VCI PLCTractionUserManual(Rev 2 00)

2009

ProgrammableLogicController(PLC) BasedTractionControllerUserManual

VirginiaControls,Inc.2513MechanicsvilleTurnpike Richmond,Virginia23223

Tel:(804)2255530 Fax:(804)2250116

email:[email protected] website:www.vacontrols.com Revision2.00

TABLEOFCONTENTS1. PREINSTALLATIONINSTRUCTIONSANDNOTES................................................11.1 1.2 GENERALNOTES.........................................................................................................................1 IMPORTANTPRECAUTIONSANDNOTES............................................................................................1

2. CONTROLLERINSTALLATIONANDWIRING........................................................32.1 CONTROLLERINSTALLATION...........................................................................................................3 2.1.1 ControllerLocationSelectionandEnvironment..........................................................................3 2.1.2 ControllerGrounding ..................................................................................................................4 . 2.2 CARANDHOISTWAYWIRING.........................................................................................................4 2.2.1 FloorSwitches.............................................................................................................................4 2.2.2 CarTopSelector..........................................................................................................................5 2.2.3 LevelingSwitches.............................................................................................................................5 2.2.4 TerminalLandingNormalSlowdownLimitSwitches..................................................................5 2.2.5 TerminalLandingNormalLimitSwitches....................................................................................5 2.2.6 TerminalLandingFinalLimitSwitches........................................................................................6 2.2.7 EmergencyTerminalLandingLimitSwitch .................................................................................6 . 2.2.8 HoistwayAccessZoneSwitches..................................................................................................6 2.2.9 DoorOpenandCloseLimitSwitches...........................................................................................6 2.3 MACHINEROOMWIRING.............................................................................................................7 2.3.1 IncomingPower...........................................................................................................................7 2.3.2 Grounding...................................................................................................................................7 2.3.3 MotorWiring...............................................................................................................................8

3. STARTUPINSTRUCTIONS..................................................................................93.1 BEFOREAPPLYINGPOWER............................................................................................................9 3.1.1 PowerandGrounding.................................................................................................................9 3.1.2 Input/OutputWiring...................................................................................................................9 3.2 APPLYINGPOWER .....................................................................................................................10 . 3.2.1 MotorRotation .........................................................................................................................10 . 3.2.2 MotorTiming............................................................................................................................10

4. FINALADJUSTMENTS....................................................................................... 1 14.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 INSPECTIONOPERATION.............................................................................................................11 FLOORPOSITIONANDSLOWDOWN...............................................................................................11 POSITIONINDICATORS................................................................................................................11 INDEPENDENTSERVICE...............................................................................................................12 CARANDHALLCALLS.................................................................................................................12 DOOROPERATION.....................................................................................................................12 FIRESERVICE............................................................................................................................13 ZONEDDUPLEX.........................................................................................................................13CommonCircuits.......................................................................................................................13 NextCar.....................................................................................................................................13 CarStart....................................................................................................................................14

4.8.1 4.8.2 4.8.3

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4.8.4 Homing......................................................................................................................................14 4.8.5 Communication.........................................................................................................................14 4.9 FAILURETIMERS........................................................................................................................17 4.9.1 StuckButtonTimer....................................................................................................................17 4.9.2 RunningTimers .........................................................................................................................17 . 4.9.3 DoorFaultTimers......................................................................................................................17 4.9.4 DoorCheckCircuitry..................................................................................................................17 4.10 FIELDADJUSTABLEFEATURES.......................................................................................................18 4.11 TYPICALTRACTIONADJUSTMENTS................................................................................................18

5. HARDWAREDESCRIPTION................................................................................ 9 15.1 MICROPROCESSORSYSTEM.........................................................................................................195.1.1.1 5.1.1.2 5.1.1.3 5.1.1.4

