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Electronic controller PAGE – 1 –

HYDRO-KLC

KLEEMANN HELLAS

KLEEMANN HELLAS
5X20 3A 5X20 3A

K-D 10

K-D 10
LD1

LD1
5X20 3A 5X20 3A

~ ~ - + ~ ~ - +

+B' -B'

C3
KD20 LD1
ON
230V C4 U2 REV2 REV1

C1
3-PHASE P2
SEQUENCE
Prim:4200/0.07
~230V 50/60Hz

VOLTAGE
Sec:2*140/0.28

F1 RD0
RELAY REM2 REM1 12VDC
20 110VAC 110VAC

25 15

30 10
0%

1B 110VAC

+B -B 10 120V RS 1S 1B'
EDO2 EDO2 EDO1 EDO1 EL D12 LEV COM

1L1 1L1 1L1 1L1

In 1A In 1A In 1A In 1A
RLU RLU
IEC 947-2 IEC 947-2 IEC 947-2 IEC 947-2

GB2-CB06 GB2-CB06 GB2-CB06 GB2-CB06


2T1 2T1 2T1 2T1
CS1 0

CS1 0

CS1 0

CS1 0
COM3

COM3

COM3

COM3
FF1 OU1 FE1

FF1 OU1 FE1

FF1 OU1 FE1

FF1 OU1 FE1


0 EDO1 EDO1 COI1

0 EDO1 EDO1 COI1

0 EDO1 EDO1 COI1

0 EDO1 EDO1 COI1


FIND POM MHS PRIC FCOU1 FCF1

FIND POM MHS PRIC FCOU1 FCF1

FIND POM MHS PRIC FCOU1 FCF1

FIND POM MHS PRIC FCOU1 FCF1


NDAC1 LDAC1

NDAC1 LDAC1

NDAC1 LDAC1

NDAC1 LDAC1

MANUAL HYDRO-KLC_Version 1.03

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 2 –
HYDRO-KLC

1 CERTIFICATES OF KLC01

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 3 –
HYDRO-KLC

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 4 –
HYDRO-KLC

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 5 –
HYDRO-KLC

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 6 –
HYDRO-KLC

2 GENERAL DISCUSSION ON KLC CONTROLLER


The electronic & electrical part of hydraulic lift KLC comprises the following:

Electronic controller HYDRO-KLC of KLC series for pre-wired installation


Pre-wired installation of the controller
- Flexible cables –Looms
- Elevator control sensors (mechanical & magnetic switches)
- Inspection control box
- Pit stop
- Shaft light

The KLC model constitutes a time-tested, reliable & up to date solution in the field of lift controller’s automation.
HYDRO-KLC is capable to achieve speeds up to 0,80 m/sec.

o Electronic controller HYDRO-KLC on its basic model can control up to 8 stops and one automatic door, in
Down Collective mode.
o With the addition of certain modifications, KLC can control bus doors in combination with semi-automatic
landing doors.
o The indicator outputs are 24VDC signals in BCD (Binary) format and 0V COMMON.

On KLC01 main board there is an on-board programming and fault-finding tool.

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 7 –
HYDRO-KLC

3 MAIN CONTROLLER BOARD DEVICES

KLC01 controller consists of the followings:

Main board KLC01

Relevelling board KLC02

Phase monitoring – phase failure relay

Rail mounted automatic circuit breakers for protection & control:

• Transformer circuit breaker for controller supply ( 6Α)

• Safety lane circuit breaker (1Α)

• Car light circuit breaker (6Α)

• Shaft light circuit breaker (6Α)

Power and auxiliary relays for control of

• The motor

• The valves

Connectors for pre-wiring installation

Thermistor Inputs (PTC) for

• The motor

• The oil

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 8 –
HYDRO-KLC

3.1 PLACEMENT OF KLC01 FUSES

FL FT FCL FPL
RAIL AUTOMATIC CIRCUIT BREAKERS
1A 6A 6A 6A
FL LEAKAGE SAFETY SWITCH - SAFETY
LINE PROTECTION SWITCH
rail automatic circuit breaker 1Α
FT TRANSFORMER FUSE
rail automatic circuit breaker 6Α
FPL SHAFT LIGHT SAFETY SWITCH
rail automatic circuit breaker 6Α
FCL CAR LIGHT SAFETY SWITCH
rail automatic circuit breaker 6Α

CONTROLLER'S FUSES ATTENTION!!!


In case of replacing a fuse,
SUPPLY BOARD K-D10 (BCAM & BVA)
be aware of the type of fuse
BOARD FUSE 3A-250V 5x20 FAST RESPONSE you use. There is danger of
BOARD FUSE 3A-250V 5x20 FAST RESPONSE damaging the circuit if a
wrong fuse is used.

