Kransysteme

Installation, Operation and Maintenance Instructions

incl. Spare parts list

for

ABUS --- Pendant control BJ 24

- 211 -D
Type HT - 611
- 1011 -S

Factory No. ___________________

Stand : 31. Januar 2007

Manufacturer
ABUS Kransysteme GmbH Tel. ##49 2261 / 37-0
Sonnenweg 1 Fax. ##49 2261 / 37247
D - 51647 Gummersbach info@abus---kransysteme.de
TNR: 120028.GB

This document may not be reproduced or given to third parties and its content must not be divulged or used for other purposes without the prior written permission of ABUS. You will be liable to
pay compensation for any breach of this provision. All patent and registered design rights reserved.
A 677.GB

These Installation, Operation and Maintenance Instructions are intended for use in an English---
speaking country by English---speaking specialist personnel.
Contents
1 General . . . . . . . . . . . . . . . . . . . 3 5 Operation . . . . . . . . . . . . . . . . . 14
1.1 Use of Operating Instructions . . . . . . 3
1.2 Use for the Intended Purpose . . . . . . 3
6 Maintenance . . . . . . . . . . . . . . 14
1.3 Standards and Regulations . . . . . . . . 3
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4 Warranty . . . . . . . . . . . . . . . . . . . . . . . . 3
6.2 Replacement of Switch Unit . . . . . . . . 15
1.5 Other notes . . . . . . . . . . . . . . . . . . . . . . 4
6.2.1 Direct control . . . . . . . . . . . . . . . . . . . . 15
6.2.2 Contactor---type control . . . . . . . . . . . 16
2 Safety . . . . . . . . . . . . . . . . . . . . 4 6.3 Replacement of
Protective Rubber Cap . . . . . . . . . . . . 17
2.1 Organizational Notes . . . . . . . . . . . . . . 4
6.4 Replacement of Housing . . . . . . . . . . 17
6.5 Replacement of Microswitch
3 Description . . . . . . . . . . . . . . . 5 for Emergency Shut ---Down Function 18

3.1 Type Overview / Type Codes . . . . . . . 5 6.6 Replacement of Surround and

Head of Emergency
3.2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Shut ---Down Switch . . . . . . . . . . . . . . . 18
3.2.1 Controls . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2.2 Bayonet Mount . . . . . . . . . . . . . . . . . . . 7
7 Disposal . . . . . . . . . . . . . . . . . . 18
3.2.3 Strain Relief . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Technical data . . . . . . . . . . . . . . . . . . . 8
3.4 Declaration of conformity . . . . . . . . . . 9 8 Service . . . . . . . . . . . . . . . . . . . 18
3.5 Circuit Diagrams . . . . . . . . . . . . . . . . . 10

9 Spare parts list . . . . . . . . . . . . 19

4 Adaptation of control line . . 12 9.1 Exampel for order . . . . . . . . . . . . . . . . 19
4.1 Shortening of sheathed control line 9.2 Pendant control, complete . . . . . . . . . 20
with BJ 24 connector system . . . . . . 12
9.2.1 Standard . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Extension of sheathed control line
9.2.2 with additional functions . . . . . . . . . . . 22
with BJ24 connector system . . . . . . . 12
9.3 Spare parts . . . . . . . . . . . . . . . . . . . . . . 23
4.3 Sheathed control line on
mobile control carrier . . . . . . . . . . . . . 13 9.4 Fax–Order . . . . . . . . . . . . . . . . . . . . . . . 33

Page 2 Data : 31.01.2007

1 General
1.1 Use of Operating Instructions
These installation, operation and maintenance instruc-
tions must be read carefully before using the ABUS
pendant control for the first time and must be available
to operating personnel at all times during the use of the
pendant control.
Apart from
. instructions for action
these instructions also include hazard, warning and
safety instructions highlighted by the following sym-
bols:
Caution: Hazard to Personnel
If you fail to comply with these instructions,
there may be an immediate risk of personal
injury; premature damage to the equipment
may also result in further risks of injury.
Compliance with the instructions given in these warn-
ings is essential.
Note:
These notes are important for the proper, ra-
tional use of the product or may concern
special features of the product.
1.2 Use for the Intended Purpose
ABUS HT pendant controls are intended for the control
of machinery, preferably for the control from ground
level of all types of hoists (electric hoists, site hoists, tra-
velling cranes, etc.).
The pendant controls are designed either for use in
contactor---type control systems or for direct control.
Pendant controls are resistant to attack by oils,
greases, fuels, caustic solutions, salts and solvents.
They are designed to degree of protection IP 65 in ac-
cordance with IEC 529 and may be used at ambient
temperatures ranging from ---20˚C to +70˚C.
Other operating conditions and modes of operation will
require special investigation and agreement. It may be
necessary to obtain the manufacturer’s approval.
In particular, the following types of use are classed as
use other than for the intended purpose:
D the movement of loads by pulling the control line
D intentional damage by impact etc.
A 677.GB
D ”inching” operation
1.3 Standards and Regulations
When installing the pendant control, you must comply
with the general regulations concerning electrical in-
stallation work.
During the operation of our products, compliance with
the applicable accident prevention regulations and
general safety regulations is also essential.
IEC 364
Regulations concerning the installation of power sys-
tems with rated voltages up to 1000 V
IEC 204
Regulations concerning the electrical equipment of
processing machinery
In the case of special applications, it may be necessary
to comply with other applicable regulations.
1.4 Warranty
ABUS will assume no liability for damage to the pen-
dant control or hoists or other equipment controlled
using the pendant control arising out of or in connec-
tion with the use of the pendant control other than for
the intended purpose or work carried out incorrectly or
by unauthorized persons. ABUS will assume no liability
for any loss or damage suffered by third parties.
Caution!
If you modify any components under your
own responsibility, assemble components
other than in accordance with the installation
instructions or use any components other
than genuine ABUS components, ABUS will
be released from any warranty obligations for
the entire equipment.
ABUS pendant controls are largely maintenance---free.
For the safe operation of the product, it is essential to
use genuine ABUS parts if any spare parts are requi-
red.
It is recommended that repair and mainten-
ance work should be carried out by the ABUS
service department.
Page 3
1.5 Other notes ral attitude of the hand and arm of the operator, reduc-
ing fatigue and having a positive effect on the position
We are very pleased that you have decided to use an
of the entire body.
ABUS pendant control and hope that the pendant con-
The newly developed configuration of the controls fa-
trol will continue to perform its task reliably and to your
cilitates optimum single---handed operation with sen-
complete satisfaction for many years.
sory feedback as an added safety feature. In addition to
having a visual indication of the position of the controls,
Pendant controls are designed with ergonomic con-
the operator’s finger or thumb can feel which control is
siderations in mind. The controls of the pendant control
actually being operated at any time.
are inclined slightly from the vertical to facilitate a natu-
_________________________________

