Operation Instructions: ABUS - Load Indicator System
Operation Instructions: ABUS - Load Indicator System
Operation Instructions: ABUS - Load Indicator System
Operation Instructions
for
Type LIS – AV
Manufacturer
ABUS Kransysteme GmbH Tel. ##49 2261 / 37–0
Sonnenweg 1 Fax. ##49 2261 / 37247
D – 51647 Gummersbach
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.
Stand : 14. April 1998
A 435.GB
These installation, operation and maintenance instructions are intended for use in an English–
speaking country by English–speaking specialist personnel.
Contents
2 Field of Application . . . . . . . . 4
2.1 Overload Shut–Down . . . . . . . . . . . . . 4 5 Operation . . . . . . . . . . . . . . . . . 9
2.2 Part–Load Switch . . . . . . . . . . . . . . . . . 4 5.1 Digital Operator Terminal . . . . . . . . . . 9
2.3 Load Totalization . . . . . . . . . . . . . . . . . 4 5.2 Basic Settings . . . . . . . . . . . . . . . . . . . 9
2.4 Taring . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5.3 Taring . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Load Population Recorder . . . . . . . . . 5 5.4 Reading the
Load Population Recorder . . . . . . . . . 9
2.5.1 FEM Groups . . . . . . . . . . . . . . . . . . . . . 5
2.5.2 Definitions . . . . . . . . . . . . . . . . . . . . . . . 6
6 Installation . . . . . . . . . . . . . . . . 9
6.1 Housing and wiring diagrams . . . . . . 9
3 Components . . . . . . . . . . . . . . 6
6.2 Regulations . . . . . . . . . . . . . . . . . . . . . . 12
3.1 LIS–AV evaluation unit . . . . . . . . . . . . 6
3.2 LIS–FC Signal Converter . . . . . . . . . . 6
3.3 Load Signal Transmitter . . . . . . . . . . . 6 7 Malfunctions . . . . . . . . . . . . . . 12
3.4 Load Indicator . . . . . . . . . . . . . . . . . . . 6 7.1 Causes and Remedies . . . . . . . . . . . . 12
7.2 Service . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Technical Data . . . . . . . . . . . . 7
4.1 Load Indicator System LIS–AV . . . . . 7 8 Disposal . . . . . . . . . . . . . . . . . . 12
A 435.GB Page 3
2 Field of Application
Function: for the two hoist speeds are immediately shut
down. Dynamic load peaks below this value do not
For load recording and evaluation, the LIS–AV load automatically result in a shut–down.
indicator system needs a load signal transmitter
(measurement axle, measurement bolt, etc.) installed c) Shut–down on sudden load increase. If the load in-
on the hoist. creases too rapidly, the relay for the main lifting
If a unit is to be used for monitoring two or three hoists, speed is shut–down. The relay is only re–activated
additional signal converters (LIS–FC) are required for when the load has ceased to increase, provided
converting the signal into a frequency signal propor- that the maximum load has not been exceeded.
tional to the load. This ensures that signals can be This function prevents rope breakage as a result of
transmitted to the LIS–AV unit over considerable dis- lifting an excessive load with a loose rope at main
tances without interference. lifting speed. Also, excessive force on the rope is
prevented if the crane hook is suddenly blocked.
The signal transmitter receives a precision power sup-
ply (10 V DC) from the LIS–AV or LIS–FC and returns a Note:
low–voltage signal proportional to the load to the LIS– In the event of an overload shut–down, the
AV/LIS–FC. In the LIS–AV unit, the signal is amplified load can always be lowered using the preci-
and evaluated by a microcontroller system. sion lifting speed. When the load has been
lowered (load below 90 % of static load
If the preset load limits are exceeded, hoist movement threshold), the overload shut–down is reset.
is stopped or other appropriate action is initiated using
relay contacts. In addition, the load signal is processed
for display on a load indicator and fed to the LAZ load
indicator in the pendant control (and/or a large load dis- 2.2 Part–Load Switch
play). The LIS–AV unit monitors both the individual load
In some applications, another shut–down point below
signals and the total load measured. Either the load
the rated load is required in addition to the overload
measured by one of the three load measurement de-
shut–down. This may be the case if part of the hall
vices or the total load may be displayed.
structure is not designed for the entire load capacity of
a crane system.
