speed, the load hook stops before the intermediate switching point is reached.

1. Release the button for lifting/lowering and press again ("stop and go").

1. The chain hoist continues running and runs over the intermediate switching point.

Reading the load display

1. The suspended load is displayed in metric tons on the LED matrix display.

The displayed load is not a calibrated measurement and is only an approximate estimate of the suspended load.

The displayed load can in the worst case deviate by up to 10% from the actual weight of the suspended load.

For an exact and calibrated weight, use a crane scale or a weighing bottom block.

Tare

The load display of the crane can be reset to zero using the “Tare” function. This enables a differential measurement, e.g. in order not to include the weight of a load lifting attachment (such as a crosshead).

Tare the hoist:

1. Select the hoist to be tared using the pendant control or the ABURemote.
2. Press and hold the “Tare” button until the load display shows 0.000.

In the case of an overload, the tare value is deleted and the load is displayed!

To reset the tare:

1. Press the “Tare” button for 5 s.

1. The LED matrix display shows the original value again.

Assigning the LED matrix displays

Load display
on the craneLoad display
on the trolley

The hoist motor has an auxiliary fan which operates independently of the hoist motor speed. The hoist motor is thus cooled even with longer operation at slow lifting speed.

If the button for lifting or lowering has been released:

1. The wire rope hoist brakes to a stop.
2. The auxiliary fan continues running for up to five minutes in order to cool the hoist motor.

The crane may only be operated up to a certain wind speed. The crane is equipped with a wind measuring system. The wind measuring system warns if a certain wind speed has been exceeded. The crane must then travel to its resting position (at the end of the crane track) within a specified time.

Yellow and/or red signal lamps flash and a horn (optional) sounds:

1. The wind speed was exceeded or the threshold for the warning was reached.

1. Set down the load.
2. Set down or remove the load lifting attachments.
3. Run the load hook upward to the highest hook position.
4. Move the wire rope hoist to the left or right to the end of the main girder.
5. Move the crane to the defined resting position.

A wind anchor is located at this resting position for securing the crane. Alternatively, the wind anchor can be of a design that secures the crane at any desired position.

1. If necessary, secure the crane.

1. The message from the load indicator system LIS is shown on the LED matrix display.

See the “Load indicator system” documentation.

A message appears on the LED matrix display:

1. The LED matrix display shows the fault code and the message from ABUControl as scrolling text.

The text speed can be set in KranOS by ABUControl.

See the ABUControl Product Manual.

Acknowledging messages

The displayed messages are divided into three categories, depending on their seriousness.

1. The category is displayed at the end of the message as “.1”, “.2” or “.3”.

• “.3”: Information message. The crane can continue to be normally operated.

To acknowledge the message display, press the emergency stop button or horn.

• “.2”: Not a serious error. The emergency stop function is triggered, the crane comes to a standstill.

To acknowledge the message display, press the emergency stop button or horn.

If the error does not occur again afterward, the crane can continue to be operated normally.

If the error occurs again afterward, the message is not displayed again. The crane can continue to be operated, however, the crane axis affected by the error can only be operated at slow travel speed.

• “.1”: Serious error. The emergency stop function is triggered, the crane comes to a standstill.

To acknowledge the message display, press the emergency stop button or horn. If the error arose from a frequency converter, the crane must be switched completely off and then back on again.

If the error does not occur again afterward, the crane can continue to be operated normally.

If the error occurs again afterward, the message is displayed again. The emergency stop function is triggered again.

Assigning messages

The digits in front of the message indicate where (e.g. on which crane axis) the error occurred and which trolley or hoist (in the case of multiple trolleys on the crane) is affected.

Third and fourth digits for the error number

• First and second digits: number of the hoist, the trolley or the crane drive in combination with the crane axis or operating range
• Third and fourth digits: error number

This results in the following combinations for the first two digits:

“Hoist drive 2” (F_2_ _) is only used with twin hoists. All other hoists have only one hoist drive (F_1_ _)

“Hoist 2” and “Hoist 3” as well as “Trolley 2” and “Trolley 3” apply to cranes with two or three trolleys.

A crane normally has one frequency converter for both crane travel drives (F14_ _). For cranes with an electronic track guidance system, each of the two crane travel drives has its own frequency converter (F14_ _ and F24_ _). For 4-wheel crane travel drives with greater power consumption of the motors, the four drives can also be divided between two frequency converters.

Overview of messages

Overview of messages for redundant travel limit switches and anti-collision devices

With a redundant travel limit switch, a crane distancing system, or trolley distancing system, two cross-type limit switches or light barriers are used on a switching point in order to additionally increase the level of safety. If both cross-type limit switches or light barriers do not simultaneously trigger when the switching point is run over, the corresponding message is displayed. Nevertheless, the crane or trolley brakes in accordance with the function.

This section is only applicable if the crane can be operated either in a building or outdoors (if the crane track leads out of the building).

1. Move the crane to the resting position in the building.

This section only applies if the crane is operated completely outdoors and if it can be secured from wind by means of a falling latch.

