ASSEMBLING & REGULATION INSTRUCTIONS FOR AYTOMATIC CABIN DOORS

ΕΓΧΕΙΡΙΔΙΟ ΤΟΠΟΘΕΤΗΣΗΣ & ΡΥΘΜΙΣΗΣ ΑΥΤΟΜΑΤΩΝ ΠΟΡΤΩΝ ΘΑΛΑΜΟΥ ASSEMBLING & REGULATION INSTRUCTIONS FOR AYTOMATIC CABIN DOORS

CABIN DOORS

INDEX PARTS DESCRIPTION 26 POSITION OF THE OPERATOR IN THE CABIN 26 ADJUSTMENT OF CLEAR OPENING IN CENTRE PARTING DOORS 27 ADJUSTMENT OF CLEAR OPENING IN SIDE OPENING DOORS 27 INSTALLATION OF GUIDE SHOES AND HANGERS 28 ADJUSTMENT OF PANELS 28 ADJUSTMENT OF WHEELS 29 LANDING DOOR COUPLING 29 CORRECT ADJUSTMENT BETWEEN CLAMP AND RETAINER 30 LOCKING DEVICE 30 ELEMENTS SITUATION 31 VVVF-4+ MODULE Programming 33 Inputs 34 Programming Examples 39 Technical Features 40 Start Up Protocol & Autoadjustment Of Vvvf (Inverter) 41 POSSIBLE PROBLEMS & SOLUTIONS 42 PREVENTIVE MAINTENANCE 43

26 PARTS DESCRIPTION 1 Fixation bracket 2 Operator 3 Plate 4 Panels 5 Tread 6 Tread support 7 Toe guard POSITION OF THE OPERATOR ON THE CABIN 1. Place the brackets in the guide tracks situated in the cabin roof (fig. 2) 2. Place the operator 220mm higher than the clear height of the cabin (fig. 1). 3. Tighten the operator to the brackets (fig. 2). 4. Let 30mm between the front part of the cabin and the outside of the operator regulated with the brackets (fig. 3). 5. Fix the brackets in the guide tracks.

27 ADJUSTMENT OF CO. IN CENTRE PARTING DOORS Slow plates: 1. Place the slow plates at the operator extremes. 2. Check that distance between them is X.(fig.1) 3. Tighten the air cord clamps (fig. 2). Fast plates: 1. Place the fast plates in flush position with the slow plates. 2. Tighten the air cord clamps (fig. 2). * X = CO + 45mm (In case of fire protected panels) *X = CO + 30mm (In case of non fire protected panels) Adjust the opening of the door by the slots of the top of the hanger plates. ADJUSTMENT OF CO. IN SIDE OPENING DOORS 1. Place the flush plates in open position. 2. Check that between the extreme plate and the end of opening there is a distance of X*, as shown fig. 1. Use the slots of the top plate for adjusting the door (see figure 1). 3. Once the fast plate is in the flush position with the slow plate, fix the syncronization cord (fig. 2).

28 INSTALATION OF GUIDE SHOES AND HANGERS Guide shoes (fig. 1) and hangers (fig. 2) installation in panel procedure. ADJUSTMENT OF PANELS The following procedure is the same for any type of cabin door (Central or side opening). 1. Once the panels are placed into their corresponding plates, slide them through the side they open till they are raised with the frames. 2. Tighen the nuts that hold the plates with the hangers (fig. 1). 3. Straigthen the panels with the help of the hanger nuts until the panel is parallel to the post (fig. 1). Check that between tread, between panel and panel, and between panel and post it exist a distance of 5mm. (fig. 2) Alignment of panels: The panels should slide smoothly in the tread. If for any reason the panels do not slide smoothly, follow these instructions: 1. Disassemble the inferior guides. 2. Straigthen the panels to remain parallel to the tread. 3. Assemble the guides.