GESeries9030 .........................................................................................................................19 . GESeries9030CPU ............................................................................................................................20 . GESeries9030PowerSupply.............................................................................................................22 GESeries9030InputandOutputModules........................................................................................23 GESeries9030Connections...............................................................................................................24 5.1.2 AllenBradleySLC500MicroprocessorSystem.........................................................................26 5.1.2.1 AllenBradleySLC500CPU...................................................................................................................27 5.1.2.2 AllenBradleySLC500PowerSupply...................................................................................................32 5.1.2.3 AllenBradleySLC500InputandOutputModules..............................................................................33 5.1.2.4 AllenBradleySLC500Connections.....................................................................................................35 5.1.3 AllenBradleyMicroLogix1500MicroprocessorSystem...........................................................36 5.1.3.1 AllenBradleyMicroLogix1500CPU....................................................................................................36 5.1.3.2 AllenBradleyMicroLogix1500BaseUnits..........................................................................................37 5.1.3.3 AllenBradleyMicroLogix1500InputandOutputExpansionModules...............................................38 5.1.3.4 AllenBradleyMicroLogix1500DataAccessTool................................................................................39 5.1.4 AllenBradleyCompactLogixMicroprocessorSystem...............................................................40 5.1.4.1 AllenBradleyCompactLogixControllers.............................................................................................40 5.1.4.2 AllenBradleyCompactLogixCompactFlashCard................................................................................42 5.1.4.3 AllenBradleyCompactLogixBattery...................................................................................................43 5.1.4.4 AllenBradleyCompactLogixPowerSupply.........................................................................................44 5.1.4.5 AllenBradleyCompactLogixInputandOutputModules....................................................................44 5.1.5 AllenBradleyControlLogixMicroprocessorSystem..................................................................46 5.1.5.1 AllenBradleyControlLogixControllers................................................................................................46 5.1.5.2 AllenBradleyControlLogixCompactFlashCard ..................................................................................47 . 5.1.5.3 AllenBradleyControlLogixChassis......................................................................................................48 5.1.5.4 AllenBradleyControlLogixPowerSupply ...........................................................................................50 . 5.1.5.5 AllenBradleyControlLogixInputandOutputModules.......................................................................51 5.2 POWERSYSTEM........................................................................................................................52 5.2.1 Transformers.............................................................................................................................52 5.3 SAFETYINTERFACEBOARD ..........................................................................................................53 . 5.3.1 DigisetTimers............................................................................................................................53 5.3.2 BypassSwitches........................................................................................................................54 5.3.3 InspectionSwitches...................................................................................................................54 5.3.4 CutoutSwitches.........................................................................................................................55 5.3.5 UDTXPotentiometer.................................................................................................................55

5.1.1

6. CONTROLLERNOMENCLATURE........................................................................ 6 5


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7. PARTSLIST....................................................................................................... 7 5 8. CONTROLLERDIAGNOSTICS............................................................................. 0 68.1 8.2 8.3 PLCMODE..............................................................................................................................60PuttingthePLCinRunMode(GESeries9030)........................................................................60 8.1.1

FACTORYRESET.........................................................................................................................60 CHANGESETTINGS.....................................................................................................................61

8.3.1 ChangeSettingswithaGESeries9030HandHeldProgrammer............................................61 8.3.2 ChangeSettingswiththeGELogicmasterSoftware.................................................................62 8.3.3 ChangeSettingswithJumpers..................................................................................................62 8.3.4 StandardSettings......................................................................................................................64 8.3.5 StandardFeatures.....................................................................................................................68 8.4 FAULTLOGGING........................................................................................................................74 8.4.1 ExaminingtheFaultTablewithaGESeries9030HandHeldProgrammer ............................74 . 8.4.2 FaultLogStatusCode................................................................................................................75 8.4.3 FaultLogMemoryAddresses....................................................................................................77 8.4.4 FaultLogCodes.........................................................................................................................78 8.5 GESERIES9030HANDHELDPROGRAMMERINSTRUCTIONS...........................................................80 8.5.1 SequencetoChecktheStatusofaCoil. ....................................................................................80 . 8.5.2 ToChangetheValueofaRegisterorStatusofaCoil...............................................................80 8.5.3 ToResettheAdjustableValuestotheFactoryDefault.............................................................80 8.5.4 ToChangetheDATE/TIME........................................................................................................81

9. TROUBLESHOOTINGSUGGESTIONS.................................................................. 2 89.1 9.2 9.3 LOCATINGFAULTS.....................................................................................................................83 I/OBOARDREMOVAL(GESERIES9030).....................................................................................83 FACTORYASSISTANCE.................................................................................................................84

10. CONTROLLERMAINTENANCE........................................................................ 5 810.1 CPUMODULEEXCHANGE...........................................................................................................85 10.2 EPROMMEMORYEXCHANGE....................................................................................................85 10.3 INPUT/OUTPUTBOARDEXCHANGE...............................................................................................87

11. FREQUENTLYASKEDQUESTIONS .................................................................. 8 . 811.1 QUESTIONSONFIELDDEVICES.....................................................................................................88 11.2 QUESTIONSONTHECONTROLLER.................................................................................................88

12. TABLEOFFIGURES........................................................................................ 9 8 13. INDEX ........................................................................................................... 1 . 9


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1. PreInstallationInstructionsandNotes1.1 GeneralNotesItisstronglyrecommendthatyoureadthismanualcarefullybeforeproceedingwiththeinstallation. ImportantinformationishighlightedbytheheadingsWARNING,CAUTION,orNOTE.Thesewordsare definedasfollows: WARNINGWarningsareusedtoindicateinstructionswhich,ifnotfollowedcorrectly, willprobablyresultinpersonalinjuryorsubstantialdamagetoequipment. CAUTION Cautions are used to indicate instructions or information which, if not observed,mayresultinsomedamagetoequipmentifcareisnottaken. NOTE Notes are used to indicate instructions or information which is especially helpful in understanding and operating the equipment, and which will usually speed uptheinstallationprocess.