BOARDS K-D10
( BVA & ΒCAM*) 1B LD48
KL8 6 LD49
2
3
1
KL19

KL11

KL13

RS 8A LD50
KLEEMANN HELLAS

COMTH

MTH+

CN3

5X20 3A
STH+

FRP
CAB

CAA

EM

SUI
ED

INS

8 LD51
1B
10 LD52
6
LD33

LD23

LD21

LD20

LD19

LD18

LD22
LD23

8A
L25

INDICATOR 8
K-D 10

KLC01

(LED) OF THE
10

POWER
IN
LD1

P2

P1

IN
KL1

SUPPLY OUT1

OUT2
LD47

LD46

OUTPUT KL31
CS1 LD42

0V
KL28
+24V

GND

GND
5X20 3A KL17 GNS
CL
LD26

K-D 10
FM
LD27
FD ENTER ESCAPE
LD29
KL14
RLU
~ ~ - + LD28

CAM+ LD30

SU LD31
KL18
GT1
U22
GT2
KLEEMANN HELLAS

LD38

5X20 3A L GND
PDC RX
TX
PDO
+5V
U27
LD1

KL12 1 2 CN1
LD39

INDICATOR COMC YO
CN2
K-D 10

L
3 4 5 6

LD3

(LED) OF THE Y
LD40

DC
D
1 2
ON

POWER KL15
LD1

DC
LD41

SUPPLY
DO
DO

COMD

OUTPUT KL26
LD34

A A
B
KLC02

C REL 4 REL 1 REL 3 REL 2


LD35

D B

COMV
KL7 LD24
5X20 3A 2 1
LD36

CAZA CN1
C
LD44
LD16

LD43
LD15

LD45
LD12

LD13

LD17

LD14
LD10

LD11
LD2

LD3

LD4

LD5

LD9
LD8
LD6

LD7

CAZ-
KLC02
K-D 10
LD5 LD2 LD4
CAZB
LD37

CAZ+ D
KL27

-BAT
KL3

KL4

KL5

KL6
C1

C2

C3

C4

C5

C6

C7
C8

L1

L2
L3

L4

L5

L6
L7
L8

C
B

~ ~ - + +BAT

*ΒCAM FOR SEMI-AUTOMATIC DOOR

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 9 –
HYDRO-KLC

3.2 LEDS & JUMPERS POSITION ON KLC01 BOARD


KLC01 is the main board of the KLC - controller series. It includes the main processor (CPU) and the
parameter programme (U27) that drives all extension boards with respect to the setting originally made by
kleemann personnel & is stored in EEPROM (U22).
motor thermistor
indicator LED

safety lane
indicating LEDs

oil thermistor maintenance controller


indicator LED indicator LED
full load indicator LED
CAA, CAB
indicator LEDS pre-final switches fireman activation indicator LED
indicator LEDS power relay
indicator LED
car inspaction
indicator LED

over load indicator LED


"busy car"
indicator LED
level zone indicator LED

direction arrow
indicator LEDS

automatic activation ΕEROM


of car light indicator paraneter memory
LEDS
Drive power relays CPU
indicator LEDS microprocessor
BIOS oparetion
magnet activation
programme
indicator LEDS

activation of door operation


over-load operation indicator LEDS
indicator LEDS floor indication
indicator LEDS

car calls
valves indicator indicator LEDS
LEDS
landing calls
indicator LEDS

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 10 –
HYDRO-KLC

3.3 EMERGENCY EVACUATION BOARD KD – 20


+B' -B'

C3 LD1
230V C4 U2 REV2 REV1

C1

P2
Prim:4200/0.07
~230V 50/60Hz
Sec:2*140/0.28

F1 RD0
REM2 REM1 12VDC
110VAC 110VAC

1B 110VAC

+B -B 10 120V RS 1S 1B'
EDO2 EDO2 EDO1 EDO1 EL D12 LEV COM

KD-20 board operates with a 12V, 2Ah rechargeable battery.

KD-20 comprises of each own charging circuit for this particular battery. The board supervises the safety lain at
all times. 110V AC during normal operation is supervised. During a power failure it supplies the safety lane with
12V DC.

At the same time 12V DC are supplied to the emergency car light as well as to the emergency evacuation
valve (coil D).

As long as the evacuation operation is on Led LD1 on KD-20 flashes.

KD-20 supplies a door contact for the opening of the door after the evacuation operation ends.

In case of BUS landing doors, the evacuation operation stops when the door locks open.

If the car stops higher than the floor level, in order to achieve the exact leveling of the car after the door lock
contact is cut, adjust timer P2. This timer adjusts the time extension of evacuation operation after the door lock
contact opens.

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 11 –
HYDRO-KLC

3.4 RE-LEVELING BOARD KLC02


LD1 LD4 LD2 LD5

KLC02
CN1
1 2

REL 2 REL 3 REL 1 REL 4

LD3

KLC02 board is required whenever any of the two following operations are needed.
a) Re-levelling with open doors
b) Pre-opening of the doors function.

Leds LD1 (B) & LD2 (A) indicate the state of the zone magnetic switches. When both LEDs are illuminated this
is an indication that the car is at a level. At the same time LD3 (RZONE) on KLC is illuminated also indicating
the stop zone.
Led LD5 (C) is illuminated along with zone leds LD1 & LD2 whenever KLC02 board links the door safeties
contacts 5E/5S & 10.
Led LD4 (SH8) is illuminated only when none of the magnetic switches is activated.

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 12 –
HYDRO-KLC

3.5 FAULT FINDING TOOL – ERROR FINDING

FAULT FINDING TOOL

Initially activate the machine room inspection control. Observe the programming tool on KLC board, with its display
and buttons.