29 ADJUSTMENT OF WHEELS 1. The adjustment will be made by the inferior wheels (eccentric), rotating the shaft we can adjust the force done to the track. 2. This adjustment may be done with an allen wrench of 5 mm and the flat key. An excessive tightening could stop the panel. Wheels are adjusted in factory, only should be regulated in case of bad functioning. LANDING DOOR COUPLING The cabin door includes the moving skate that does the opening of the landing door. When the cabin door is closed, the moving skate remains closed, so that while the cabin is moving it does not work with the landing locks (fig.1). Before the opening manoeuvre, the moving skate opens and unlocks the landing lock so that it can start the opening and closing of the landing door. In the closing cycle, the movements will be other way round, moving the skate while closing, and closing the skate to free the landing lock, so that the landing door will be ready to close and the cabin free to move. The correct position of the skate is centred in relation with the rollers of the landing lock.

30 CORRECT ADJUSTMENT BETWEEN CLAMP AND RETAINER Once the skate is placed (145mm between the end of the plate and the shaft of the skate), in locked position, adjust the clamp-retainer set by the slots (8 x 25) of the support with a gap of 0,5 mm in the horizontal and vertical shaft. Doors 4 panels between CO 600 until CO 915 the measure is 80mm. LOCKING DEVICE Figure A1 and B1 correspond to a lock set and figures A2 and B2 show an open position. In these drawings we can notice the correct situation of the locking mechanism parts. 1. Locked position, between landing cam and movement bushing should be 10mm to allow the cabin fit (fig. A1 and B1). 2. Check when cabin is in the floor the locking device and cam work allowing a correctly opening of the door (fig. A2 and B2).

31 ELEMENTS SITUATION D - Distance between treads = 30mm

32 TECHNICAL MANUAL & ELECTRONICAL MODULE REGULATION VVVF-4+

33 PROGRAMMING 1 DESCRIPTION OF SWITCHES The unit may be programmed using the DIL switches on the front of the unit. If any change is made to any of the above switch selections, the Mains Supply to the VVVF-4+ unit MUST be switched OFF and ON again to read the new programming. The switches functions are: 1 & 2 Inputs: ON: 1 Input The door control unit will be controlled by a single input. Any voltage between 12 to 250 volts AC or DC applied between terminals 8 & 10 will open the doors. Without any signal the door remains open. In the contrary the door remains close. OFF: 2 Inputs The door control module will be controlled by two independent inputs. Any voltage between 12 to 250 volts AC or DC applied between terminals 8 & 10 will cause the doors to close. And between terminals 12 & 10 will cause the doors to open. In the absence of a signal, the doors will remain static. If both inputs are applied then the open signal has priority. 2 3 4 Automatic / Semiautomatic: ON: Automatic: Operators with skate (automatic landing). In this case a special movement is made for locking and unlocking the skate OFF: Semiautomatic: Operators without skate (Semiautomatic landing door). Rotation sense (photocell): ON: The control unit is expecting to control left hand or centre opening doors. OFF: The control unit is expecting to control right hand opening doors. (Special Note: The sense is defined from the outside of the car, refering to the direction taken when the door is opening.) Master and Slave: ON: Master: The door control unit will execute instructions directly. Example: operation of the Photoelectric Detector will cause the doors to re-open immediately under control of the door control unit. OFF: Slave: There is no automatic re-open movements. The photocell will only react to instruction given by the main lift controller by the inputs. Example: operation of the Safety Edge Detector will cause the door operator module to give a signal to the main lift controller via the PHOTOCELL (36, 37, 38) output. The main lift controller then must remove the close signal and put the open signal.