1.2 ImportantPrecautionsandNotesThefollowinggeneralrulesandsafetyprecautionsmustbeobservedforsafeandreliableoperationof yoursystem. WARNING: If you need to change the EPROM program chip on the CPU, make sure youreadtheinstructionsandknowexactlyhowtoinstallthenewchip.Pluggingthe EPROMchipinupsidedownmaydamagethechip.Staticelectricitycandamagethe EPROM,soavoidtouchingthepinsonthechip,andgroundyourself(bytouchingthe controller cabinet) before touching the chip or the controller. Do not expose the EPROM program chip to bright light, and do not remove the label over the EPROM programchipwindow. WARNING:Theelevatorcontrollermustbeinstalledbyexperiencedfieldinstallation personnel. The field installation personnel must know and follow all the rules and regulations pertaining to the safe installation and running of elevators. Additional informationforspecificdevices(suchasthedooroperator,etc.)istheresponsibilityof themanufacturersofthosedevices. WARNING: This equipment is designed and built to comply with ANSI A17.1, ASME A17.5 and CAN/CSA B44.1 and must be installed by a qualified contractor. It is the responsibilityofthecontractortomakesurethatthefinalinstallationcomplieswith allapplicablelocal,stateandnationalcodes,andisinstalledsafely.


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WARNING:The3phaseACpowersupplytothisequipmentmustcomefromafused disconnect switch or circuit breaker which is sized in accordance with all applicable national, state and local electrical codes, in order to provide the necessary branch circuit protection for the controller and motor. Incorrect motor branch circuit protectionmaycreateahazardouscondition. WARNING:Propergroundingisvitalforthesafeoperationofyoursystem.Bringthe ground wire to the ground stud that is labeled "GND" or "G". You must choose the properconductorsize.Seenationalelectricalcodearticle25095,ortherelatedlocal applicablecode. Payspecialattentiontopointshighlightedinthismanner.Theyareofspecial considerationandarefrequentlyoverlooked.


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2. ControllerInstallationandWiring2.1 ControllerInstallation2.1.1 ControllerLocationSelectionandEnvironmentMountthecontrollerinalocationthatprovides: Forimprovedcontrollerreliability: Keepthemachineroomclean. Donotinstallthecontrollerinadustyarea. Donotinstallthecontrollerinacarpetedarea,orareawherestaticelectricityisaproblem. Keeproomtemperaturebetween0Cto50C(32Fto122F),and95%noncondensingrelative humidity.Extendedhightemperatureswillshortenthelifeofelectroniccomponents.Provide adequateventilationorairconditioningasrequiredifnecessary. Avoidcondensationontheequipment.Keepthecontrollerawayfromsourcesofcondensationand water(suchasopenwindows)asthesecancreateahazardousconditionandcandamagethe equipment. Donotinstallthecontrollerinahazardouslocationandwhereexcessiveamountsofvaporsor chemicalfumesmaybepresent.ANEMA12,NEMA4orNEMA4Xratedenclosurecanbeprovided ifnecessary. Makesurepowerlinefluctuationsarewithin10%. HighlevelsofradiofrequencyemissionsmaycauseinterferencewiththecontrollerMicroprocessor, andproduceunexpectedandevendangerousresults.Thiscouldbecausedbyhandheld communicationsdevicesusednearthecontroller. adequatesupportfortheweightofthecontroller, adequatelightingforinstallationandmaintenance, convenientaccessfortheroutingofrequiredconduitsandcables, convenientaccesstootherdevicesinthemachineroom, aminimumofvibration(supplyadditionalbracingorreinforcementifrequired).


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2.1.2 ControllerGroundingGroundingofthecontrollermustconformtoallapplicablecodes.Propergroundingis essentialtothesafeoperationoftheequipment.Itwillalsoreducethelikelihoodofnoise inducedproblems,whichcouldincludeCPUcrashes,orI/Ocommunicationerrors. Thegroundingwireshouldbesizedpertheapplicablecodes.

Connectthegroundtoagoodbuildingground,suchasthestructuralsteelofthe building,oracoldwaterpipe.

2.2 CarandHoistwayWiringReviewtheschematicsandfieldwiringdiagramsbeforeattemptingtohookupthecontroller.

2.2.1 FloorSwitchesTheFloorSwitches,ifused,arenormallyopencontactsthatshouldcloseundereachofthefollowing conditions: 1. thecarisattheslowdownpointabovethefloor,OR 2. thecarisattheslowdownpointbelowthefloor,OR 3. thecarisatthefloor(optional),OR 4. thecarisbetweentheupanddownslowdownpointsofthatlanding(optional). Conditions(1)and(2)arerequiredtochangethefloorrelaysandinitiateslowdown.Condition(3)is requiredattheterminallandings,butisoptionalattheintermediatelandings.Condition(4)isoptional. Therearemanyacceptablemethodsofprovidingthefloorswitchsignals,suchasbyhavingasingleFloor Switchatfloorlevel,andanadjustablelengthcamonthecar,orbyhavingtwoFloorSwitchesperfloor, andafixedlengthcamonthecar.TheFloorSwitchesmaybemountedonthecariftheyareinseparate rows.Itisrecommendedthatthemethodusedallowforseparateadjustmentoftheupanddown slowdowndistances. NOTE:Recommendedslowdowndistanceisabout6"forevery25fpmofcarspeed,for speedsofupto200fpm.Minimumrecommendedtargetlengthforthefloorswitches is1". Ifthereareshortfloors,refertotheschematicforspecialinstructions,ifrequired. NOTE:TheterminallandingFloorSwitchesmustbemaintainedwhilethecariswithin doorzoneoftheterminallanding.