2 Safety
2.1 Organizational Notes . The product must be tested before it is commis-
Operating, maintenance and repair personnel must sioned for the first time and following any major
have read and understood the operating instructions modifications.
before starting work. Please follow the instructions given in the docu-
The owner of the product is responsible for ensuring mentation for the machine or equipment controlled
safe and non---hazardous operation. In this connec- using the pendant control.
tion, compliance with the following requirements is es-
sential:
. The operating instructions must be made available
to operating personnel and operating personnel
must be familiarized with these instructions.

Page 4 Data : 31.01.2007

3 Description

3.1 Type Overview / Type Codes

The ABUS range of pendant controls includes the following models, see Fig. 1:

ABUS type HT---D pendant control for controlling power circuits (direct control)
ABUS type HT---S pendant control for controlling control circuits (contactor–type control)

HT 211 D HT 211 S

300

300
30

30
78
78

HT 611 S HT 1011 S
40 45 40 40 30

460
40 30

380
45

78 78

Fig. 1

A 677.GB Page 5
The complete type designation of the pendant control is based on the ABUS type code which is explained below:

HT 6 1 1 D N 2 2 2 K
Use of lower row
K = crane travel drive
S = slewing drive
Crane travel: 2 = 2–stage
Trolley travel: 2 = 2–stage
Hoist drive: 2 = 2–stage
N = emergency shutdown
Control type:
D = direct control
S = contactor–type control
1 reserve space
Installation space for
emergency shutdown switch
Number of Installation spaces (2, 6 or 10)
ABUS pendant control

3.2 Design
Fig. 2 shows the external and internal parts of a pen- 8
dant control

1. upper section of housing 7

2. Emergency stop switch
3. protective cap 2
4. cover
5. switch unit
6. lower section of housing
7. pin contacts
8. isolator of connector
3

6
3.2.1 Controls
The controls and indicators on an ABUS pendant con-
trol are installed in two separate control areas depend-
ing on their importance and the frequency of use. The 5 1
section with the controls which are used most often is Fig. 2
extremely compact and is inclined towards the oper-
ator to facilitate use.
The upper section also includes the emergency shut ---
down switch, which has a central control function. The
emergency shut ---down switch is positioned for opti-
mum operation and ease of access at all times.

Page 6 Data : 31.01.2007

3.2.2 Bayonet Mount
ABUS pendant controls are designed for ease of use
and for comfortable holding and access. You must not
attempt to move a load by pulling the pendant control.
For maintenance work and in emergencies, the pen-
dant control can easily be disconnected from the strain
relief device and from the electrical cabling. The unit is
equipped with a quick ---acting bayonet mount for this
purpose (Fig. 3). 2
The bayonet lock of the sheathed control line consists
of the bayonet nut, the conical sleeve and the socket
insert with pin contacts. To disconnect the pendant
control unit from the control lines, it is only necessary to
turn the bayonet nut (2) a quarter of a turn (90˚) to the
left.

Fig. 3

3.2.3 Strain Relief

Strain relief is provided by the sheath of the control line.

A 677.GB Page 7
3.3 Technical data
Housing
Degree of protection to DIN 40050 IEC 144: IP65
Protection: total insulation to VDE 0100 Section 7
impact–resistant plastic, weatherproof and
Material:
corrosion resistant
Ambient temperature range: -20°C to +70°C

Switches
a. ABUS pendant
p control unit for direct control
designed for the direct switching of power circuits
Short circuit current: 16 A
Rated insulation voltage Ui (Group C) 500 V
Rated operating current Ie (with 400 V / 50 Hz): 5A
S i life
Service lif in
i mixed
i d operation:
ti with motor output:
((75%
5% AC3
C3 u undd 25%
5% AC4,
C , sswitching
tc g frequency
eque cy 1.5 kW 1.5x106 S
600 operations per hour, duty cycle 40%) 2.2 kW 0.6x106 S
Mechanical service life 2.0x106 S
(S = number of switching operations)
b. ABUS pendant
p control unit for contactor–type
yp control systems
y
designed for the switching of control circuits
Short circuit current: 10 A
Rated insulation voltage Ui (Group C) 500 V
Rated operating current Ie (with 250 V / 50 Hz): 5A
Service life in mixed operation:
p (S = number of switching operations)
(AC11 230 V) 2.0x106 S

Page 8 Data : 31.01.2007

3.4 Declaration of conformity

We ABUS Kransysteme GmbH

Address Sonnenweg 1
D --- 51647 Gummersbach
hereby declare, that the product:

Designation ABUS pendant control

Types HT 211, HT 611, HT 1011

in Series production
is in accordance with the european guidlines

73/23/EEC Low voltage

89/336/EEC Electromagnetic compatibility

referring to the version in force on the date of issue.

