ABUS Training

ABUS – Basic Training

Introduction

• ABUS company was founded in year 1963 by Mr. Werner Bühne.

• ABUS Company name is derived from the family name August Bremicker
Und Söhne.

• One of Europe’s leading crane manufacturers, offering customers tailor-

made solutions.

• Covers the entire load range from 80kgs to 120T and can easily be adapted
to any factory shape or application conditions.
 Hoist Designation
GM 2063 H6 - 201. 4/1. 063. E 160

diameter of running wheel (mm)

model E; D; DB; DQA; Z; S; U
model generation
hook path (m)
reeving 4/1
FEM group 1Am
speed of rope (m/min)
motor version L6; H6; U6
load capacity kg x 100
Size of model
range
 Hoist Designation
GM 2 320. 6 - 1 / EF 14

Size
Model

No. of Falls
Lifting Speed(m/min)
Load Capacity, Kg

Size of model
Range
Product Range - EOT

• Single Girder EOT crane

• Single Girder EOT Underslung Crane

Product Range - EOT

• Wall Travelling Crane

• Double Girder EOT Crane

Product Range - EOT

• Light Weight Cranes (LWC)

ABUS Hoists Model

model E
monorail trolley
load capacity
• 1t - 16t
ABUS Hoists Model

model U
bottom flange trolley
load capacity
• 6.3t - 25t
ABUS Hoists Model

model S
Side running trolley
load capacity
• 3.2t - 10t
ABUS Hoists Model

model D
Double rail trolley
load capacity
• 1t - 63t
ABUS Hoists Model

model DA
Double rail trolley
load capacity
• on enquiry
ABUS Hoists Model

model DQA
Double rail trolley
load capacity
• 1t - 40t
ABUS Hoists Model

model Z
Double rail trolley with twin hoist
load capacity
• 8t - 120t
ABUS Hoists Model

model ZA
Double rail trolley with twin hoist
load capacity
• on enquiry
ABUS Hoists Sectional View
Assemblies

Flat Gearbox

Hoist Motor
Brake Assembly

AZF Motors
Assemblies

Hoist Motor GM7000

AZF Motors
Assemblies

Hoist Motor GM 7000

AZF Motors
Assemblies Hoist Motor GM 7000.7
Hoist Motor GM 800.5
Hoist Motor GM 5000.4
Hoist Motor GM 3000.5

AZF Motors
Assemblies
Hoist Motor GM 7000.7
Hoist Motor GM 800.5
Hoist Motor GM 5000.4
Hoist Motor GM 3000.5

AZF Motors
Assemblies Hoist Motor GM 7000.7
Hoist Motor GM 800.5
Hoist Motor GM 5000.4
Hoist Motor GM 3000.5

AZF Motors
Assemblies

Fan Cover

Terminal box

Motor

Gearbox

Wheel

AZP Motors with Drive Wheels

Assemblies

Fan Cover

Fan with Brake

Liner

Brake coil

Stator winding

Rotor

Fly Wheel

Planetory
AZP Motors with Drive Wheels Gearbox
Assemblies- End Carriage Section

Bearing

Wheel Cut Section

End Carriage

Indicator for wheel replacement

Chain Hoist-Sectional View

Gearbox

Stator Winding

Rotor

Brake Liner

Brake coil
Slipping Clutch

Liner

Pressure Plate

Torque Adjustment Nut

Bearing

Gear & Pinion

Slipping Clutch is used in chain hoist, LT & CT motor gearboxes. It is set at a certain
Torque. During overloading, if the torque exceeds the rated torue, it slips and
disengages the output shaft and thus protects the motor from burning.
Slipping Clutch
Chain Hoist-Sectional View

I-Bolt

Slipping
Clutch

Torque
Adjustment Nut
Slipping Clutch

Slipping
Clutch
Assemblies
Trolley Drive Module E

Hoist Trolley
Trolley Drive
Assemblies
Trolley Drive Module Z

wheel diameter ≤ 280 mm wheel diameter ≥ 350

planetary gearbox mm flat gearbox
Assemblies

Rope Guide

Rope Drum
Assemblies
Bottom Block

2/1 4/1 8/2

 Load Pin

Black Silicon Blue Silicon

800-1100  750 
 Load Pin

F
strain gauge F

carrier sensor
wire
 Fly Wheel

Flywheel is the power house which stores energy and delivers when needed.
 Bolts

Description Old New

Colour Black Galvanized
Lubrication Oil Grease
Torque 554Nm 450Nm

HR stands for high resistance and

HV for Hochfeste Bolzen mit Vorspannung (High resistance bolts for pretension)
 Friction Plate