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2.2.2 CarTopSelectorThepulsingtypeCarTopSelectorprovidesFloorChange/SlowdownsignalsandLevelingsignals,asshown onthecartopselectorsheetintheschematic.Thesignalsshouldbeanormallyopencontactthatclosesas describedbelow. 1. UPSLOWDOWNclosesattheSlowdowndistancebelowthefloor.Thissignalisrepeatedforeach speedrequiredforfastercars,orforshortfloorconditions.(Refertotheschematic) 2. DOWNSLOWDOWNclosesattheSlowdowndistanceabovethefloor.Thissignalisrepeatedfor eachspeedrequiredforfastercars,orforshortfloorconditions.(Refertotheschematic) 3. UPandDOWNLEVEL,andDOORZONE/LOWLEVEL.(See"LevelingSws") NOTE:Recommendedslowdowndistanceisabout6"forevery25fpmofcarspeed,for speedsofupto200fpm.Minimumrecommendedtargetlengthforthefloorswitches is1". Anextraresettargetisrequiredateachterminallanding,asshownontheschematic,sothatthe UpSlowdownSwitchisclosedwhenthecarisinthelevelingzoneatthetoplanding,andthe DownSlowdownSwitchisclosedwhenthecarisinthelevelingzoneatthebottomlanding. Thesetargetsareusedtoresetthefloorpositionattheterminallandings. Iffullspeedisnotachievedonaonefloorrun,thenadditionalslowdownsignalsmayberequiredfor differentspeeds.Thismayapplytohighspeedcars,ortoinstallationswithshortfloors.Refertothe Selectorinstallationsheetintheschematicfortheexactrequirementsfortheselectorforeach particularinstallation.

2.2.3 LevelingSwitchesTheUpLevelSwitchisanormallyopencontactthatcloseswhenthecarisinthelevelingzonebelowthe floor,andtheDownLevelSwitchisanormallyopencontactthatcloseswhenthecarisinthelevelingzone abovethefloor.AdjustthedistancebetweentheUpLevelSwitchandtheDownLevelSwitchtobeequal tothelengthofthelevelingvane/targetplusthedesiredDeadZonedistance(usually1/4"to1/2").The actuallengthofthelevelingtargetisnotcritical(exceptinsomeshortfloorsituations)andisusually610". Positionthelevelingvane/targetsothatwhenthecarisfloorleveltheUpandDownLevelingSwitchesare centeredaroundthevane/target,andbothswitchesareopen. TheDoorZoneSwitchisaswitch(orswitches)activatedbythelevelingvane/targetwhenthecariswithin 3"offloorlevel.Ifthelevelingvane/targetis6"long,thenonlyoneswitchisrequired,mountedbetween theUpandDownLevelingSwitches,otherwisetwoswitcheswiredinseriesshouldbeprovided.

2.2.4 TerminalLandingNormalSlowdownLimitSwitchesTheTerminalLandingNormalSlowdownLimitSwitchisanormallyclosedcontactthatopenswhenthecar isclosertoaterminallandingthantheminimumslowdowndistance.Itwillpreventthecarfromrunning intotheterminallandingatfullspeed.Itshouldbeadjustedtoopenapproximatelyoneinchbeyondthe pointwherethenormalslowdown(fromthefloorswitchesorthecartopselector)isinitiated.

2.2.5 TerminalLandingNormalLimitSwitches PLCTractionControllerUserManual Page5

TheTerminalLandingNormalLimitSwitch(sometimescalledaDirectionalLimitSwitch)isa normallyclosedcontactthatopenswhenthecarhastraveled1"pastfloorlevelataterminal landing.ThecarshouldnotbeontheTerminalLandingNormalLimitSwitchwhenthecaris floorlevelattheterminallanding.TheLimitSwitchwillpreventthecarfromtravelingfurther awayfromthenormalareaofcartravel,butallowsthecartorunbacktowardsthenormalareaofcar travel.

2.2.6 TerminalLandingFinalLimitSwitchesTheTerminalLandingFinalLimitSwitch,whererequiredbycode,isanormallyclosedcontactthatopens whenthecarhasgoneaconsiderabledistancebeyondfloorlevelataterminallanding.Itwillpreventany furthermovementofthecarineitherdirection.Consulttheapplicablecodesforthepropersettingofthis switch.