The following harmonized standards were used:

EN ISO 12100 Safety of machinery, tools and plants

EN 61000---6---4 Electromagnetic compatibility; interference emission
EN 61000---6---2 Electromagnetic compatibility; resistance to interferences

and the national standards, instructions and specifications

EN 418 Safety of machinery, Emergency shut ---down systems

EN 60204 T1 Electrical equipment of machines; general requirements
EN 60204 T32 Electrical equipment of machines; requirements for hoists
EN 60947 Low ---voltage switchgear

and the standards referred to therein.

Technical documentation is completely available.

The operating instructions belonging to it are in the language of the land of users.

Name: Gerald Krebber

Department manager
Development

Gummersbach, 31.01.2007 ___________________________ _________________________

Signature of authorised person Indication for the subscriber

This declaration is in accordance with EN 45014.

The company ABUS Kransysteme GmbH runs a certified quality management system according to DIN EN
ISO9001:2000.

A 677.GB Page 9
3.5 Circuit Diagrams
The diagrams below show the circuitry of ABUS pendant controls and the pin allocation of the control cable con-
nection socket.

A A
1 ---X2 2 ---X2

1 ---S1 1 ---S1

2 4 2

3 3

4 ---S21 4 ---S21

5 ---S22 5 ---S22

---S42 6 7 ---S41

6 7 5
---S62 8 9 ---S61

---N222S---B

HT 211D - N200-B HT 611D - N220-B

27.1 27.1 29.1
27.2 27.2 29.2

1 1 1
2 2 2
- S1 2122 - S21 012 1323 - S22 012 4353 - S1 21 22 - S21 012 13 23 - S22012 43 53 - S41012 13 23 - S42 012 43 53
Emer- 2221 lifting 1424 lowering 4454 22 21 14 24 44 54 14 24 44 54
Emer- lifting lowering right left
gency
stop gency
2 3161 2 3363 stop 2 31 61 2 33 63 2 31 61 2 33 63
3262 3464
32 62 34 64 32 62 34 64
26.1

28.1
26.2

28.2

28.3
28.4

26.1

28.1

30.1
26.2

28.2

28.3

30.2

30.3
28.4

30.4

- X2 1 2 3 4 5 6
- X2 1 2 3 4 5 6 7 8 9 10

HT 211S - N200-B HT 611S - N220-B

30

- S1 21 - S21 115 21
- S1 21 - S21 - S41
012 4
115 21 1b 1a
0 1 2 11 21
22 lifting 12 14 - S22 22 24 012 4 6 5
Emer- 012 31 5 4
41
Emer- 22 lifting 12 14 - S22
0 1 2 31
22 24
41 right
12 14 - S42
0 1 2 31
22 24
41
gency
lowering32 34 42 44 5 4 7 6
27

stop gency 32 34 42 44 32 34 42 44
lowering
27

1a 1b stop left
1a 1b
2 3 4
2 3 4 2 3 4
28.1

28.2

28.3
26

29

31.1
28.1

31.2

31.3
28.2

28.3
26

29

- X2 1 2 3 4 5 - X2 1 2 3 4 5 6 7 8

Fig. 4

Page 10 Data : 31.01.2007

Notes: Caution! If the control line is used with an
ABUS pendant control for direct control, this
D If item 24 (4) on the socket insert is not used, this blind contact pin must always be in position.
position must be equipped with a coding pin, which
- must be removed in combination with a contactor--- D If S41 / S42 or S61 / S62 are to be used for the con-
type pendant control trol of a slewing drive or other equipment with a ro-
- must be broken off at the marked point in combina- tating motion, symbol (5) should be used instead of
tion with a direct control system, so that the pin can symbol (6).
no longer be removed D If a symbol is rotated 45˚, the guide lugs (7) must
be removed.

HT 611D - N202K/S-B
27.1 29.1
27.2 29.2

1 1
2 2
- S1 2122 - S21012 1323 - S22 012 4353 - S61012 1323 - S62 012 4353
2221 1424 4454 forward 1424 backward 4454
lifting lowering
Emer-
gency 3161 3363 3161 3363
2 2 2 2
stop
3262 3464 3262 3464
26.1

28.1

30.1
26.2

28.2

28.3

30.2

30.3
28.4

30.4
- X2 1 2 3 4 5 6 11 12 1314

HT 611D - N222K/S-B
27.1 29.1 29.3
27.2 29.2 29.4

1 1 1
2 2 2
- S1 2122 - S21012 1323 - S22012 4353 - S41012 1323 - S42012 4353 - S61012 1323
- S62012 4353
2221 lifting 1424 lowering
4454 right 1424 left 4454 forward 1424 backward4454
Emer-
gency
stop 2 3161 2 3363 2 3161 2 3363 2 3161 2 3363
3262 3464 3262 3464 3262 3464
31.1
26.1