Friction Plate is used to connect the Girder with the End Carriage
Wire Rope Checking
 Load Population
FEM Group Full Load Hour

1 Dm M1 100

2 Cm M2 200

3 Bm M3 400

4 Am M4 800

5 Am M5 1600

6 Am M6 3200

7 Am M7 6300

8 Am M8 12500
 Load Population
SWL: 10T, FEM Group: 1AM, Year: 2011
LIS Display: 690hrs.
1shift: 8hrs (100%)
1hr unloading trucks: 8.5T (12.5%)
2hr loading trucks: 4.5T (25%)
 Duty Cycle in Chain hoist
Every chain Hoist has a duty Cycle of 40% ED
1/3 slow
2/3 fast

Chain Hoist do not have cooling fan, so it should

get sufficient time to cool down

Maximum ED available is 60%

 Limit Switch Installation
Fan Type Limit
Switch

Limit Switch should always move in the direction opposite to the direction of
the crane
 LIS AP

LIS AP is used either with LIS SE or LIS SV. It helps in finding out the wear.
 Hoist Control
• Direct Control: PCB Card
• Indirect Control: Control Panel

We can have direct control for hoist upto 2.5Kw. (Chain Hoist)
For higher rating we need to go for Indirect Control (Wire Rope Hoist)

Control Panel PCB Card

Assemblies

Plugin Connector

Control Panel
Geared Limit Switch
LIS
Technical features of the LIS (1)
Overload protection device
• 110 % Shut down at static load conditions
• (125 % Shut down)
• Shut-down points are variably adjustable

Shut-down of main lifting in case of sudden (Fast)

and rough (Jurq) load lifting
• If the unit detects a sudden and rough load lifting the main
lifting is switched off. The hoist is now operated in precision
lifting operation, under the condition that the „Lifting button“ is
pressed.

Cranedge India Pvt.Ltd.

Technical features of the LIS (2)
Load evaluation (Calculation) and load display
• LIS - SV at stand still of the motor
• LIS - SE only with running motor

Operating hours counter

P 6.3
Technical features of the LIS (3)
Device is adjustable
• digital service unit
ABUS
Signalling of malfunction
• via digital service unit

Memory protected against power failure

• to store hoist operating data

Guided running up to load

• the motor always starts with precision lifting

Cranedge India Pvt. Ltd.

Technical features of the LIS (4)
Protected operational level (adjustment level)
• with PIN - no.
• Changeable parameters are protected by CODE no.
• Last 3 PIN no. used are stored.
Inputs
• electrically isolated

Outputs
• are switched via separated relays for „LIFTING“
and „LOWERING“
Easy maintenance
• thanks to plug-in terminal blocks

Control voltage (A1 - A2)

• 220 V AC • 110 V AC • 48 V AC
Cranedge India Pvt. Ltd.
 Technical features of the LIS
Monitoring logic(5)
inside the LIS - SE

• The contactors for „LIFITING“ or „LOWERING“ cannot switch

simultaneously.(Paralaly)

• Not getting command „LIFTING“ and „LOWERING“

simultaneusly

Cranedge India Pvt. Ltd.

What the LIS display reads (1)
Display in digital service unit
• In the Power-Down-Modus the
display shows a horizontal bar
running from left to right.

• If the unit detects a control signal for

„LIFTING“ (E6) the display changes to
steps running from bottom left to top
right.

• If the units detects a control signal for

„LOWERING“ (E2) the display
changes to steps that run from top
left to bottom right.

Cranedge India Pvt. Ltd.

 How to Access Parameters

Selecting of menu level 2

• After selection of the last digit of flashes

the
0055
PIN number.

• Press „ENTER“ button until

Keep
pressed

the P 0.0 0
display shows P 0.00.

• Call ABUS (No)

 ABUS Load measuring system LIS
LIS
Load - Indication - System

Load measurement with Load recording with Option

measurement axle motor current (rotating
field performance)
Load population
recorder P5.2
LIS - AV
LIS - SM Load display in
P/B. pendant
LIS - SV LIS - SE
Large load
display
 Why two systems ?
Total load capacity 10 t
Hoist 1 Hoist 2
5t 5t
LIS - SE LIS - SE

LIS – SE is applied when:

=
Total capacity of crane Total capacity of both
system (10t) hoists(5+5=10t)