2.5 Load Population Recorder The following precautions have therefore been taken in
order to achieve safe working periods (S.W.P.).
(optional)
If a load population recorder is integrated in the LIS–AV,
the actual operating conditions of a hoist can be re- Cranes and hoists are subdivided into various groups
corded. In addition to the total running time T, which is in accordance with FEM 9.511.
equivalent to the time during which the motor is
switched on, the actual load on the hoist is recorded.
For this purpose, the unit evaluates the load measure- The operator of a standard hoist is responsible for en-
ments on a continuous basis. suring that the actual operating conditions of the hoist
are recorded and documented in the test book at least
The LIS–AV unit calculates the actual use S, the load once per year. In the course of regular inspection, the
spectrum factor Km and the remaining service life of the inspector must also verify and determine whether the
hoist in accordance with FEM 9.755 from these values. hoist is still being operated within its safe working
The load spectrum factor is equivalent to the load po- period.
pulation with which the hoist was operated.
When the theoretical service life D has elapsed, cranes can have the actual hours of use S and other para-
and hoists connected to them may represent a risk to meters displayed at any time (see Section 5.4). This
persons and machines. If a load population recorder is evaluation must be made and documented by the in-
used, it is easier to determine the actual hours of use S, spector.
from which the remaining service life is calculated.
The FEM group is stored in the LIS–AV unit and can be
In the case of standard hoists equipped with an LIS–AV displayed using the operator terminal (see Section
with integrated load population recorder, the operating 4.4). The group is indicated in hours at full load.
conditions are recorded electronically. The inspector
A 435.GB Page 5
2.5.2 Definitions from initial commissioning through to final decommis-
Theoretical service life sioning of the hoist.
The theoretical service life D is the calculated hours of Remaining service life
service of a crane or a hoist over a period of about 10 The remaining service life or theoretical remaining ser-
years taking into consideration the group determined vice life of a hoist is the difference between the actual
in accordance with FEM 9.511. hours of use S and the theoretical service life D. If the
Actual hours of use remaining service life is less than 5 % of the value in the
The actual hours of use S represent the effective use of table, the hoist must be overhauled.
the unit determined on the basis of operating hours and Safe working period (SWP)
load populations. The hoist is within its safe working period if S/D is less
Total service life than or equal to 1.
The total service life of a standard hoist is the period
_________________________________
3 Components
3.1 LIS–AV evaluation unit The LIS–AV and LIS–FC units are coordinated using the
operator terminal incorporated in the LIS–AV.
The LIS–AV unit (Fig. 1) is designed to evaluate the
measurement axle signal of one hoist. The measure-
ment axle is connected to terminals B+, B–, U+ and U–
of the unit. B+ and B– supply a stabilized voltage of 10 3.3 Load Signal Transmitter
V to the measurement axle. The load–proportional volt- Strain gauge transmitters requiring a 10 V DC power
age signal at terminals U+ and U– is in the range from 0 supply can be used as load signal transmitters. The
to 35 mV. transmitter must supply a load–proportional millivolt
If the unit is used for monitoring two or three hoists, the output signal. Any measurement bolts, tension straps
load–proportional frequency signals from the LIS–FC and load cells in accordance with the technical data
units are connected to terminals F1–GND and may be used.
F2–GND.
The LIS–AV allows the signal amplification to be ad-
The functions of the isolated control inputs E1 to E4 are justed to the sensitivity of the load signal transmitter
as follows: used. Even if the sensitivity of the transmitter is not
known, it is possible to calibrate the system using a
E1, E2 = selection of value for display / known load. As the output signal of the transmitter is
Preselection of load population recorder only of the order of a few millivolts, it must be connected
E3 = taring to the LIS–AV or LIS–FC unit using a shielded cable.