28.1

30.1

31.2

31.3
31.4
26.2

28.2

28.3

30.2

30.3
28.4

30.4

- X2 1 2 3 4 56 7 8 9 10 1112 1314

HT 611S - N202K/S-B
30

- S1 21 - S21
012 115 4
21 1b 1a - S61
0 1 2 11 6 5
21
22 lifting 12 14 - S22 22 24 forward
12 14 - S62 22 24
Emer- 0 1 2 31
5 4
41 0 1 2 31
7 6
41
gency 32 34 42 44 32 34 42 44
backward
27

stop lowering
1a 1b
2 3 4 2 3 4
31.1
28.1

31.2

31.3
28.2

28.3
26

29

- X2 1 2 3 4 5 9 10 11

HT 611S - N222K/S-B
30 32

- S1 21 - S21
012 115 4
21 1b 1a - S41
012 116 5
21 1a 1b - S61
012 118 7
21

22 lifting 12 14- S22 22 24 right 12 14- S42 22 24 forward12 14 - S62 22 24

Emer- 012 315 4
41 012 317 6
41 012 318 8
41
gency
stop lowering 32 34 42 44 left 32 34 42 44 backward32 34 42 44
27

1a 1b

2 3 4 2 3 4 2 3 4
31.1
28.1

31.2

31.3

33.1
28.2

28.3

33.2

33.3
26

29

- X2 1 2 3 4 5 6 7 8 9 10 11

Fig. 5

A 677.GB Page 11
4 Adaptation of control line
4.1 Shortening of sheathed con- 4.2 Extension of sheathed control
trol line with BJ 24 connector line with BJ24 connector sys-
system tem
2 sleeves are installed in the sheath of each sheathed If a control line needs to be extended, you must use a
control ling. connection element consisting of:
If a sheathed control line needs to be shortened, the 1. coupling
sleeves may be pushed to other positions inside the 2. socket spacer ring
sheath. 3. plug spacer ring
The coupling sides and the spacer rings are marked
with plug and socket symbols.
(see Fig. 7).

Bayonet lock BJ 30

socket
spacer ring
Sleeve Snap hou-
sing BJ 30

Clamp Socket part

socket symbol

coupling

Sheath
plug symbol
Connector
part

Snap hou-
sing BJ 30
Fig. 6
plug spa-
cer ring
Shortening:
1. Push the sleeves to the required positions. Bayonet lock BJ 30
2. Form a loop and apply the clamps in the area of the
sleeves (see Fig. 6)
Caution! Fig. 7
Cable ties must not be used to shorten the
control line. Otherwise, the sheath will no Any standard sheathed control line may be used for ex-
longer provide strain relief. tension in combination with spare parts set AN 102282.

Page 12 Data : 31.01.2007

Installation of connection element: 4.3 Sheathed control line on mo-
bile control carrier

3b

3a

2a

2b

Fig. 9
Fig. 8

Extension of control line

1. Insert spacer rings into the bayonet lock in accord-

ance with the symbols.
The spacer rings are slotted.
2. a. Insert plug---type connector into coupling.
b. Lock bayonet lock.
3. a. Insert plug---type connector into coupling.
b. Lock bayonet lock.

A 677.GB Page 13
5 Operation
The pendant control is used for the control of the ma-
chines to which it is connected (normally hoists and
hoist trolleys). The pendant control is ergonomically
designed, allowing operation with one hand.
If you release the switch, the unit is decelerated to a
standstill.
If you operate the emergency stop switch, the unit is
stopped immediately, whatever the operating situation.

The two---stage push buttons of the pendant control

cab be used for operating pole---changing motors. A
mechanical or electrical interlock in the pendant control
prevents simultaneous operation in two opposite direc-
tions.
Inching operation should be avoided. 3
Inching may lead to severe erosion of the contacts and
premature wear of the switch unit.

The functions of the pendant control are as follows

(Fig. 10):

. If the button is released 4

⇒ the unit is at a standstill.

. button pressed to first stage (1)

⇒ precision / slow speed

. button pressed to second stage (2)

⇒ main / fast speed 1

. Red emergency stop switch pressed (3)

⇒ unit is stopped even if another button is pressed.
2
. To reset the unit, turn red emergency stop switch to
right. (4).

In combination with infinitely variable speed control,

the first stage ensures a constant speed while the se-
cond stage activates an acceleration ramp set at the Fig. 10
factory.
If you release the switch from stage 2 to stage 1, the
speed which you have reached is maintained.
_________________________________

6 Maintenance
6.1 General
Caution:
Each time you start work, the strain relief components,
Work on pendant controls must only be per-
the pendant control housing and the control cable
formed by electricians or other suitably quali-
must be inspected for any damage.
fied personnel.
Compliance with accident prevention regulations and
general safety regulations is essential during the oper-
ation of our products (see Section 2 above).