LEVEL 0
15/05/05 12:45:25

ENTER ESCAPE

At this point if Esc button is pressed, the version and its date will be displayed.

KLC01
V2.29 11/05/05

By pressing the Enter button we enter to the basic menu. Then using the left or right buttons we navigate
among the 4 main menu categories. In order to access one just press the Enter button.
1.PARAMETER 2.CHECK FAULT 3.ADJUST 4. SECRET FUNCTIONS
PROGRAMMING HISTORY DATE / TIME

Choose menu ”PARAMETER PROGRAMMING” and press Enter. Now navigate through the various sub-menus with

the buttons and choose the needed one by pressing Enter.

GENERAL TIMERS TRAVEL TIMER

Choose for example sub-menu ”GENERAL TIMERS” and then parameter “TRAVEL TIMER” and press Enter.

TtravF 60 sec
At this point you will see the following:

In order to change the value use buttons .

Register the new value by pressing Enter.

You can now access more parameters in this menu and change their values or move back to previous menus by
pressing Esc. If you want to leave the menu and set the lift in normal operation, press Esc button a few times until
you see the following screen on the display.

LEVEL 0
15/05/05 12:50:25

ENTER ESCAPE

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


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HYDRO-KLC

PARAMETER SETTINGS
GENERAL TIMERS
TRAVEL TIMER HIGH SPEED ( TtravF 20-60 sec / def. 20 sec)
It is the maximum allowed time for the car to travel on high speed to the next level. This time is updated every
time the car reaches a level.

TRAVEL TIMER SLOW SPEED (TtravS 6-45 sec / def. 20 sec)


It is the maximum allowed time for the car to travel on low speed.

TRAVEL TIMER RELEVELLING (Trelev 0-15 sec / def. 10 sec)


It is the maximum allowed time for the car to re-level on low speed.

TIMEDELAY BETWEEN CALLS (TcarIdle 0-10 sec / def. 5 sec)


It is the minimum time needed to pass after a travel has been concluded in order another call to be performed.

AUTO PARKING TIMER ( Tparking 0-10 min / def. 0 min)


Set the time after which you want the car to park.

PARAMETERS LEVEL FUNCTIONS


NUMBER OF FLOORS (Nfloor 2 – 8 / def. 8 )
Total number of levels

PARKING LEVEL CHOICE (Nparking 0 – 7 / def. 0)


Set the level where you want the cat to park. The car is going to park there until a new call is registered. If the
car parks for more than 15 minutes on this floor the automating homing function will be enabled and the car
will be sent to the bottom floor, so that the piston will be fully closed.

PARAMETERS OF DOOR FUNCTIONS


TYPE OF DOOR (Dtype 0 H 1 / def. 0)
Setting of the landing door type
0 = Semi-automatic door
1 = Automatic door

DOOR SIGNALS PERMANENT( DcExtend YES OR NO / def. NO)


Setting of a permanent door close signal or not
NO = Door close signal will go off as soon as the door closes
YES = Door close signal will stay on till a door open signal is given

PARKING WITH OPEN DOORS (ParkADo YES OR NO / def. NO)


Setting of the door position on the parking level
0 = Door open
1 = Door closed

DOOR OPEN TIME ON LEVEL (TdoorDA 1 - 45 sec / def. 7 sec)


Set the time you want the door to stay open on level after the end a travel

PARAMETERS ELEVATOR MOTION


CHOICE OF LIFT TYPE ( Dtype 0 H 1 / def. 0)
Set the type of the lift
0 = Traction 1 speed / 2 speeds
1 = Hydraulic ∆ – Υ/∆

SOFT STOP A (Tstop 0 – 3000msec / def. 0 msec)


Set the time delay after which the motor will be immobilized. Time starts after a stop signal has been given.

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 14 –
HYDRO-KLC

SOFT STOP B (Tvalve 0 – 3000msec / def. 400 msec)


Set the time delay after which the valve block will be deactivated. Time starts after a stop signal has been
given.

Υ/∆ TIMER START TIME (TstDel 0 – 5000msec / def. 2000 msec)


Star – delta time. The time after the star motor connection will be switched to delta connection. For direct start
up set the time to zero.

SAFETY THERMISTORS

FIRE-FIGHTING PARAMETERS
DEFINE FIREMAN TYPE (FIRE 0 – 2 / def. 0)
Activation and choice of Fireman type
0 = Fireman operation de-activated.
1 = French Fireman type.
2 = English Fireman type.

DEFINE FIREMAN LEVEL (NFIRE 0 – 7 / def.0)


Set Fireman level.

INDICATION PARAMETERS
CAR CALL INDICATION L.E.D.s FLASHING (CalFls YES OR NO / def. NO)
No = Call indication L.E.D.s not flashing.
Yes = Call indication L.E.D.s flashing.

INDICATION ARROWS FLASHING (Arrfls YES OR NO / def. NO)


Direction arrows operation choice
No = Indication arrows not flashing.
Yes = Indication arrows flashing.

DOWN LANDING CALLS FLASHING (ExDfls YES OR NO / def. NO)


No = Down landing calls not flashing.
Yes = Down landing calls flashing.