2.2.7 EmergencyTerminalLandingLimitSwitchTheEmergencyTerminalLandingSlowdownSwitchshouldbeinstalledasrequiredbytheapplicable codes.ItisanormallyclosedcontactthatopensafterthecarhasgonebeyondtheTerminalLanding NormalLimitSwitch.

2.2.8 HoistwayAccessZoneSwitchesTheHoistwayAccessLimitSwitcheslimitthemotionofthecaronHoistwayAccess,bydisablingthecar ifitmovesawayfromtheaccessfloor.Installthezoneswitchestostopthecarfromrunningdownifthe topofthecargoesbelowfloorlevelatthetopaccessfloor,andtostopthecarfromrunningupifthe cargoesabovethesecondfloorwhileonHoistwayAccessatthebottomfloor.

2.2.9 DoorOpenandCloseLimitSwitchesTheDoorOpenLimitSwitchisopenwhenthedoorsarefullyopen,andclosedatallothertimes.Itwill deenergizethedooropenrelaysinthedooroperatorwhenthedoorshaveopenedfully. TheDoorCloselimitSwitchisopenwhenthedoorsarefullyclosed,andclosedatallothertimes.Itwill deenergizethedoorcloserelaysinthedooroperatorwhenthedoorshaveclosedfully. NOTE:ManyproblemsinoperationcanbeattributedtofailuresintheDoorOpenor Close Limit Switches (including long door times, improper door operation on Fire Service,inabilitytogoontoortoclearFireService,etc.)AlwayschecktheDoorOpen andCloseLimitSwitchesifunusualoperationoftheelevatorisobserved. NOTE:ItisrecommendedthattheDoorCloseLimitSwitchbeadjustedsothat,asthe doors are closing, the Car Door Contact closes before the Door Close Limit opens. ConsulttheDoorOperatorManufacturer'sinstallationinstructionsforfurtherdetails ontheadjustmentofthedoors. NOTE:2000(orlater)codecompliantcontrollerswillnotrunwithouttheDoorClose Limitoperationproperly. NOTE: If a solid state door operator unit is being used, check the appropriate schematics to see if any changes are required on the actual operator. These may PLCTractionControllerUserManual Page6

include changing resistors in the operator, and adding a diode for proper open and closetorque.

2.3 MachineRoomWiringMountthecontrollerfirmlyandinstallallrequiredconduitsbeforewiringthecontroller.Notewhere ducthasbeenprovidedinthecontrollerforcustomeraccess,beforedecidingwheretolocateconduit openings. WARNING:Donotallowanymetalshavingstogetintorelaysorcontactors,orinor behindtheelectroniccomponents,asthesecouldcauseseriousdamagetopersonnel ortheequipment.

2.3.1 IncomingPowerWARNING:The3phaseACpowersupplytothisequipmentmustcomefromafused disconnect switch or circuit breaker which is sized in accordance with all applicable national, state and local electrical codes, in order to provide the necessary overload protectionforthecontrollerandmotor.Incorrectmotorbranchcircuitprotectionmay createahazardouscondition. IncomingACpowerwiringshouldbedonebyaqualifiedandlicensedelectrician,usingtheappropriate sizewiresfortheinstallation.Considerthemotorsizeandtypeofstarter,andalsothelengthofwire requiredfromthemainpowerdistributioncenterindeterminingtheproperwiresize. Properbranchcircuitprotectionanddisconnectdevice(s)mustbeprovided,asrequiredbyapplicable local,stateandnationalcodes.

2.3.2 GroundingWARNING:Propergroundingisvitalforthesafeoperationofyoursystem.Bringthe groundwiretothegroundstudthatislabeled"GND"or"G1".Youmustchoosethe proper conductor size and minimize the resistance to ground by using shortest possible routing. See national electrical code article 25095, or the related local applicablecode. Propergroundingisvitalforthesafeoperationofyoursystem,andwillalsoreducethelikelihoodof noiseinducedproblems,whichcouldincludeCPUcrashes,orI/Ocommunicationerrors. Thegroundingwireshouldbesizedpertheapplicablecodes. Connectthegroundtoagoodbuildingground,suchasthestructuralsteelofthebuilding,oracold waterpipe. Connectthegroundonthecontrollertothestudlabeled"GND"ortheterminal"G1",asshownon thecontrollerschematic.


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2.3.3 MotorWiringConnectthemotorasshownontheschematic.Consulttheapplicablecodesforproperwiresizingand circuitprotectionforthemotorbeingused.


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3. StartUpInstructionsTractionsystemsshouldnotberunintemporarymode,butshouldusethePLCtoprovideallrequired signalsforrunningthecar.Otherwiseproceedthrougheachofthesestepsandchecksbeforeapplying power.

3.1 BeforeApplyingPowerThesystemhasbeenprogrammedandtestedforthespecificelevatorsystem,sonofurtherchanges shouldbemadewithoutconsultingwithVirginiaControls.