Example of a wind anchor at the end of the crane track

1. Set down the load.
2. If necessary: Set down or remove the load lifting attachments.
3. Move the trolley to the left or right to the end of the main girder.
4. Move the crane to the resting position at the end of the crane track.
5. Run the crane until the falling latch closes.
6. Make sure the crane is secured.

This section only applies if the crane is operated completely outdoors and if it can be secured from wind by means of a rail clamp.

1. Set down the load.
2. If necessary: Set down or remove the load lifting attachments.
3. Switch on the rail clamp.
4. Make sure the crane is secured.

This section only applies if the wire rope hoist can lift/lower with double lifting speed.

The function is continually activated and must be switched on separately.

1. Lift/lower the load with the crane as usual.

1. ABUControl or the LIS-SV on ABUS electrics 3 ascertains the suspended load.
2. The wire rope hoist can be accelerated to a greater maximum lifting speed than normal, depending on the weight of the suspended load.

• With a light load (down to an empty load hook), the maximum lifting speed of the wire rope hoist is up to twice the normal maximum speed.
• The heavier the load, the lower the maximum speed when lifting or lowering.
• At the maximum load, the wire rope hoist can only be lifted/lowered at the normal maximum lifting speed.

Normal lifting speedHigher lifting speed (maximally double lifting speed)

This section only applies to wire rope hoists with the option of super-precision lifting.

The super-precision lifting 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.

Switching super-precision lifting on and off

1. Wait until the crane stops.
2. With pendant control: Switch super-precision lifting on or off with the rotary switch.
3. With ABURemote: See the ABURemote product manual.

1. Wait about 2 seconds until the super-precision lifting function has switched on or off.

Lifting/lowering loads in super-precision mode

1. Operate the wire rope hoist as usual.

1. The wire rope hoist lifts/lowers very slowly and thus can be used to position the load with great precision.

1. Observe the duty cycle in super-precision lifting! It amounts to 1/3 that of normal operation.

If the hoist motor normally has a duty cycle of 60%, the duty cycle in super-precision lifting is 20%. The hoist motor may then be run for a maximum of 2 minutes within a 10-minute period.

The “Sway control” function considerably reduces the swinging movement of the load hook during trolley and crane travel on a crane with ABUControl. See the “ABUControl” product manual.

Switching sway control on and off

See the ABURemote product manual.

The sway control initially functions only with a crane with a single trolley or with a crane with several trolleys, providing the unused trolley is in the parking position.
During the joint operation of several trolleys or in tandem operation, the sway control must be separately enabled. See the ABUControl Product Manual.

For ABURemote with individual control: If a load hook is in the highest hook position (top hoist limiter), the sway control can be switched on for the other load hook.

Crane and trolley travel with sway control

1. Operate the crane as usual.

1. ABUControl uses the travel speeds of crane and trolley, the hook position and the length of the load lifting attachment to calculate how much the load would normally sway, and accelerates and brakes the travel motors in such a way that the swinging movement is reduced.
2. The acceleration and braking distances are not substantially altered.
3. The function does not compensate for external influences such as wind, impacts against the load or load hook, or manual movements.

Instructions for sway control for multiple trolleys:

The calculation of the sway control only functions correctly in joint operation of multiple trolleys or in tandem operation if the crane operator observes these conditions:

• Crane and trolley must be the same type and size.
• The load must be slung correctly:

Hook position

A uniform collective load must be slung so that the hook position and the length of the lifting tackle added together results in the same total length in each case.

Hook position

An uneven collective load must be slung so that the hook position, the length of the lifting tackle and the distance to the centre of gravity added together results in the same total length in each case.

• The length of the lifting tackle must be entered:

In joint operation of multiple trolleys, the length of the lifting tackle for trolley 1 must be entered.

In tandem operation, the length of the lifting tackle from the first crane must be entered. The first crane has the IP address 192.168.1.1

The electronic track guidance system is automatically switched on and cannot be switched off.

1. Operate the crane as usual.

1. Sensors measure the distance of both wheels of an end carriage to the crane track.
2. 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.

When fitted to a trolley, the LED matrix display can also show the numbers “1” and “2” to indicate the trolley assignment.

1. The assigned number of the trolley is displayed at the foremost position on the LED matrix display.

See the ABURemote product manual.

See the pendant control product manual.

See the ABURemote product manual.

See the pendant control product manual.

The control is without synchronisation control. This can result in a change in the distance of the trolleys to one another, or in the position of the load during transport, for example, due to different loads placed on the drives with differing load distribution, to different braking differences and to tolerances of the components.

If changes occur in the distance of the trolleys to each other or in the position of the load:

1. Allow the crane to come to a complete standstill.
2. Switch to trolley I or trolley II.
3. Compensate for the changed distance of the trolleys or the changed position of the load through lifting/lowering or trolley travel to the right/left.
4. Switch to joint operation again.

ABUControl has a synchronization control system. Thus, the synchronous travel of all crane axes is automatically controlled.