Page 14 Data : 31.01.2007

6.2 Replacement of Switch Unit . Install flexible conductors with crimp contacts (13)
of the new switch unit in the isolator, one after the
other, taking care to position each conductor in the
correct recess. Please use the dismantling tool (14)
6.2.1 Direct control
to dismantle the crimp contacts of the old unit. To
do so, position the dismantling tool on the contacts
Contents of spare parts package:
and pull the old conductors out of the isolator.
see Fig. 43; Page 27
. Insert the crimp contacts of the new switch unit.
Installation:
. check whether the crimp contacts are clipped
. Disconnect the pendant control from the control firmly into position.
cable by unlocking the bayonet mount (Fig. 11).
. Remove ABUS screw cover (1) using a sharp . Reassemble the pendant control in reverse order of
dismantling and connect it to the control cable.
screwdriver, width apropos 1 mm.
. Undo the 6 housing screws (2). Remove lower sec-
tion of housing.

14 10

11
1 2

12
15

13

7
6

Fig. 11
. Remove cable tie (12) (Fig. 12).
. Unscrew the 2 mounting screw (8), 4 switch unit
screws (6) and 2 clamping screws (7).
. Remove isolator (9) from upper section of housing. Fig. 12

A 677.GB Page 15
6.2.2 Contactor---type control
Contents of spare parts package:
see Fig. 44; Page 28
Installation:
Replace old switch block (black) by new switch block
(white)
. Disconnect the pendant control from the control
cable by unlocking the bayonet mount (Fig. 13).
. Remove ABUS screw cover (1) using a sharp
screwdriver, width apropos 1 mm.
. Undo the 6 housing screws (2). Remove lower sec-
tion of housing. (Fig. 13).
The faulty switch block can now be completely re-
moved and replaced by a new unit.
In the case of an 18---pole connector, the red con-
necting wires supplied, with crimp contacts, must
be pressed into the appropriate holes in the con-
nector.
In the case of a 24---pole connector, the three grey
connecting wires must be used.
. Then, all the wires must be connected to the new
switch block (white).
Caution!
Make sure that the wires are connected
correctly.

. Fasten the switch block in place using the four

fastening screws, arrange the wires using the cable
ties supplied. Install the pendant control in the re-
verse order of dismantling and connect it to the
control line.
1 2

Fig. 13
. Remove cable tie (25) (Fig. 14).
. Remove the four fastening screws of the faulty
switch block from the upper shell.
. When replacing a switch block of the new type
(white), all you need to do is pull off the flat con-
nectors and push them onto the new switch block.
. When replacing a switch block of the old type
(black) by a new switch block (white), you must re-
move the existing flat connector (connection 1 on
the circuit board). The three other wires (2, 3, and 4
on the circuit board) soldered to the circuit board
must be disconnected from the connector using
the dismantling tool supplied (black for 18---pole Fig. 14
connector or white for 24---pole connector).
(Fig. 14, Pos. 22).

Page 16 Data : 31.01.2007

6.3 Replacement of Protective
Rubber Cap
Contents of spare parts package:
2 protective rubber caps (5), Fig. 15 / Fig. 16
. Disconnect the pendant control from the control
cable by unlocking the bayonet mount (Fig. 11)
. Remove ABUS screw cover (1) using a sharp
screwdriver, width approx. 1 mm.
. Undo the 6 housing screws (2). Remove lower sec-
tion of housing.
. Unscrew the 4 switch unit screws (Fig. 12) and
take off the faulty rubber cap (11).
. Lift off switch unit (1) or (2)
. replace eventually the switch actuator head (6).
. insert new protective rubber cap (5) and place the
switch unit back in its position.
. Reassemble the pendant control in reverse order of
dismantling and connect it to the control cable.
4 6 5 4 6 5
3 2
3 1
Fig. 15 Fig. 16
A 677.GB
6.4 Replacement of Housing
Contents of spare parts package:
1 upper housing section, pre---assembled
1 lower housing section, pre---assembled
2 (6) protective rubber caps
Installation:
. Disconnect the pendant control from the control
cable by unlocking the bayonet mount (Fig. 11).
. Remove ABUS screw cover (1) using a sharp
screwdriver, width approx. 1 mm.
. Undo the 6 housing screws (2). Remove lower sec-
tion of housing.
. Unscrew the 2 mountings screws (8), 4 switch unit
screws (6) (Fig. 12).
. Remove isolator (9) from upper section of housing.
. Take the switch unit (3) with conductors out of the
upper housing section.
. Reassemble the pendant control in reverse order of
dismantling.
. Connect the pendant control to the control cable.
Page 17
6.5 Replacement of Microswitch
for Emergency Shut---Down
Function
Contents of spare parts package:
2 microswitches (11), Fig. 12, Side 15
Installation:
. Disconnect the pendant control from the control
cable by unlocking the bayonet mount (Fig. 11)
. Remove ABUS screw cover (1) using a sharp
screwdriver, width approx. 1 mm.
. Undo the 6 housing screws (2). Remove lower sec-
tion of housing.
. Unscrew the 2 mounting screws (8) and the 4
clamping screws (10) (Fig. 12).
. Replace the microswitch (11) and connect the flex-
ible conductors to the new microswitch.
. Screw microswitch to upper housing section.
. Reassemble the pendant control in reverse order of
dismantling and connect it to the control cable.
_________________________________
7 Disposal
When an ABUS pendant control is no longer needed, it
can be disposed of in an environmentally compatible
way. ABUS pendant controls are high---quality prod-
ucts with a long service life which require almost no
maintenance.
For disposal of the pendant control, proceed as
follows:
dismantle the pendant control into its constituent ma-
terials (plastic, rubber and metals).
_________________________________
8 Service
Note:
The ABUS service centre can be reached day
and night on the following numbers:
Page 18
6.6 Replacement of Surround and
Head of Emergency Shut---
Down Switch
Contents of spare parts package:
1 emergency shut ---down switch unit, complete
Fig. 12, Side 15
Installation:
. Disconnect the pendant control from the control
cable by unlocking the bayonet mount (Fig. 11)
. Remove ABUS screw cover (1) using a sharp
screwdriver, width approx. 1 mm.
. Undo the 6 housing screws (2). Remove lower sec-
tion of housing.
. Unscrew the 2 mounting screws (8) and the 3
fastening screws (15). Remove the isolator (9)
. Install the isolator (9) in the new emergency shut ---
down switch surround.
. Reassemble the pendant control in reverse order of
dismantling and connect it to the control cable.
Recycle the separated materials.
If recycling is not possible, dispose of the pendant con-
trol as special waste.
Phone: ##49 2261 / 37 - 237
Fax: ##49 2261 / 37 - 265
Data : 31.01.2007
9 Spare parts list