SU INDICATION FLASHING (SuFls YES OR NO / def. NO)


Overload indication operation choice
No = Overload indication not flashing.
Yes = Overload indication flashing.

CAR LIGHT TIMER (Tlight 0 – 60 sec / def. 20 sec)


Setting of time delay after which car light will switch off.

LIFT IN USE TIMER (Tci 0 – 60 sec / def. sec)


Once all control signals, after the last travel, switch off this timer begins counting. Upon completion of the Lift
in use timer any other automatic operation timers begin counting.

POINT OF GONG ACTIVATION (StrPos 0 OR 1 / def. 0)


0 = Signal for voice announcer will be activated upon completion of a travel.
1 = Signal for voice announcer will be activated the moment the lift’s speed changes from high to low.

GONG SIGNAL DELAY (Tgong 100 – 3000 msec / def. 500 msec)
Set the time that the gong signal will last.

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 15 –
HYDRO-KLC

KLC CONTROLLER FAULTS

1) TRAVEL TIMER HIGH SPEED: Timer for high-speed travel has run out.
Controller action: Lift goes out of operation. The only action possible is re-levelling towards the up direction.
In order to clear the fault either toggle inspection switch ON/OFF or reset elevator.
Error message: (TRAVEL TIMER) (12CHAR)

2) TRAVEL TIMER SLOW SPEED: The timer for low-speed travel has run out.

Controller action: Lift goes out of operation. The only action possible is re-levelling towards the up direction.
In order to clear the fault either toggle inspection switch ON/OFF or reset elevator.
Error message: (TRAVEL TIMER SLOW SPEED) (13CHAR)

3) TRAVEL TIMER RE-LEVELLING: The timer for re-levelling operation either in up or down direction has run
out.

Controller action: Lift goes out of operation. No action possible. In order to clear the fault either toggle
inspection switch ON/OFF or reset elevator.
Error message: (RE-LEVELLING TIMER) (12CHAR)

4) Inspection control on top of the car activated.


Message: (INSPECTION ACTIVE) (15CHAR)

5) Machine room maintenance control active.


Message: (MAINTENANCE ACTIVE) (13CHAR)

6) Inspection control on top of the car and machine room maintenance control active at the same time.
Lift under inspection operation but no movement can be achieved. Switch off one of the two.
Error message: (MAIN AND INS ACTIVE TOGETHER) (14CHAR)

7) Motor thermistor STH activated:


Α) If STH is activated while elevator in motion, lift stops on the next oncoming level(only if lift was traveling
upwards) without opening the doors and then it is re-directed automatically to the lowest level, where it will
stop, open doors and stay out of operation until fault is gone. In order to clear the fault either toggle
inspection switch ON/OFF or reset elevator. Check motor thermistor.
Error message: (MOTOR THERMISTOR) (16CHAR)
Β) If STH is activated while elevator is in inspection mode then only downward movement is available. Fault
will be rendered only if STH signal is removed. Check motor thermistor.

8) Oil thermistor MTH activated:


Α) If MTH is activated while elevator in motion, lift stops on the next oncoming level(only if lift was traveling
upwards) without opening the doors and then it is re-directed automatically to the lowest level, where it will
stop, open doors and stay out of operation. Fault will be rendered only if MTH signal is removed.
Error message: (OIL THERMISTOR) (14CHAR)
Β) If MTH is activated while elevator is in inspection mode then only downward movement is available. Fault
will be rendered only if MTH signal is removed.

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 16 –
HYDRO-KLC

9) Safety chain point 1B is cut while lift in motion:


Lift stops immediately, all registered calls are cancelled. When and only if 1B is made again then the lift is
automatically directed to the lowest level and stays there out of operation. In order to clear the fault either
toggle inspection switch ON/OFF or reset elevator.
Error message: (SAFETIES CUT POINT -1B-) (13CHAR).

10) Safety chain point 6 is cut while lift in motion:


Lift stops immediately, all registered calls are cancelled. Fault is rendered automatically.
Error message: (SAFETIES CUT POINT -6-) (12CHAR).

11) Safety chain point 8A is cut while lift in motion:


Lift stops immediately, all registered calls are cancelled. Fault is rendered automatically.
Error message: (SAFETIES CUT POINT –8A-) (16CHAR).

12) Safety chain point 8 is cut while lift in motion:


Lift stops immediately, all registered calls are cancelled. Fault is rendered automatically.
Error message: (SAFETIES CUT POINT -8-) (15CHAR).

13) Safety chain point 10 is cut while lift in motion:


Lift stops immediately, all registered calls are cancelled. Fault is rendered automatically.
Error message: (SAFETIES CUT POINT -10-) (16CHAR).

14) After the end of a travel main contactors do not drop:


All registered calls are cancelled and lift goes out of operation. In order to clear the fault either toggle
inspection switch ON/OFF or reset elevator.
Error message: (MAIN CONTACTORS MONITORING) (16CHAR).

15) Overload input SUI is activated:


If elevator is parked at a level when SUI is activated then doors open and stay open until signal SUI is gone.
While SUI input is on, SU output is activated and the following error message is displayed: (OVERLOAD
ACTIVATED) (16CHAR)
If on the other hand lift is in motion when SUI is activated, signal is ignored until lift reaches the level.