34 INPUTS POWER INPUTS 220-250 V SINGLE PHASE AC (5, 6, 7): The circuit has been designed to operate on a mains supply of 230 Volts AC (+10%,-15%, 50 or 60 Hz). The unit will consume approx 1 Amp from the supply. In the case of using the new External Emergency Passenger Release System the connection of the power from the main supply (230V) is done directly on the unit (3 NEUTRAL - 2 GROUNDING - 3 PHASE). From there onwards through the interconnection between of the 2 boxes (VVVF4 5-6 - 7 & Emergency Unit 5-6 - 7) the power is trasmitted to VVVF (page 35). CONTROL INPUTS (8, 9, 10, 11, 12): The circuit can work with external voltage inputs or by means a volt free contact input. It is important that the Door Operator Module has a GOOD EARTH CONNECTION. 12. Opening Signal: Is an isolated signal with an impedance of 20 komh and a sensibility from 12 to 250V. used for ordering the door. If we use the control with only one input, it will be closing signal and door will open. 11. 0 Volts: Is the negative pole of 12V. When using an internal voltage it should bridged to common (10). 10. Common: Is the reference used for the two inputs. 9. 12 Volt: Isolated 12 Volts output available to control the door via a volt free contact. Features are: a. This supply must only be used for this purpose. b. This contact must be isolated from any other power supply. 8. Close signal: It has the same characteristics as the open signal. SERIAL PORT (13, 14, 15, 16): The serial port is used to connect with external devices like the diagnostic console, interfaces and future expansion devices. Operating speed 1.200 Baud, current loop.

35 PHOTOCELL (17, 18, 19, 20): One of the most relevant characteristics of this control is the optional incorporation of a photocell. It is composed by a emitter and receptor infrared. OTHER INPUTS (26, 21, 25, 23): 26. Landing signal: This input is for connecting the external emergency current supplier that allows the opening manouvre in the case of power failure by a battery of 12V, able to give power during 15 seconds for a passengers rescue. 21. Reopening: This signal is for installing the cabin door swich or an external barrier. This signal has priority to the closing signal. Use contacts free on tension. For activating close one contact with the main supply +12V. (23). 25. Slow Closing: This input orders to the operator to close the door slowly regardless of the barrier and control signs. Is created for working with detection of fire centres. 23. + 12 V. COM: This terminal is used for giving with an isolated contact a reopening order or a slow closing. Always use contacts free of tension and usually open.

36 EMERGENCY SUPPLY INPUTS (66-67-28-29) AND INTERCONNECTION WITH VVVF The KLEFER VVVF can be connected with an optional External Emergency Passenger Release System powered by a 12V battery. In the case of Power Failure the battery provides sufficient power to release trapped passengers. The Door opening manouevre is controlled by a free voltage contact, applied between terminals 66 & 67. Special attention should be paid to the following points: The connection of the power from the main supply (230V) is done directly on the Unit. ( 3-Neutral 2 Ground 1 Phase ). From there onwards through the interconnection of the two boxes (VVVF4 5-6-7 & Emergency Unit 5-6-7), the power is transmitted to the VVVF4. On the connections 66 & 67 of the Emergency Unit connect the magnetic Normally Open Switch (NO), which through the assistance of a magnetic belt closes the circuit. Special attention should be paid to the connection of the battery. On connector 28 of the Emergency Unit connect the negative pole and on connector 29 the positive. In any other case the 20A fuse will be burned. The Battery automatically recharges itself, once its capacity drops below 70%, and may take up to 48 hours. The situation of the battery is indicated through a led on the Emergency Unit showing the following three different statuses. 1. When the led is ON it means that battery is charging. If this lasts for more than 48 hours the battery is defective and should be replaced (2Ah and above). 2. When the led is flashing everything is operating properly. 3. When the led is flashing every 15 seconds a cut in electricity has occurred.

37 OUTPUT RELAYS AND LED INDICATORS (from 30 to 41): Output relays have been provided to give continuous information to the main lift controller concerning the status of the doors. One 5 Amp/250 Volts volt free change over contact is provided on each relay that may be used by the main lift controller to pilot such information as doors fully opened, doors fully closed, Photoelectric detection, obstruction in the doorway and door control O.K.. Opened: Led indicator and relay activated when the doors are fully open. Closed: Led indicator and relay activated when the doors are fully closed and locked. Photocell: Led indicator and relay activated when the photocell or the reopening input is operated. Obstruction: Led indicator and relay activated when an obstacle is detected that stops the doors from closing. The signal will reset when the doors reach the opened or closed position. Status: Blinking led indicating proper working conditions.