9.1 Exampel for order

Notes for individual part orders

Orders for individual parts should be sent to your local ABUS partner or to:

ABUS Kransysteme GmbH

Sonnenweg 1
D – 51647 Gummersbach

Phone ##49 2261 37 – 121 , 425 , 421 , 145 , 411

Telefax ##49 2261 37 – 414
eMail info@abus---kransysteme.de

Please give the following data in all orders:

1. Serial no.
2. Number of operating instructions
3. Page no.
4. Item no.
5. Part no.
6. Quantity

Example order:

1. 2. 3. 4. 5. 6.

123456 A 677 Page 20 1 30262 2

Caution!
This spare part is only valid for the pendant control series with 24---pin connectors.

A 677.GB Page 19
9.2 Pendant control, complete

9.2.1 Standard
Part
Designation
number

The part number of the entire pendant control is located under

the bayonet lock.

Fig. 17

70268 HT 211D --- N200 --- BJ24

Fig. 18

Fig. 19 70269 HT 611D --- N220 --- BJ24

70270 HT 611D --- N202K --- BJ24

70271 HT 611D --- N202S --- BJ24

70272 HT 611D --- N222K --- BJ24

70273 HT 611D --- N222S --- BJ24

Part
Designation
number

Page 20 Data : 31.01.2007

 70274 HT 211S --- N200 --- BJ24

Fig. 20

70275 HT 611S --- N220 --- BJ24

70276 HT 611S --- N202K --- BJ24

70277 HT 611S --- N202S--- BJ24

70278 HT 611S --- N222K --- BJ24

70279 HT 611S --- N222S --- BJ24

Fig. 21

A 677.GB Page 21
9.2.2 with additional functions
Part
Designation
number
70285 HT 211S --- N200 --- BJ24; HUG teach in button
70290 HT 211S --- N200 --- BJ24; trolley preselection “1 --- 1+2 --- 2”
HT 611S --- N200 --- BJ24; preselection Pos. 1---2 +
70291
HUG teach in button
70286 HT 611S --- N220 --- BJ24; HUG teach in button
70292 HT 611S --- N220 --- BJ24; trolley preselection “1 --- 1+2 --- 2”
70288 HT 611S --- N222K --- BJ24; HUG teach in button
Abb.: 71252 HT 611S --- N222S --- BJ24; HUG teach in button
Sonder
71463 HT 611S --- N222K --- BJ24; horn
71458 HT 611S --- N222K --- BJ24; Key switch for emergency stop
71465 HT 611S --- N222K --- BJ24; trolley preselection “1 --- 1+2 --- 2”
71468 HT 611S --- N222K --- BJ24; FGS Überbrücken --- Taster
71457 HT 611S --- N222K --- BJ24; tare
71466 HT 611S --- N222K --- BJ24; LAZ without tare
71467 HT 611S --- N222K --- BJ24; tare and LAZ
71203 HT1011S --- N222K --- BJ24; trolley preselection + horn
71205 HT1011S --- N222K --- BJ24; trolley preselection + tare
71206 HT1011S --- N222K --- BJ24; trolley preselection + tare + LAZ
Fig. 22 71459 HT1011S --- N222K --- BJ24; horn + tare + LAZ
71460 HT1011S --- N222K --- BJ24; horn + tare
HT1011S --- N222K --- BJ24; trolley preselection +
70293
HUG teach in button
HT1011S --- N222K --- BJ24;preselection Pos. 1---2 +
70294
HUG teach in button
HT1011S --- N222K --- BJ24; Key switch for emergency stop +
70295
HUG teach in button

Page 22 Data : 31.01.2007

9.3 Spare parts
Part
Designation
number

13319 Crimping pliers

Fig. 23

Fig. 24 38705 Dismantling tool for CDM crimped contacts

HT211D pendant control housing with push buttons (empty

13500
housing)

Fig. 25

HT 211S pendant control housing with push buttons (empty

13570
housing)

Fig. 26

A 677.GB Page 23
 Part
Designation
number

Fig. 27

HT 611D pendant control housing with push buttons (empty

13580
housing)

HT 611S pendant control housing with push buttons (empty

13590
housing)

Fig. 28

HT 1011S pendant control housing with push buttons (empty

102254
housing)

Fig. 29

Page 24 Data : 31.01.2007

 Part
Designation
number

Spare parts kit, bottom shell, HT211D pendant con-

trol
Bottom shell HT 211 D 1
13641 Round string D=2,5mm 1
Cheese---head screws 6
Washer 8x4x1 6
Installation instruction 1