© ABUS Kransysteme GmbH,

2000
 TWIN LIS SE CONNECTION

• LIS SE LIS SE

• F1 F2 F1 F2
 front view of the LIS - SE with external part load
switch
control HT HT HT= push button pendant
voltage

main voltage 1L01 K21 K22 K23 K1

(0 - 500 V 50/60 Hz) 2L01

L1 L3 A2 1L01 EA E6 E7 21 22 12
ABUS
L2 A1 23 2L01 14 11

LIS - SE
AN 17787 (A1 - A2 = 230 V)
AN 17788 (A1 - A2 = 110 V)
AN 17789 (A1 - A2 = 48 V)

+12 -12 Q +5 GND RXD TXD F1 F2 F3 I1 I2 I 3 GND E5 E4 E3 E2 E1

    
yellow

red

blue

lifting /lowering #
load display HT
current measu- rement module

Tare HT
1 2 3

fast #
part load switch

# = mutual monitoring of overload shut-down and „fast load increase“ for crane installations with 2 hoists
© ABUS Kransysteme GmbH,
2000

07.05.2001
 Parameter Setting.(LIS-SE)
PARAMETERS UNITS DESIGNATION
P 0.0 10t TOTAL LOAD CAPACITY
P0.1 5t DISPLAY AND INPUT LOAD CAPACITY,
HOIST 1
P1.1 0-17 DISPLAY AND INPUT MOTOR TYPE
P1.2 0-97,999 DISPLAY AND INPUT WINDING
RESISTANCE
P1.3 NA DISPLAY AND INPUT CURRENT
CORRECTION FACTOR
P4.1 0-110 DISPLAY AND INPUT OVER LOAD SHUT
DOWN HOIST 1
P9.9 NA QUIT PARAMETER LEVEL
NAME PLATE CHART
 CALIBRATION LIS- SE
• P2.3
• This parameter is use for automatically
measuring and recording the point needed for
the precision and main lift load lines following
a defined program.
• Enter P2.3 (Not that operate the up/down
from pendent or remote do not press the
contactors)
• Showing Pro1= precision lift setting with zero
load using the pendent or remote control the
precision lift must be operated until the motor
is shut down after about 5 sec.the rotating
• Showing Pro2
• Main lift setting zero load using the pendent
or remote control the main lift must be
operated until the motor is shut down after
about 5 sec. the rotating field power is
automatically measured and recorded.
• Lift known load in precision lift until load is
suspended then press the emergency from
pendent or remote more than 5 sec. after the
emergency shut down has been reset.
• Pro3
• Precision lift setting known load using
• The precision lift must be operated. The
rotating field power is automatically measured
and recorded.
• Pro4
• Main lift setting known load using the
pendent or remote control. The main lift must
be operated until the motor is shut down after
5 sec. the rotating field power is automatically
measured and and recorded the power
recorded is indicated on the display until the
key is released.
• Then down the load calibration is completed.
 Why two systems ? LIS -SV
Total load capacity 8 t

Hoist 1 Hoist 2
7t 3.2 t
LIS - SV LIS - SV
F1 F2 F1 F2

LIS – SV is used when the following

applications are required:

>
Load capacity of crane Sum of the individual load
girder (8t) capacities of the hoists
(5+5=10t)

© ABUS Kransysteme GmbH,

2000
 PARAMETER SETTING LIS- SV
• Pr no. LIS 1 LIS 2 DESIGNATION
• P0.0 8t 8t Total load capacity
• P1.0 7t 3.2 t hoist 1 capacity
• P2.0 3.2t 7t hoist 2 capacity
• P3.0 0t 0t hoist 3 capacity
• P1.3 0.781 0.879 zero point freq. hoist 1
• P1.4 12.56 10.32 amplification factor
hoist1
• P2.3 0.879 0.781 zero point freq. hoist 2
• P2.4 10.32 12.56 amplification factor
hoist2
 Errs
• If the hoist is shut down because the
maximum limit of the inching
operation counter is exceeded, the 1
total number of inching operations 7
flashes

completed is displayed

This indication is displayed :

 if the rotating field power Prot. < 10 W

 faulty connection / phase sequence U_

 wrong input of the motor data I LIS-SE
only
 wrong current flow direction through the transformers
 faulty relay inside the LIS
 faulty contactor K 21 (coil)
 no potential on input 1L01
Technical features of the LIS (6)
Monitoring of two hoists in tandem
operation

Analysis of mains voltage conditions

420
400
380
Voltage
Voltage

360
340
320
-50 0 50 100 150 200 250 300 350 400 450 time/ms

Cranedge India Pvt. Ltd.

Thank You