16) If full load input FL is activated then all landing calls are registered but not followed until signal is gone.
Error message: (FULL LOAD) (14CHAR).

17) If Fire-fighter input FIR is activated then lift goes into fireman’s operation according to programmed settings
and the following error message is displayed:
Error message: (FIREFIGHTER OPERATION) (11CHAR).

18) If both pre-limit switches up and down are activated at the same time then lift goes out of operation. It is
possible to move elevator on machine room maintenance operation but not on inspection mode on top of the
car. Fault is rendered only after a reset operation.
Error message: (BOTH PRE-LIMITS ACTIVE) (16CHAR).

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 17 –
HYDRO-KLC

19) While re-levelling operation


Error message: (RELEVELLING) (15CHAR).

20) If elevator tries to re-level while not inside a zone level then lift goes out of operation.
Error message: (RE-LEVELLING FAILURE) (16CHAR).

21) If elevator fails to close car door contact (8A) after 5 successive efforts lift goes out of operation.
Error message: (LANDING DOOR FAILURE) (16CHAR).

22) If elevator fails to close landing door contact (8) after 5 successive efforts lift goes out of operation.
Error message: (CAR DOOR FAILURE) (16CHAR).

23) If elevator fails to close landing door lock contact (10) after 5 successive efforts lift goes out of operation.
Error message: (LOCK FAILURE) (14CHAR).

24) If while programming, a non valid value is assigned to a parameter then:

Error message: (PROGRAMMING FAULT) (16CHAR).

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 18 –
HYDRO-KLC

TERMINAL STRIP
ANALYSIS
C
COON
NNNE
ECCTTIIO
ONND DRRA AWWIIN
NGGSSO OFF IIN
NIIT
TIIA
ALL
S
STTAARRTTU UPPOOFF
T
THHEEL LIIF
FTT ((P
PRRE
ESSSSIIN
NGG))

-
CONNECTIONS
SHAFT – CAR – MACHINE ROOM

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 19 –
HYDRO-KLC

4 CONNECTION DIAGRAM OF VARIOUS TYPES OF CONTROLLER-


MOTOR COUPLING

CONNECTION DIAGRAM OF A MOTOR WITH A DELTA COUPLING


U1 W2


U1 W2

W1 W1
V1 V1
U1 V1 U2
U1 V1 U2

L3 L3
L2 L2
L1 L1 W1 V2
W1 V2

GROUND AT THE OIL TANK

CONNECTION DIAGRAM OF A MOTOR WITH A STAR COUPLING


U1
U1

Y
W1 W1
V1 V1
U1 U1 V1
V1

L3 L3
L2 L2
L1 L1 W1
W1

GROUND AT THE OIL TANK

CONNECTION DIAGRAM OF A SINGLE-PHASE MOTOR

Ν'
N
L'
N
L

GROUND AT THE OIL TANK

CONNECTION DIAGRAM A MOTOR WITH A COUPLING OF STAR-DELTA

Υ/∆
U1 W2
V2 U1 W2

U2
W2
W1 V1 U2
V1 U2
V1
U1
L3 L3
W1 V2
L2 L2 W1 V2

L1 L1

GROUND AT THE OIL TANK

The above correspondences of interconnection between the controller of


Kleemann and the motor, are based to the internal configuration, of the winding
armatures of the motter that this figure indicates.
W2 U2 V2

W2 U2 V2

U1 V1 W1

U1 V1 W1

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


4.1
safety chain & tank's connections car's connections doors connections
pre-finals connections
TERMINAL STRIP A TERMINAL STRIP B TERMINAL STRIP C TERMINAL STRIP

1S Α48 0V 0
1B Β48 24V CS1
6 C48 INS DC
8A D48 CAA DO
8 D12 CAB EDO1
10 COM CAZ+ EDO1
COMTH CAZB CAM+
0V CAZA
HYDRO-KLC

STH CAM-
Electronic controller

MTH CAZ- LDAC


FM 0V LEV NDAC
TERMINAL STRIPS OF THE KLC CONTROLLER

FD 24V BAT- CAL


EM SUI EL PAL
ED FL BAT+ COML
SU
PAGE – 20 –

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 21 –
HYDRO-KLC

4.2.1 CONNECTION DIAGRAM OF TERMINAL STRIP A


[safety chain & pre-finals connections – automatic car door]

safety chain & pre-finals


connections [automatic car door]

TERMINAL STRIP A

1S Upper limit switch


1B car stop - pit stop / speed
governor / safety gear /
6 rope loosening contact

8A car door (automatic)


contact
8
locks
10

0V
24V
FM
direction arrows
FD
upper pre-final
EM
lower pre-final pre-final mechanical
ED switches (N.C)

note: In case that a contact does not exist, place a bridge to


the respective condact points.

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


Electronic controller PAGE – 22 –
HYDRO-KLC

4.2.2 CONNECTION DIAGRAM OF TERMINAL STRIP Α


[safety chain & pre-finals connections – semi-automatic car door]
safety chain & pre-finals
connections [semi-automatic car door]

TERMINAL STRIP A

1S
Upper limit switch
1B car stop - pit stop / speed governor /
safety gear / rope loosening contact
6
car door (semi-automatic)
8A contact
BUS door contact
8
locks
10

0V
24V
FM
direction arrows
FD
upper pre-final
EM
lower pre-final pre-final mechanical
ED switches (N.C)

note: In case that a contact does not exist, place a bridge to


the respective condact points.