Fig. 30

Spare parts kit, bottom shell, HT211S pendant con-

trol
Bottom shell HT 211 S 1
13642 Round string D=2,5mm 1
Cheese---head screws 6
Washer 8x4x1 6
Installation instruction 1

Fig. 31

Spare parts kit, bottom shell, HT611D pendant con-

trol
Bottom shell HT 611 D 1
13643 Round string D=2,5mm 1
Cheese---head screws 6
Washer 8x4x1 6
Installation instruction 1

Fig. 32

Spare parts kit, bottom shell, HT611S pendant con-

trol
Bottom shell HT 611 S 1
13644 Round string D=2,5mm 1
Cheese---head screws 6
Washer 8x4x1 6
Installation instruction 1

Fig. 33

Spare parts kit, bottom shell, HT1011S pendant con-

trol
Bottom shell HT 1011 S 1
102255 Round string D=2,5mm 1,008m
Cheese---head screws 6
Washer 8x4x1 6
Installation instruction 1
Fig. 34

A 677.GB Page 25
 Part
Designation
number

3352 Pendant control hand support cap (cover)

Fig. 35

13596
Direction arrow sign, spare parts
Pendant control symbol sign

Fig. 36

Spare parts kit, emergency stop unit with cap

Emergency stop unit, pendant control 1
Emergency stop cap, red 1
Emergency stop cap ring 1
Emergency stop gasket,
pendant control 1
Torsion spring 1
13665 Emergency stop switch shaft 1
Catching plate 2
Compression spring 1
Cheese---head screws 3x10 3
Packing, pendant control 1
Emergency stop sign, pendant control 2
Fig. 37 Nameplate 1
Washer 8x4x1 1
Installation instruction 1

Spare parts kit, emergency stop unit with cap (black)

Emergency stop unit, pendant control 1
Emergency stop cap, black 1
Emergency stop cap ring 1
Emergency stop gasket,
pendant control 1
Torsion spring 1
76828 Emergency stop switch shaft 1
Catching plate 2
Compression spring 1
Cheese---head screws 3x10 3
Packing, pendant control 1
Emergency stop sign, pendant control 2
Fig. 38 Nameplate 1
Washer 8x4x1 1
Installation instruction 1

Page 26 Data : 31.01.2007

 Part
Designation
number

Fig. 39
Connector pin insert
102256 Connector part BJS24 1
Crimped contact pin BJ24 24
Dismantling tool (normal) 1

ABUS bayonet lock for control line

Connector part BJS24 1
Crimped contact pin BJ24 15
Packing ring 25 x 3 1
Packing ring 25 x 2 1
Bayonet lock BJ30 1
Snap housing BJ30 1
101293 Conical sleeve BJ30 1
Strain relief device BJ 30 1
Cable tie 100 x 2,5 2
Dismantling tool (normal) 1
Socket part BJB24 1
Fig. 40 Crimped contact socket BJ 15
Packing ring 26,2 x 3 1
Installation instructions 1

BJ 24 installation kit, contact spare parts kit

Crimped contact BJ 50
102257 Crimped contact pin BJ24 50
Dismantling tool (normal) 1
Strain relief device BJ 30 1
Cable tie 100 x 2,5 2
Fig. 41

Rubber cap spare parts kit, 2 pcs

Rubber cap,
13515 pendant control push button 2
Shaft support 2
Fig. 42 Installation instructions 1

Spare parts kit, direct control switch block

Switch block, HT---D/BJ24 1
Dismantling tool (normal) 1
102258 Cable tie 100 x 2,5 2
Rubber cap,
pendant control push button 2
Installation instructions 1

Fig. 43

A 677.GB Page 27
 Part
Designation
number
Spare parts kit, contactor control switch block
Switch block, HT---S 1
Dismantling tool
(normal; white) BJ 24 1
Dismantling tool
104598 (normal; black) BJ 18 1
Red connecting cable BJ 18 3
Grey connecting cable BJ 24 3
Cable tie 100 x 2,5 2
Rubber cap,
Fig. 44 pendant control push button 2
Installation instructions 1

Emergency stop microswitch replacement kit

13460 Switch elements ZA51Ö 2
Installation instructions 1
Fig. 45

Fig. 46 Switch block, rotary switch, 0---1---2/2W

Rotary switch, 0---1---2/2W 1
Dismantling tool (normal) 1
102271 Cable tie 100 x 2,5 2
Rotary switch for pendant
control emergency stop unit 1
Rotary switch for
pendant control panel 1
Switch block, rotary switch, 1---0---2/2W
for example for trolley preselection I/I+II/II
Rotary switch, 1---0---2/2W 1
Dismantling tool (normal) 1
102272 Cable tie 100 x 2,5 2
Rotary switch for pendant
control emergency stop unit 1
Rotary switch for
Fig. 47 pendant control panel 1
Switch block, turn key 1---0---2/2W
Fig. 48 Drehtaster 1---0---2/2W 1
Dismantling tool (normal) 1
102273 Cable tie 100 x 2,5 2
Rotary switch for pendant
control emergency stop unit 1
Rotary switch for
pendant control panel 2

Switch block, 1---stage push button/2W

z.B. für Fahrgrenzschalter überbrücken, als hornntaster oder
102274 als taretaste
Switch block, push button, 1/2W 1
Dismantling tool (normal) 1
Cable tie 100 x 2,5 2
Fig. 49