1. Only for hoist with frequency converter: ABUControl monitors the speed of the two hoists and automatically controls the lifting speed. This ensures a constant lifting speed of both hoists during lifting and lowering, even with unequal load distribution.
2. ABUControl monitors the speed of the trolley drives and automatically controls the trolley travel speed. Thus, both trolleys travel at the same constant speed.
3. ABUControl monitors the distance of the two trolleys to the respective end of the main girder, uses this to calculate the distance of the trolleys to one another, and controls the trolley travel speed so that the distance between the two trolleys remains constant.
4. Only with twin hoist: The synchronization control system is deactivated shortly before the switching point of the top and bottom hoist limiters. This is necessary so that the wire rope on the two cable drums of the twin hoist can be balanced. During acceleration in the opposite direction, the synchronization control system is automatically activated again. The load hook thereby stops briefly.

If the crane is to be used to turn loads, the overload protection is possibly equipped with additional functions in order to also detect an overload of the hoist even when it is lowering or stopped.

See the order-specific crane documentation.

See the “ABUS Tandem Control System” product manual.

Activating tandem operation

Working with two cranes in tandem operation:

Check the following points before beginning work in tandem operation. If there is any damage or problems arise, do not work with the crane; inform coworkers and supervisors.

Switch on tandem operation at the transmitter:

1. Check whether the two cranes are not being used independently of one another by another person.
2. Allow the cranes to come to a complete standstill. Do not switch to tandem operation during travel.
3. Activate tandem operation at the transmitter.

See the ABURemote product manual.

1. On both cranes the white signal lamp “Crane active” lights up.

Check the crane/trolley travel limit switch and hoist limiter:

1. Check the braking function of both cranes and trolleys in tandem operation.
2. Check the shut-down function of both cranes and trolleys in tandem operation.
3. Check the hoist limit switch of both hoists in tandem operation.

1. If one of the crane drives or trolley drives brakes or halts, or if one of the hoists brakes or halts, the other crane and the other trolley are also synchronously controlled.

Controlling an individual crane with the tandem control system switched on (individual operation)

With the tandem control system switched on, it can be necessary to control an individual crane briefly (e.g. for slinging the load or compensating height differences).

During this, the other crane must be blocked and must not move (e.g. through another crane operator). This mode of operation is called individual operation.

Switching to individual operation in tandem operation (controlling one individual crane and blocking the other crane):

1. Allow both cranes to come to a standstill.
2. Select one of the two cranes on the transmitter.

See the ABURemote product manual.

1. The crane selected is now activated in individual operation.
2. On the selected crane the white signal lamp “Crane active” lights up.
3. The crane not selected is blocked for the duration and cannot be controlled (e.g. by another crane operator).
4. On the crane that is not selected the white signal lamp “Crane active” goes out.

1. Operate the crane selected.
2. Select both cranes again at the transmitter.

Slinging the load for tandem operation

In order to sling a joint load, switch tandem operation on first, then sling the joint load in individual operation (control one crane and block the other), then transport the load using both cranes in tandem operation.

1. Select lifting tackle or load lifting attachments which will hold the load safely even if the load is accidentally brought out of plumb alignment.
2. Activate tandem operation at the transmitter.

See the ABURemote product manual.

1. Select one of the two cranes for individual operation on the transmitter.
2. Move the load hook to the required hook position in individual operation.
3. Attach the lifting tackle or load lifting attachments safely to the load and hook.
4. Select the other crane for individual operation on the transmitter.
5. Move the load hook to the required hook position in individual operation.
6. Attach the lifting tackle or load lifting attachments safely to the load and hook.
7. Select tandem operation for both cranes on the transmitter and lift the load.

Operating cranes in tandem operation

1. Use the buttons for crane travel, trolley travel, lift and lower to lift and transport the load.

See the ABURemote product manual.

1. Only for hoist with frequency converter: ABUControl monitors the speed of the two hoists and automatically controls the lifting speed. This ensures a constant lifting speed of both hoists during lifting and lowering, even with unequal load distribution.
2. ABUControl monitors the speed of the crane drives and trolley drives and automatically controls the travel speed. Thus, both cranes and trolleys travel at the same constant speed.
3. ABUControl monitors the distance between both cranes and controls the crane travel speed so that the distance between the two cranes remains constant.

The optical anti-collision device also works in tandem operation. This prevents the collision of the two cranes in tandem operation with further cranes on the same crane track.

Braking and shut-down functions of the crane travel limit switch, trolley travel limit switch, hoist limiter

In tandem operation, the crane travel limit switch and the trolley travel limit switch, as well as the hoist limit switch, are evaluated together.

If one of the crane drives or trolley drives brakes or halts, or if one of the hoists brakes or halts, the other crane and the other trolley are also synchronously controlled.

Overload protection

In tandem operation, the overload protection of both cranes is jointly evaluated.

If one of the cranes is overloaded, the other crane is stopped simultaneously.

Deactivating tandem operation

1. Set down the joint load.
2. Deactivate tandem operation at the transmitter.

See the ABURemote product manual.

1. The tandem control is now switched off. Both cranes can now be used independently of each other again. Both cranes can now be used independently of each other again.