3.1.1 PowerandGroundingWARNING: Confirm that the voltage of the incoming power matches the controller beforeapplyingpowertothecontroller. Checkthesystemforimpropergroundsbeforeapplyingpowertothecontroller. Withthepoweroff,removethefusesfromthesecondaryofthemaincontrolcircuittransformer ("CCXF").Checkthesafetycircuit(terminals1through6,and14,16,18,19)forgrounds.UsingaVolt Ohmmeterconnectoneleadtoterminal35(ground)andtouchtheotherleadtoeachterminaltobe tested.Theresistanceshouldbeconsiderablygreaterthan100ohms. NOTE:Ifthefusesarenotremoved,themeterwillreadashortthroughthewindings ofthemaincontrolcircuittransformer. Withthefusesstillremoved,applypowertothecontroller,andverifythatthevoltageatthesecondary ofthemaincontrolcircuittransformer("CCXF")is110125VAC.

3.1.2 Input/OutputWiringNOTE:Theinput/outputboardsareequippedwithquickdisconnectterminalblocks. Duringtheinitialinstallation,youmaywanttoremovetheterminalblocks,hookup yourfieldwirestotheterminalblocks,testthefieldwiringfornoshortstogroundor hot(terminal1)beforepluggingtheseterminalsbackintotheI/Oboards. Withthepoweroff,andthefusesremoved,checkeachinputpointforgrounds,asdescribedinthe previoussection,"PowerandGrounding".Ifagroundisobserved,checktheschematictodetermineif thisiscorrect(itusuallyisNOT!). Withthepoweroffcheckeachoutputforgrounds,alsocheckforshortstothehotside(terminal1). Notethatsomefielddevices,suchasbuzzers,willhaveverylowresistance. WARNING:Eachoutputpointshouldbeisolatedfromgroundandthehotside.


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3.2 ApplyingPowerRemoveallfusesbeforeapplyingpower.Reinsertthefuses,onecircuitatatime,checkingeachcircuit beforeaddingthenext.Checkforthepropervoltageatthetopofeachfuseholderbeforeinstallingthe fusesforthatcircuit. ItisrecommendedthatyoustartupthecontrollerinInspectionmode,whichcanbedonebyopening theInspectionSwitch,orremovingthefieldwire(s)fromterminal23. WhenpoweristurnedontotheprogrammablecontrollerthePower,OKandRUNlightsonthePower Supplyshouldcomeon.Theprogrammemoryisprom(ProgrammableReadOnlyMemory),sodoesnot requirethebatterytomaintainit. WARNING: The field wire in terminal 23 is HOT. If it is removed, make sure it is insulated and labeled. Reconnect it when the car is to be taken off Inspection Operation.

3.2.1 MotorRotationOntractionsystemswithanMGset,checkfortheproperrotationoftheMGDrivemotorandthe Hoistmotor.Alsonotethepolarityoftheloopconnectionsasshownontheschematic.Confirmthatthe polarityofthetachometersignal,ifused,iscorrect. IfaReversePhaserelayisprovided,checkthattheOKlightisonwhenpowerisappliedtoit.IftheOK lightisnoton,thenreverseanyonthetwowiresconnectedtotheA,B&Cterminals.

3.2.2 MotorTimingTRUPRunTimer.(usedwithWyeDeltastartersonly)Itisenergizedpresettimeafterthemotor startstorunandchangestheconnectionofthemotorfromWyetoDelta.Therecommended settingis5.0secondsforMGsets(seethestartersheet).


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4. FinalAdjustmentsWhenthecontrollerisreadytoberuninautomatic,itisrecommendedthatafactoryresetbe performed.Thiscanbedoneby(1)Turningoffthepower;(2)Putthecaroninspection;(3)Jump terminals1to21and1to22;(4)TurnonthepoweruntiltheRunlightonthePowerSupplyhascome on;(5)Turnoffthepower,andremovethejumpers,andcontinueasnormal. Asthewiringiscompleted,thefollowingmodesofoperationcanbecheckedandused.

4.1 InspectionOperationTorunthecaronInspectionOperation,thesafetystring(includingthedoorcontacts,terminallanding normalslowdowns,normalsandfinals)shouldbeoperational. TheDoorsClosedrelay(DC)shouldbeenergized,andthecorrespondinginputontheI/Oboardshould beon. TheInspectionInput(normallyInputA3)shouldbedeenergized. PressingtheUpRunandRunButtonswillenergizethe1stLandingCarCallButtonInput,whichwill causetheUpDirectionandDoorCloseoutputstocomeon. WhentheDoorsClosedinputcomeson,theuprunoutputswillenergize,andthecarwillrunup. (Downdirectionissimilar)

4.2 FloorPositionandSlowdownTheprogramisinPROM(ProgrammableReadOnlyMemory).Thefloorrelaysandfireservicerelaysare maintainedintheMicroprocessorRAMmemoryandareheldthroughpowerlossbythebatteryinthe PowerSupply.Thefloorrelaysmayneedtoberesetwhenthecontrollerisinitiallyinstalled.Thiswillbe accomplishedwhentheelevatorhitsanyfloorswitch.Withapulsingtypeselector,thefloorpositionis resetateitherterminallandingwhenaslowdownswitchandalevelingswitchareenergizedatthesame time. NOTE:Iffloorswitchesareused,theyshouldbemaintainedattheterminallandings, sothattheyareenergizedwheneverthecarisintheslowdownzoneatthatlanding. Makeyourfinaladjustmentsfortheslowdowntargets.Allslowdowndistancesshouldbeequal. Ifapulsingselectorarrangementisused,remembertoinstalltheresettargetsattheterminallandings.