38 TEST PUSHBUTTON (50): Operation of the Test pushbutton will cause a door open or close cycle. AUTOADJUSTMENT PUSHBUTTON (51): The Autoadjustment pushbutton is used to set up the doors. The doors will do 3 complete movements at first the doors will close completly, then the doors will open slowly counting the pulses from the encoder built into the drive motor until they reach the open mechanical stop, and after a short delay the doors will close. From the information gained the microprocessor will calculate the acceleration and deceleration ramps and the bracking torque required to give the optimum control of the doors. Once the autoadjustment has been completed the parameter are stored in non- volatile EEPROM and will be used to calculate the optimum performance. The doors will open slowly for the first operation after power has been removed from the door control unit. Autoadjustment only needs to be used when setting the initial parameters or when changes such as connecting or removing the Fermator Safety Detector are made. For Advanced Start Up Protocol & Autoadjustment of the VVVF (INVERTER) see Appendix I CLOSE SPEED (52): The door closing speed can be independently adjusted from 150 mm/s upto 600 mm/s. OPEN SPEED (53): The door opening speed can be independently adjusted from 200 mm/s upto 1.000 mm/s. SAFETY (54): This potentiometer is used to set the closing pressure onto an obstacle in the doorway. The closing pressure can be set between 40 and 150 Nw. ENCODER (55): An integral quadrature pulse encoder is connected to this input. The purpose of the encoder, which is situated inside the motor, is to inform the control of the exact position and speed of doors. MOTOR (56): Output to the 3 phase motor varying the voltage and frequency to control speed and torque. ON/OFF SWITCH (57): Disconnects the unit from the 230 Volts AC mains supply. Caution: When the supply is switched off, capacitors in the control system will remain charged for a short time. Allow 60 seconds before handling the Control Card or Motor.

39 PROGRAMMING EXAMPLES MASTER: 1 INPUT Configuration 1. ON: 1 Input. 2. Depends on type of door. 3. Depends on type of door. 4. ON: Master photocell. Inputs 1. (8) Close Closes the doors with voltage between terminals 8 & 10. Open the doors when the voltage between terminals 8 & 10 is removed. 2. (17...20) Photocell Doors will reopen if the photocell beam is broken. 3. (21-23) Reopening Doors will not close if this signal is active. SLAVE: 2 INPUTS Configuration 1. OFF: 2 Inputs. 2. Depends on type door. 3. Depends on type door. 4. OFF: slave photocell. 4. Obstacle Door will open if an obstacle is detected by the motor ceasing to rotate. 5. (25-23) Slow Closing Closes regardless of the state of the photocell. Priorities 1. (21-23) Reopening. 2. Obstacle. 3. (25-23) Slow Closing. 4. (17...20) Photocell. 5. (8) Close. Inputs 1. (8) Close Closes the doors with voltage between terminals 8 & 10. 2. (12) Open Open the doors with voltage between terminals 12 & 10. Pryority to close. 3. (17...20) Photocell Does not re-open the doors when activated but provides signal to main controller via the Photocell relay. 4. (21-23) Reopening Doors will not close if this signal is active. 5. Obstacle Doors will not re-open if an obstacle is detected by the motor ceasing to rotate. 6. (25-23) Slow Closing Closes regardless of the state of the photocell. Priorities 1. (12) Open. 2. (21-23) Reopening. 3. (25-23) Slow Closing. 4. (8) Close.

40 TECHNICAL FEATURES POWER SUPPLY AC voltage range... 230v +10%, -15%. AC/DC Frequency supply...50...60 Hz Minimum supply...70 ma-13 W Open door power...0,6 A-80 W Nominal power... 0,93 A-140 W Maximum power... 1,38 A -190 W INVERTER Carrier frequency... 16 KHz Frequency range...0,5...100 Hz Voltage range... 40...200 V AC III Maximum output current... 4 A Positional control...quadrature encoder MOTOR Asynchronous three phase...6 poles Voltage supply...250 V Power...250 W Thermic class...b-130 C Nominal speed... 900 RPM INPUTS Impedance...20 KOhm Voltage... 12...230 V AC/DC OUTPUTS Contacts...Switched R. contact... 50 mw Swich time...5 ms Output current...5 Α max Voltage...250 V PRESTACIONES Open Speed... 200...1000 mm/s Close speed... 150...600 mm/s Maximum acceleration... 800...1500 mm/s 2 Safety force... 40...150 N adjustable Maintenance torque (Opened Door)... 80 Nm/cm