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HYDRO-KLC

4.3 CONNECTION DIAGRAM OF TERMINAL STRIP B


[tank’s connections]
tank's connections
TERMINAL STRIP B

Α
Α48
Β
Β48
C
C48
D valve coils
D48
D12
D12VDC
COM
COMTH
MCS MCS: motor thermistor
STH MRT: machine room thermostat
MRT OTP OTP: oil thermistor
MTH
0V
24V
over load over load contact
SUI
full load full load contact
FL

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Electronic controller PAGE – 24 –
HYDRO-KLC

4.4 CONNECTION DIAGRAM OF TERMINAL STRIP C


[car’s connections]
car's connections
TERMINAL STRIP C

0V
24V REVISION
SWITCH
INS
CAA
CAA magnetic proximity
CAB switches
CAB
black
CAZ+
CAZB
brown
CAZB magnetic proximity
black switches of the
CAZA re-leveling zone
brown
CAZ-
blue LEV
LEV
BAT- safety lights
(12V DC)
EL
BAT+
over load indication
SU or (buzzer)

When the contact of the revision's switch of the car is open you may then
use "ascent"(3) with "START" & "descent-button" (2) with "START" of the
revision.
When the contact of the switch mentioned above closed, then the revision is
deactivated and the controller is in normal operation.

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4.5.1 CONNECTION DIAGRAM OF TERMINAL STRIP D


[automatic doors]
automatic doors connections
TERMINAL STRIP D
Door Open
36 37 39 40
0 FERMATOR FERMATOR
door open button
photocell obstruction photocell contact
CS1 obstruction contact
DC to FERMATOR door close signal (8)

DO to FERMATOR door open signal (12)

EDO1 to FERMATOR contact (26) open door command


after the emergency
EDO1 to FERMATOR contact (27) evacuation
CAM+ retiring cam
magnet
CAM-
LDAC door supply
NDAC 220V AC

CAL car lights (42V or 230V *)


* according to the customer request
PAL shaft lights (42V or 230V *)
COML * according to the customer request

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HYDRO-KLC

4.5.2 CONNECTION DIAGRAM OF TERMINAL STRIP D


[semi-automatic doors]
semi-automatic doors
connections
TERMINAL STRIP D

0
CS1
DC
DO
EDO1
EDO1
CAM+ retiring cam
magnet
CAM-
LDAC door supply
NDAC 220V AC

CAL car lights (42V or 230V *)


* according to the customer request
PAL shaft lights (42V or 230V *)
COML * according to the customer request

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HYDRO-KLC

4.6 CONNECTION DRAWING OF FLOOR INDICATIONS


BCD

TO CONNECTOR KL27 (A) Α

TO CONNECTOR KL27 (B) B


TO CONNECTOR KL27 (C) C

TO TERMINAL STRIP Β (+24) +


TO TERMINAL STRIP Β (0V) -
4.7 CONNECTION DRAWING OF FLOOR INDICATIONS – BCD MODE
BCD
TO CONNECTOR KL27 (A) A
TO CONNECTOR KL27 (B) B
TO CONNECTOR KL27 (C) C
D

+
TO TERMINAL STRIP Β (0V) -

A
B
C
D

+
-
.....

A
B
C
D

TO TERMINAL STRIP Β (+24) +


-

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HYDRO-KLC

4.8 CAR CALLS – LANDING CALLS

LEVEL 0

CAR CALLS
TO CONNECTOR KL3 (C1)

LEVEL 1
TO CONNECTOR KL3 (C2)

LEVEL 2
TO CONNECTOR KL3 (C3)
..........

LEVEL 8
TO CONNECTOR KL4 (C8)

TO CONNECTOR KL5 (L1) LEVEL 0

LEVEL 1
TO CONNECTOR KL5 (L2) LANDING CALLS

TO CONNECTOR KL5 (L3) LEVEL 2


..........

LEVEL 7
TO CONNECTOR KL6 (L8)

TO TERMINAL STRIP Β (+24)

TO TERMINAL STRIP Β (0V)

Landing calls have to follow down collective automation.

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HYDRO-KLC

The control board needs information about the exact position of each floor and at the same time of each slow down
position.
This information is supplied to the control board thanks to the magnets. The magnetic switches are divided into two
categories with respect to the operation they accomplish:
1 Operational magnetic switches (CAA, CAB)
2 Zone magnetic switches (CAZA, CAZB).

1. Operational magnetic switches (CAA, CAB)

The two stylus magnetic switches (N.O.) CAA & CAB are activated from a
number of magnetic stripes, supplying signals to the main control board
about slow position and levels. The number of the magnetic stripes is
determined with respect to the number of levels.
[Magnetic stripes No.= (levels – 1) x 4].
Moreover, along with zone magnets they determine whether the re-
levelling operation will take place or not.
Level Operation magnetic switches CAA, CAB are connected to the revision box
and are mounted vertically (one above the other) on a special aluminium
holder. The holder on its turn is mounted on the topside of the car frame.
The corresponding magnetic stripes are 8cm in length and are mounted
vertically on the same rail where CAA & CAB are mounted.