4.3 PositionIndicatorsVerifythatthefloorpositionchangesproperlyasthecargoespasteachlanding.Floorchangeshould takeplaceattheslowdownpointbeforeeachlanding. IfthePositionIndicatordoesnotmatchtheactualcarposition,runthecartoaterminallandingreset target(withpulsingselectoronly).


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4.4 IndependentServiceIndependentServiceisusefulforfinaltuneupofthecar.InitiateIndependentServicebyturningonthe IndependentServiceSwitchinthecar,orbyjumpingtheIndependentServiceSwitchinput. OnIndependentService,thehallcallswillbeignored.Thecarwillrunfromcarcallsonly,andwillpark withthedoorsopen.Toclosethedoors,jumpterminal1toterminal28("DoorCloseButton"input). Thisjumpermaybelefton,ifdesired,sothatthecarmayberunbyjumpingthedesiredcarcallinput. NOTE:Torunthecarfromthemachineroom,withoutthedoorsopening,removethe wirefromtheDoorOpenLimitSwitchInput(whichisusuallywiredtoterminal7X). NOTE: If the car does not run, verify that no door protective device (Door Open Button, Safety Edge, Electric Eye, Infrared Curtain) is holding the doors open. Verify that the car is not stuck in leveling. Verify that the Door Close Button input is energized.

4.5 CarandHallCallsToobservetheoperationofthecarandhallcalls,thesystemmustbeinautomaticoperation.Verify thatallcarandhallcallswork. NOTE:OnDUPLEXsystemsthedoorsmustbeallowedtooperateforthecallstobe canceledproperly. Eachcallwillbecanceledwhenthecarinitiatesslowdownforthecall,orwhenthedoorsstarttore openforthecallifthecarisalreadyatthefloor. Ifbothhallcallsareenteredatanintermediatelanding,andnoothercallsareinthesystem,thedoors willcloseafteransweringoneofthecalls,thenreopeninresponsetotheothercall.

4.6 DoorOperationVerifythatanyrequiredchangestothedooroperator,asshownonthedooroperatordrawings,have beenmadecorrectly. ChecktheDoorOpenandCloseLimitsforproperoperation. Ifthedoorsattempttoopenfortoolong,theopencyclewillbestopped.Thecarwillthenrespondto othercalls,andtrytoopenthedoorsagain. Ifthedoorsfailtocloseproperlywithinapresettime,thedoorswillreopen,andtrytocloseagain.If thedoorsclosed,butthecardoesnotruninresponsetoacall,thedoorswillrecycle,andthecarwill tryagain. Forveryslowdoors,theDoorStuckTimer,whichinitiatestheDoorOpenandDoorCloseFail,as describedabove,mayneedtobeincreased.Itisnormallysetat15seconds. IfNudgingOperationisactivated,theElectricEyewillbedisabledwhentheNudgingTimerhastripped ANDthedoorsarefullyopen.Ifthenudgingtimertripswhilethedoorsareclosing,theNudgingBuzzer PLCTractionControllerUserManual Page12

willturnon,andtheElectricEyewillremainactive.Ifthedoorsdoreopenfully,thentheElectricEye willbecutout.TheSafetyEdgeInputremainsactiveonnudging.

4.7 FireServiceFireServicePhase1maybeinitiatedbyturningoffaSmokeSensorinput,orbyenergizingtheHallFire Switch"On"input. ConfirmthatthecarreturnstothecorrectMainandAlternatelandings. ConfirmthatthecaroperatesasrequiredonCarFireService(Phase2)operation. NOTE: To reset Hall Fire Service (Phase 1), most codes require the Bypass input be energized. To disable Hall Fire Service, jump the Hall Bypass input on. On 2000 (or later)FireCode,FireService(Phase1)isresetwhentheHallFireSwitchisturnedfrom BypasstoOff. NOTE:IfCarFireService(Phase2)appearstobeoperatingincorrectly,checktheDoor Open and Close Limits for proper operation. Most codes require that the doors be fully open before allowing a change in the mode of operation on Car Fire Service. Most codes require that Hall Fire Service (Phase 1) be in effect for the car to return automatically to the main fire landing when the Car Fire Switch is turned to the off position.