Page 28 Data : 31.01.2007

 Part
Designation
number

Switch block, 2---stage push button/2W

102275 Switch block, push button, 2/2W 1
Dismantling tool (normal) 1
Cable tie 100 x 2,5 2

Fig. 50

Key switch O---R. key removable at left, 1 NO, 1 NC

102276 Key switch BJ24 ∅ 18 1
Dismantling tool (normal) 1
Cable tie 100 x 2,5 2
Fig. 51

Key switch O---R. 2---position, locking in position, key

removable at left and right, 1 NO, 1 NC
102277 Key switch BJ24 ∅ 18 1
Dismantling tool (normal) 1
Cable tie 100 x 2,5 2
Fig. 52

Key switch O---T. key removable at left, 1 NO, 1 NC

Key switch BJ24 ∅ 18 1
102278
Dismantling tool (normal) 1
Cable tie 100 x 2,5 2

Fig. 53

4---digit display unit

102279 LAZ---2 HT load display unit 1
Dismantling tool (normal) 1
Cable tie 100 x 2,5 2

Fig. 54

A 677.GB Page 29
 Part
Designation
number

26486 Key for key switch Nr. 311

26487 Key for key switch Nr. 320

Fig. 55

Blind plug for ABUS pendant control, complete

27315 Blind plug PG 7 1
O---Ring 12 x 2 1
Hexagonal nut PG 7 1
Fig. 56

33576 Socket contact for BJ control line (CDM)

Fig. 57

33577 Pin contact for ABUS pendant control, BJ (CDM)

Fig. 58

33564 Socket part BJB24

33565 Connector part BJS24

Fig. 59

Signal lamp, 230 V, for ABUS pendant control, com-

plete
102280 Signal lamp, 3---colour LED 1
Dismantling tool (normal) 1
Cable tie 100 x 2,5 2
Fig. 60

Signal lamp, 48 V, for ABUS pendant control, comple-

te
102281 Signal lamp, 3---colour LED 1
Dismantling tool (normal) 1
Cable tie 100 x 2,5 2

Fig. 61

Connection element, double pendant control

102284
Connecting element installation kit 1
Fig. 62

Page 30 Data : 31.01.2007

 Part
Designation
number

Shortening of control line

102283 Hose clamp ∅ 22 2
Installation instructions 1

Fig. 63

Connection element for control lines

102282 Connecting element spacer ring 1
Connecting element BJ24 1
Installation instructions 1
Fig. 64

Strain relief mount, complete (set)*

(only for chain hoist)
Spacer bolts, M5 L25mm SW 2
Mounting bracket, 50x31x3x44 1
102401 Lock washer S 5 2
Fillister---head screw M5 x 10 2
Installation instructions 1
Rope clamp 3,5mm 4
Spring hook 50x5x8 0,1t 2
Fig. 65 Hose clamp ∅22 1

Protection tube for VFS with platform

102370 Hose clamp ∅22 1
Tube NW23 0,400m
Fig. 66
Strain relief clamp for use on non---ABUS hoists*
Strain relief clamp 2
Fillister---head screw M5x15 2
Hexagonal nut M5 2
Rope clamp 3,5mm 4
76827 Snap housing BJ30 1
Cable joint PG21 round 1
Bayonet lock BJ30 1
Socket part BJB24 1
Crimped contact socket BJ 24
Packing ring 26,2x3 1
Fig. 67 Packing ring 25x2

572 Strain relief cable, 3mm

Fig. 68

* the strain relief cable AN572 must be ordered separately (long control line + 1000 mm)

A 677.GB Page 31
Control line with tube, with BJ24 connector system at both ends
6---wire 10---wire 15---wire
BJS24/06--- BJS24/10--- BJS24/15---
SC6x1---BJB24/06 SC10x1---BJB24/10 SC15x1---BJB24/15
Length mm Parts number
1000 70309 70327 70345
1250 70310 70328 70346
1500 70311 70329 70347
1750 70312 70330 70348
2000 70313 70331 70349
2250 70314 70332 70350
2500 70315 70333 70351
2750 70316 70334 70352
3000 70317 70335 70353
3250 70318 70336 70354
3500 70319 70337 70355
3750 70320 70338 70356
4000 70321 70339 70357
4250 70322 70340 70358
4500 70323 70341 70359
4750 70324 70342 70360
5000 70325 70343 70361
5250 70362
5500 70363
5750 70364
6000 70365
6250 70366
6500 70367
6750 70368
7000 70369
7250 70370
7500 70371
7750 70372
8000 70373
8250 70374
8500 70375
8750 70376
9000 70377
9250 70378
9500 70379

Caution!
Special control cables are used for pendant control HT---10.

Page 32 Data : 31.01.2007

9.4 Fax–Order

Just copy this form, fill it in and fax it to us

To your local ABUS partner, or to:

ABUS Kransysteme GmbH

Spare Parts Sales Dept.

Fax. (0) 22 61 / 37 – 414

Spare parts order (Ersatzteil---Bestellung)

Fabrication Number of Op- Page no. of Item no. Part no. Quan-
no. erating Instruct. spare part tity

Fabrik–Nr. Nr. der Betrieb- Seiten–Nr. des Pos.–Nr Teil–Nummer Stückzahl

sanleitung Ersatzteiles

A 677.GB

______________________ ________________________________ _________________

Date Signature Stamp

A 677.GB Page 33