START UP PROTOCOL & AUTOADJUSTMENT OF THE VVVF (INVERTER) 41 1. Put the cabin between floors, in order to make adjustments separately from landing doors. 2. Put the door middle opened, after switching off the unit (switch 57). 3. Disconnect the signals coming from the main controller (8, 9, 10, 11, 12 & 21, 23, 25). 4. Programm in 2 INPUTS and MASTER (Microswitches 1 in OFF and 4 in ON) independently to how you will program the doors afterwards. Microswitches 2 and 3 according to the kind of door. (Right-Left-Central sense and semiautomatic or automatic landing door). 5. Adjust the 3 potentiometers (52, 53, 54) in maximum, in order to overcome little mechanical disorders. 6. Switch on the unit by means the main switch (57). 7. The door must remain stopped. If the door moves check the micro switch 1 in OFF position. 8. Press the AUTO ADJUSTMENT button (51) to make an auto adjustment cycle. Α. The door should close. In case it opens you should check the micro switch 3 and if it is correct then any motor phases is inverted and it will have to interchange 2 of them and make the auto adjustment again. If the door doesn t move, check the motor wires and the motor connector (56). If the door stops before closing completely, the information from the encoder is not correct. Check the encoder (55) and try the auto adjustment again. If the door stops in the locking skate movement, check manually if the locking and de-locking skate movement is made easily and completely. (See the Mounting cabin doors instructions). If the door doesn t close completely disconnect the VVVF and check if there is any mechanical obstruction. B. Once the door is fully closed it will activate the CLOSE led and after a few seconds will open slowly and the led will be deactivated. The door should open slowly until the mechanical rubber stopper. If it only opens 26cm, the encoder information doesn t arrive to the VVVF. Check the connections or change the encoder or the wire if they are damaged. If it doesn t open completely, check the mechanical because the motor torque is enough to drag any kind of door (Check the wheels, the leaves, e.t.c.) C. The door will close again without hitting. If the door doesn t close, one encoder phase fails. Verify the wire and the encoder. If the door stops for some seconds before the close movement there is too much mechanical friction detected by the system. The system will work, but the door operator should be checked mechanically. If the door closes hitting, check the microswitch No.2 (type of landing door). At this point by pressing TEST button the door will make a closing or opening movement. It should open and close without hitting with the standard movements pre-programmed. So now it is the time to adjust the speeds (52 and 53). D. Be sure that the 3 movements (CLOSE-OPEN-CLOSE) are well completed when running the autoadjustment function. Check all the functions: obstruction, photocell, the inputs, open/close movements, etc. E. If the VVVF control works correctly, we can switch off the circuit and program according to your requirements and connect the input signals from the manoeuvre lift control.