In such a way that magnetic switches will be facing one of the rails of the
elevator.

Fitting the magnets.

Operational magnets are divided into two categories:


A) Levelling & re-levelling magnets
B) Slow down magnets

a. Levelling & re-levelling magnets


The car is positioned exactly at the bottom floor level. Having the car in this position one magnet is placed 3 – 5 cm
above top magnetic switch CAA and another one 3 – 5 cm below the bottom magnetic switch CAB (see figure). The
same is done for every floor. The indicated distance (3 – 5 cm) depends on the inertia of the system when moving
on low speed. Thus, this distance may vary from one system to another in order to achieve exact levelling of the car.
When the car is levelled, the magnetic switches CAA & CAB should be in between the two magnets.

b. Slow down magnets


First of all the desired distance, in which the car is to slow down, from high to low speed is calculated.
In hydraulic elevators this distance follows a one to one relation to the speed of the system. E.g. if full speed is U =
0.60m/sec then the distance should be S = 60cm. Thus, measuring from top magnetic switch CAA on a distance S
(as calculated) upwards we place one magnet. Correspondingly, on the same distance S below the magnetic switch
CAB we place another magnet.

This is done for every floor except the end floors. As stated further on the slow down magnets for the end floors are
replaced with the mechanical switches EM (up travel switch) and ED (down travel switch).

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Down travel switch

On the bottom floor, instead of placing a magnet for slowing down the car in the downward movement, a
mechanical switch is used. This is the bottom travel switch ED.

When this switch is cut (contact opens) it is ensured that the car will move further on downwards ιn low speed.
At the same time ED switch “informs” the control board that the car is near the bottom end of the shaft either
during RESET operation or NORMAL operation.

Up travel switch

On the top floor, instead of placing a magnet for slowing down the car in the upward movement, a mechanical
switch is used. This is the top travel switch EM.

When this switch is cut (contact opens) it is ensured that the car will move further on upwards ιn low speed. At

the same time EM switch “informs” the control board that the car is near the top end of the shaft either during
RESET operation or NORMAL operation.

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2. Zone magnetic switches (CAZA, CAZB)

The zone magnetic switches are:


a) CAZA (transport contact).
b) CAZΒ (Ν.Ο. contact)
The zone magnetic switches CAZA, CAZB are activated by a number of magnetic
stripes and “inform” the control board whether the car is situated on a level zone
or not. The number of magnetic stripes needed, is defined by the number of the
levels.
[Magnetic stripes No.= levels x 2].
Moreover, along with levelling & re-levelling magnets they determine whether the
re-levelling operation will take place or not.

Zone magnetic switches CAZA, CAZB are connected to the revision box and are
mounted one besides the other on a special aluminium holder. The holder on its
turn is mounted on the topside of the car frame in such a way that the magnetic
switch will be facing both sides of the same rail (see figures below). The
corresponding magnetic stripes are 20 cm in length and are mounted vertically on
both sides of the rail.

Fitting the magnets

For example, position the car exactly at the bottom floor level. Having the car in this position, two magnets (20
cm) are placed on both sides of the same rail, in such a way that the two magnetic switches are facing the
middle of the corresponding magnet. Follow the procedure above for each level.

Level

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006


5
In this particular example:
Length between 2 floors = 3m. Car's speed = 0,63m/sec.
1S
final limit
switch

7cm
LEVEL 3
LEVEL 3 1Β
20cm

EM

63cm

11cm
N.C.
Contact

3m
0V Higher floor

LEVEL 2
LEVEL 2

63cm
63cm

11cm
HYDRO-KLC

3m
intermediate floors
PLACING THE MAGNETS IN THE SHAFT
Electronic controller

LEVEL 1

63cm
LEVEL 1

63cm

11cm
ED

3m
lower floor
N.C.
Contact
LEVEL 0

63cm
LEVEL 0 0V
PAGE – 32 –

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11cm
Electronic controller PAGE – 33 –
HYDRO-KLC

5.1 FITTING THE MAGNETS IN THE SHAFT BLOCK DIAGRAM


Fit operational magnetic switches on aluminium holders

Fit zone magnetic switches on aluminium holders

Position car on bottom end level (level 0)

Place magnet 8cm above CAA magnetic switch

Place magnet 8cm under CAB magnetic switch Move to the next level

Place the 20cm magnet for magnetic switch CAZA NO

Is this the
Place the 20cm magnet for magnetic switch CAZB highest level ?

Position car on bottom end level (level 0) YES

Place down travel mechanical switch 60cm above level 0

Position car on level 1

Place magnet 60cm below level Move to the next level

ΟΧΙ

Place magnet 60cm over the level Is next level the


highest level ?

