ABUS electrics 3: Setting switching points for backup limiter and top hoist limiter

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.

─ 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.

Select the appropriate reference edge on the wire rope hoist and on the bottom block from the following drawing.

Read the dimensions C1 and C2, or alternatively A1 and A2 or B1 and B2, from the following table.

Reference edge for A-, B- and C-dimension on the wire rope hoist Z. (The reference edge for the A-, B- and C-dimension for the wire rope hoist ZA does not essentially differ).

─ 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.

Table: Hook headroom for wire rope hoists of type E. With larger track gauges please heed the following!

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

Only with E-design wire rope hoist with larger track gauge

This section only applies to wire rope hoists of the design "E" with a larger track gauge than given in the table above.

Calculating larger hook headroom

The hook headroom has to be enlarged as of a certain track gauge.

Add the additional dimension from the above table to the hook headroom.

Track gauge	Installation size 800 Reeving 4/1	Installation size 1000 Reeving 2/1	Installation size 1000 Reeving 4/1	Installation size 2000 Reeving 2/1	Installation size 2000 Reeving 4/1	Installation size 3000 Reeving 2/1	Installation size 3000 Reeving 4/1	Installation size 5000 Reeving 2/1	Installation size 5000 Reeving 4/1	Installation size 6000 Reeving 2/1
300	0	0	0	0	0	0	0	-	-	-
350	49	39	45	43	53	62	80	0	0	0
400	98	78	89	86	106	124	160	76	74	76
450	146	117	134	129	159	187	240	152	148	152
500	195	156	178	172	212	249	320	228	222	228
550	-	-	-	-	265	311	401	304	296	304
600	-	-	-	-	318	373	481	380	370	380
650	-	-	-	-	371	435	561	456	444	456
700	-	-	-	-	424	498	641	532	518	532

Bypass top hoist limiter manually, so that the backup limiter can be travelled to.

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.

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.

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.

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).

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

Hook headroom	Backup limiter switching point

Bottom hoist limiter switching point	Top hoist limiter switching point

					Switching point Backup limiter			Switching point Top hoist limiter			Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Type	Size	Reeving	Track gauge [mm]	Hook headroom (dimension C) [mm]	A1 [mm]	B1 [mm]	C1 [mm]	A2 [mm]	B2 [mm]	C2 [mm]	Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
E	800	4/1	Up to 300	400	165	70	380	215	120	430	55	71
E	1000 *	2/1	Up to 300	567	210	105	525	310	205	625	120	154
E	1000 *	4/1	Up to 300	500	230	125	480	279	175	530	60	77
E	2000	2/1	Up to 300	580	180	70	540	280	170	640	130	172
E	2000	4/1	Up to 300	500	195	80	480	245	130	530	65	86
E	3000	2/1	Up to 300	664	215	70	625	315	170	734	160	214
E	3000	4/1	Up to 300	580	235	90	560	285	140	610	80	107
E	5000	2/1	Up to 350	830	295	110	790	395	210	890	178	238
E	5000	4/1	Up to 350	825	375	190	805	425	240	855	89	119
E	6000	2/1	Up to 350	830	295	110	790	395	210	890	194	260

				Switching point Backup limiter			Switching point Top hoist limiter			Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Type	Size	Reeving	Hook headroom (dimension C) [mm]	A1 [mm]	B1 [mm]	C1 [mm]	A2 [mm]	B2 [mm]	C2 [mm]	Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
S	800	4/1	343	335	245	323	385	295	377	55	71
S	1000	4/1	420	420	315	400	470	365	450	60	77
S	2000	4/1	440	405	290	420	455	340	470	65	86
S	3000	2/1	699	520	370	659	620	470	760	160	214
S	3000	4/1	550	540	395	530	590	445	580	80	107

				Switching point Backup limiter			Switching point Top hoist limiter			Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Type	Size	Reeving	Hook headroom (dimension C) [mm]	A1 [mm]	B1 [mm]	C1 [mm]	A2 [mm]	B2 [mm]	C2 [mm]	Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
U	5000	4/1	1132	270	80	1110	320	130	1160	89	119
U	6000	2/1	1256	235	50	1215	335	150	1315	194	260
U	6000	4/1	1241	260	70	1220	310	120	1270	97	130
U	7000	2/1	1615	330	90	1575	430	190	1675	254	342

					Switching point Backup limiter			Switching point Top hoist limiter			Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
Type	Size	Reeving	Track gauge [mm]	Hook headroom (dimension C) [mm]	A1 [mm]	B1 [mm]	C1 [mm]	A2 [mm]	B2 [mm]	C2 [mm]	Dead range (switching hysteresis)	Hook path per rotation of the adjusting screw
D	800	4/1		144	170	80	125	220	130	175	55	71
D	1000	4/1		195	190	85	175	240	135	225	60	77
D	2000	2/1		295	160	50	255	260	150	355	130	172
D	2000	4/1		215	175	60	195	225	110	245	65	86
D	3000	2/1		315	190	45	275	290	150	375	160	214
D130	3000	4/1		260	230	85	240	280	134	290	80	107
D160	3000	4/1		260	225	80	240	275	129	290	80	107
D	5000	2/1		440	240	50	400	340	150	500	178	238
D	5000	4/1	160	385	285	100	365	335	150	415	89	119
D	5000	4/1	200	385	305	120		355	170
D	5000	4/2		320	330	220	280	430	320	380	178	238
D	6000	2/1		520	235	50	480	335	150	580	194	260
D	6000	4/1		267	260	73	247	310	123	297	97	130
D	6000	6/1		606	355	168	586	405	218	636	65	87
D	7000	2/1		572	344	103	532	444	203	632	254	342
D	7000	4/1		501	380	139	481	430	189	531	127	171
D	7000	6/1	to 2000	717	520	280	690	570	330	745	85	114
D	7000	6/1	from 2000	897	520	280	875	570	330	925	85	114
D	7000	4/2		236	240	50	195	340	150	295	254	342
D	7000	8/2		516	260	70	495	310	120	545	127	171