42 POSSIBLE PROBLEMS & SOLUTIONS The door doesn t answer to the test or auto-adjustment buttons. Switch OFF (57) and try again. The door only closes 35cm. This is the clear entrance of any controller that has never been adjusted. Therefore an auto adjustment is required. The door opens but doesn t close. Check if the photocell LED is activated. Check if the close signal arrives to the system using a multimeter or the console. Check if the re-opening signal is activated. Check that there is no stray voltage in the open signal. The door re-opens by itself. Check the sensibility of the re-opening (# 54) Safety regulation potentiometer. Check that the photocell is not activated. Check that there is no mechanical obstruction on the door. In case of having the same problem, disconnect the photocell and try again with the TEST button, and if the door doesn t open totally there must be a mechanical obstruction on the door. The photocell is activated intermittently. Check the grounding connection (#6). Check the correct plugs connection. Remove the photocell wiring from any place where there are electric noises such as motors, supplies wiring, etc. If you can use a console, please check the stability of the signal. Do not extend the wires especially the reception one (green colour). Take in mind that in master mode the system recognizes automatically the photocell detector after making a complete open - close cycle with the beam free controlled by the input signals. The door doesn t reach the fully open position. The mechanical adjustment of the door is not correct, as the motor of the door operator has always enough power to open in normal circumstances. The door reopens when the skate is closing. Check the regulation of the skate, because probably the locking system of the skate is not well adjusted and the door has a mechanical friction, and consequently the door reopens and the obstruction LED lights. The door hits when it opens. Check that the skate un-locking is well fixed before the door starts to open. In case the skate is not fully fixed you should check the skate adjustment because it is probably too hard. The ON LED is activated and the door doesn t obey to the signals. There has been an obstruction at opening and then the door enters into an out of order stage during 15 seconds. There is a continuous obstruction and the lift controller has not changed the close signal by the open signal in slave mode. There has been a short circuit in the output of the motor, and the system will be deactivated during 3 seconds. The door hits when is fully opened, the open LED is not activated and the system gets out of order. Check the tension of the toothed belt, because probably it is not correctly adjusted and it slips on the pulley of the motor and consequently the encoder is sending a wrong information. The system gets power but doesn t work and the led ON is off. Check if the external fuse is burned and change it for another of the same type (250V, 4A ceramic fast speed).

43 The LEDS are working but the door doesn t move. The power module (and the internal fuse related) is blown and the controller must be sent back to be repaired. Do not try to change it by yourself as it could give an electric shock and damage more components. The motor is moving intermittently. Check the wiring connections or if a phase of the motor is falling. The door opens less centimeters in each movement and the opened led is activated, but the door is not really opened. If the motor box protection has been de-mounted, be sure that the encoder wire is free inside the box. Maybe the wire is pressed between the motor and a plastic nerve and the encoder information does not arrive properly to the VVVF. How to check the correct direction of rotation of the motor. Disconnect the input signals from the controller, the encoder wires and program the switch 1 in ON position. (Only mains supply and motor connected). Switch on the circuit. If the door starts to open, then the turning sense is correct, but if the door starts to close, interchange two motor phases. Connect the encoder wire and the system inputs. How to check the encoder If the door opens 26cm only, the encoder information doesn t arrive to the VVVF. Check the connections or the wires if they are damaged or change the encoder. If during the start up, the door opens completely (after closing), it remains opened, although the CLOSED led is activated, a phase of the encoder is failing and we have to interchange the two central wires. Even if after the above the door doesn t work properly, change the encoder. PREVENTIVE MAINTENANCE FOR CABIN DOORS VVVF 1. Check and replace the electric contact as necessary. (Approximately after 2 million cycles). 2. Periodically check that the closing cycle ends resting on the rubber stop. 3. Concentric and eccentric wheels require no maintenance. Replace them when they have signs of wear, noisy operation... (Approx. after 10 million cycles). 4. To prolong the life of the hanger wheels keep the top tracks clean. Never apply grease to the top tracks. 5. Once a year grease the shafts of the skate. Use only SAE-20 lubricants (Do not use spray lubricants). 6. Replace the guide shoes when they appear to be worn. 7. Periodically check the tension of the belt. With the correct tension the life of the belt is almost unlimited. 8. Once a year grease the shaft of return splined pulley (Do not use spray lubricants). 9. Periodically check and adjust the tension of the air cords. Replace them when they have signs of breaks, wear... (approximately after 6 million cycles). 10. Synchronization wheels (air cord pulleys) need no maintenance. Replace them when the have signs of wear, cracks or noisy operation... (approx. 8 million cycles).

Βιομηχανική Περιοχή Κιλκίς, 61100 Ελλάδα Τηλ: 23410 75 730 Fax: 23410 75 733 Kilkis Industrial Area, 61100 Greece Tel: +30 23410 75 730 Fax: +30 23410 75 733 www.klefer.gr, commercial@klefer.gr