E4 = load population recorder / The cable should be as short as possible and must not
Enabling of precision lift relay be routed via any terminals. In addition, the connecting
cable must not be installed directly next to a power
Output Q supplies a serial data protocol for the control cable.
of the ABUS load indicators LAZ (display in pendant
control) and GLZ (large load display).
The 5V power supply for the LAZ unit is provided by the
LIS–AV unit.
3.4 Load Indicator (OPTIONAL)
The GLZ unit has an integrated 24 V AC power supply. The LIS–AV is equipped with contacts for the connec-
tion of an ABUS load indicator. The load can then be
The integrated digital operator terminal DBE is used for indicated by a three or four–digit LAZ load indicator in-
reading and setting the variable parameters of the corporated in the pendant control and/or a large GLZ
LIS–AV unit (see also Section 5.1). load indicator. Both types of load indicator are so de-
signed that it is easy to read the load value even in poor
visibility.
1 = signal at input
0 = no signal at input
_________________________________
4 Technical Data
A 435.GB Page 7
4.4 List of Parameters
Menu level 1 = press enter key for two seconds
* The values can only be changed on level 2 after entering a PIN number under P6.0.
6 Installation
Attention! 6.1 Housing and wiring diagrams
Before commissioning, it is essential to check
The dimensions required for the installation of the
whether the equipment voltage is in accor-
LIS–AV and LIS–FC are given in the drawings 1 and 2.
dance with the control voltage and whether
the wiring of the equipment is in accordance
with the wiring plans attached to the opera-
ting instructions.
The ABUS LIS–AV / LIS–FC must only be in-
stalled by specialists.
A 435.GB Page 9
LIS – AV LIS – FC
Fig. 1 Fig. 2
Wiring diagram for system with one hoist (with monitoring circuit)
Fig. 3
Fig. 4
A 435.GB Page 11
6.2 Regulations Safety warnings:
You must not carry out any work inside the unit.
The load indicator system LIS–AV is in accordance with
In the event of a defect in an LIS–AV unit, please contact
the following codes and standards:
our service department. (see Section 7.2).
EMC 89/336/EEC (electromagnetic compatibility)
In order to avoid the risk of serious injury and severe
NSR 73/23/EEC (low voltage)
damage, only persons qualified to work on electric
power systems may work on the units. Before installing
EN 50081–1 VDE 0839
any commissioning the units, these persons must care-
EN 50082–2 VDE 0839
fully read the operating instructions and observe the
safety instructions.
Electrical installation work must be performed in ac-
cordance with the following general codes and stan-
Attention!
dards:
Any modifications to ABUS products and any
parts installed in or on ABUS products which
IEC 364
could impair the safety of the products must
Requirements for the installation of power systems with
be approved by the manufacturer. ABUS will
rated voltages up to 1000V
not be liable for any injury, loss or damage
which may occur as a result of modifications
IEC 204
which have not been approved or the use of
Requirements for the electrical equipment of proces-
products other than for the intended pur-
sing machinery
pose.
For special applications, other standards and regula-
Note:
tions may also be applicable.
ELECTROMAGNETIC COMPATIBILITY
The unit has been designed in accordance
with the EMC directive no. 89/336/EEC.
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7 Malfunctions
7.1 Causes and Remedies
The LIS–AV displays the following error codes on the operator terminal or the load display.
The input and output voltage data required for trouble- 7.2 Service
shooting are stated in Section 4 ”Technical Data”.
Notes:
If any other malfunctions occur, please contact our ser-
The ABUS Service Centre can be reached
vice centre (see Section 7.2).
day and night.
_________________________________
8 Disposal
ABUS products are designed with a view to recycling mentally compatible disposal when they are no longer
and have a modular structure which facilitates environ- required.