ΝΑΙ
Place up travel mechanical switch 60cm below last level

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RE-LEVELLING OPERATION WITH OPEN DOORS

The two operational magnetic switches, as already stated, they also take part in the re-levelling operation.
There is the possibility the car position, on a level with respect to the level to be altered due to loading or
unloading of the car.
This kind of movement is “realised” by magnetic switches CAA & CAB, informing the control board on which
direction the re-levelling movement should be done.
When the car is levelled the two magnetic switches CAA & CAB should be in between the magnets. When
CAA “sees” the top magnet of a level the control board “knows” that re-levelling movement downwards should
be done. Correspondingly, when CAB “sees” the bottom magnet, the control board performs relevelling
movement upwards. In order any relevelling movement to be performed by the control board, at the same time
both magnetic switches CAZA & CAZB should be inside the zone level. If not none correction movement is
eligible. Moreover, when CAZA & CAZB are inside the zone level then KLC02 board is able to bridge the safety
lane for the doors. Thus, relevelling can also be performed with doors opened.

Example:

On the specific level the car has stopped a few centimetres above the level. The

magnetic switches aren’t in between the magnets. CAA remains active, “sees” the
top magnet, informing the control board that re-levelling movement downwards
should be done. At the same time the car should be inside the zone level, as seen

in figure below.

level zone

CAZA

CAZB

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Re-levelling movements

When the car enters the zone of any level, magnetic switches CAZA & CAZB are activated at the same time by the
zone magnets. KLC02 board, on the main control panel, with respect to the incoming signal from CAZA, CAZB “decides”
if the car is on a zone level or not. In case it is, it feeds to the main board KLC01 the “RZONE” signal.

RZONE = car on a zone level

As long as the car is on a zone level, the control board, through KLC02 board can operate re-levelling movements with
either opened or closed doors.
KLC02 board is capable of bridging 6 & 10 of the main board safety lane upon reception of “SH8” signal from KLC01.
While KLC02 board receives SH8 signal, from KLC01, bridges the safety lane between 6 and 10. During the re-leveling
operation signals RZONE – SH8 should be present at the same time 6 and 10 of the safety lane should be carrying
110V AC.

SH8 = doors safety lane bridging


6 – 10.

Upwards re-levelling

In case of loading the car or due to piston oil loss (only in case of hydraulic elevators), the car may immerse with
respect to the level. Then the upwards re-levelling follows the following block diagram:

CAZA KLC02 CAZB

RZONE

SH8 KLC01
KLC01 Charges power relay
CAB Charges the relay of A48 valve

KLC02
NO bridges 6 & 10
safeties

RE-LEVELLING
FAILED

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Downwards re-levelling

In case of unloading the car, it may elevate with respect to the level. Then the downwards re-levelling follows the
following bloc diagram:

CAZA KLC02 CAZB

RZONE

SH8 KLC01
CAA KLC01
Charges the relay of A48 valve

KLC02
NO bridges 6 & 10
safeties

RE-LEVELING
FAILED

MOUNTING ZONE MAGNETS (RE-LEVELLING WITH OPEN DOORS).

In case the zone level is formed (not by 20cm magnets) by two or more magnets, their magnetic field should be
taken into account.
They all have to produce the same polarity of magnetic field towards the magnetic switches.

Same polarity on two magnets forces them apart Place the magnets on the rails with the
same polarity facing the rail
Don’t forget than the EN-81 part 1 & 2 Standard § 7.7.1, amended by
British national variation BS 5655 § V.3.14 requires that:
7.7.1 PROTECTION AGAINST THE RISK OF FALLING
It shall not be possible in normal operation to open a landing door (or any of the panels in the case of a multi-
panel door), unless the car has stopped, or is on the point of stopping, in the unlocking zone of that door.
The unlocking door shall not extend more than 0,20 m above and below the landing level.
In the case, however, of mechanically operated car and landing doors operating simultaneously, the unlocking
zone.

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HYDRO-KLC

CONTROLLER KLC
CONTENTS
§ Title page
1 Certificates of KLC01 2

2 General discussion on KLC controller 6

3 Main controller board devices 7

3.1 Placement of KLC01 fuses 8


3.2 LEDs & jumpers position on KLC01 board 9
3.3 Emergency evacuation board KD – 20 10
3.4 Re-leveling board KLC02 11
3.5 Fault finding tool – error finding 12
Fault finding tool 12
Parameter settings 13
KLC controller faults 15

Terminal strip analysis 18


4 Connection diagram of various types of controller-motor coupling 19
4.1 Terminal strips of the KLC controller 20
4.2.1 Connection diagram of terminal strip A 21
[safety chain & pre-finals connections – automatic car door]
4.2.2 Connection diagram of terminal strip Α 22
[safety chain & pre-finals connections – semi-automatic car door]
4.3 Connection diagram of terminal strip B 23
[tank’s connections]
4.4 Connection diagram of terminal strip C 24
[car’s connections]
4.5.1 Connection diagram of terminal strip D 25
[automatic doors]
4.5.2 Connection diagram of terminal strip D 26
[semi-automatic doors]
4.6 Connection drawing of floor indications 27
4.7 Connection drawing of floor indications – BCD mode 27
4.8 Car calls – landing calls 28
1. Operational magnetic switches (CAA, CAB) 29
2. Zone magnetic switches (CAZA, CAZB) 31

5 Placing the magnets in the shaft 32


5.1 Fitting the magnets in the shaft block diagram 33
Re-levelling operation with open doors 34

Drawings

MANUAL HYDRO-KLC_GB _Version 1.03 20/02/2006

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