4.8 ZonedDuplexTheDuplexSystemwillkeeponecarattheMainDispatchLanding,astheLobbyCar,andallowtheother car,ortheFreeCar,tostopatitslastcall.TheLobbyCarwillanswercallsintheLobbyZone,andthe FreeCarwillanswerallothercalls.TheLobbyCarmayleavethelobbytoassisttheFreeCarunder variousloadconditionsasdescribedbelowunderStartControl.The"LobbyZone"isanadjustablegroup oflandingsbutthefactorypresetvalueisnormallytheLobby/Mainlandingandanylandingsbelowthe Lobby/Mainlanding.Allotherlandingsareinthe"UpperZone".Ifacaris"Next"inazone,thenitwill answercallsinthatzone,otherwiseitwillanswercallsintheotherzone.Ifbothcarsareinservice,acar willalwaysbehomedtotheMainLobbylevel.

4.8.1 CommonCircuitsSeveralcircuitsneedtobeenergizedwheneithercarison.TheseincludetheHallCalls,FireService,and someothercircuitsthatmayberequiredforaparticularjob(suchasEmergencyPower,Hospital Service,etc.).ThesecircuitsgettheirpowerfromeithercarbymeansoftheVR(Voltage)relay(seethe schematic).

4.8.2 NextCarA"NextCar"isselectedfortheLobbyZoneandtheUpperZone.Thiscarwillbeassignedhallcallsinthe respectivezone.Theothercarmayanswercallsinazonewhereitisnot"Next",butitwillnotnormally besenttocallsoutsideitszone.The"NextCar"assignmentscanbeseeninthecommunicationsignals (seebelow). PLCTractionControllerUserManual Page13

4.8.3 CarStartTheCarSTARTfeaturecontrolswhenthecarwillrespondtoregisteredHallCallsbycontrollingthe internaldirectioncircuits.WhentheSTARTcircuitisenergizedthecarwillimmediatelybegintorespond toHallCalls.ThereisaseparatestartcircuitfortheLobbyZoneandtheUpperZone.Acarwillalways respondtoCarCallsimmediately. TheSTARTcircuitisenergizedifANYofthefollowingconditionsaretrue: 1. ThecarisNextinthatzone. 2. Thecarisintheotherzone,andisNOTnextinthatzone.(Thismeansthatbothcarsareintheother zone,sothecarthatisnotnextintheotherzonewillbepulledintothiszone.) 3. Thecall(s)inthiszonehavebeenregisteredforapresettime.(Thisallowstheothercartohelpin heavytrafficsituations.) 4. Thecarisnotinnormalgroupoperation(CommunicationOutputPoint5willbeoff). 5. Theothercarisnotinnormalgroupoperation(CommunicationInputPoint5willbeoff). 6. Theothercarhasacallbehindit,(CommunicationInputPoint5willbeflashing). 7. EmergencyPowerisactivated,andthiscarisassignedtorun.

4.8.4 HomingIftherearenocarsattheMainDispatchlanding,the"Next"carintheLobbyZonewillhome,orreturn, totheMainDispatchLanding.Ifthereisno"NextCar"intheLobbyZone,thenthefirstavailablecarwill hometotheLobby.Ifdesired,the"Free"carcanbesetuptohometoaspecific(adjustable)landingin theupperzone,ortohometotheMainlanding.(SeetheseparatedescriptiononFeatureAdjustments.) Acarwillhomeifthefollowingconditionshavebeenmetfor2seconds: 1. Thecarisingroupoperation(notonInspection,IndependentService,FireService,LoadWeighing etc.). 2. TheStopSwisnotthrown. 3. Thecarisnotstuck. 4. Thedoorsareclosed. 5. ThecarisnotattheMainDispatchLanding. 6. Thecarisnotrunning. 7. Theothercarisingroupoperation. 8. TheothercarisnotnextintheLobbyZone. 9. Theothercarisnotrunningdown. 10. Theothercarisnothoming.

4.8.5 CommunicationCommunicationbetweeneachcarisachievedthroughtheInputandOutputModules.Thatis,the CommunicationOutputsonElevatorAareconnectedtotheCommunicationInputsonElevatorB,and


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similarlytheCommunicationOutputsfromElevatorBareconnectedtotheCommunicationInputson ElevatorA.AMultiplexingsystemisusedtoallowthecommunicationofmorethanjustthe8 Input/Outputpoints.Thisoperatesasfollows: TheOutputPoint1turnsonandoffregularlytosequencethedatatransfer.Theprogramnowcan transmittwopiecesofdataoneachoutputpoint,onepiecewhenPoint1isONandonepiecewhen Point1isOFF.TheMicroprocessorreceivingdatawillmonitorPoint1,andcheckthestatusofeach otherCommunicationPointjustafterPoint1goesONandalsojustafterPoint1goesoff.IfPoint1is notgoingonandoff,thentheprogramassumestheotherMicroprocessorisoutofservice. CommunicationData IfPoint1isON... AndPoint2isON,thecarisCANCELINGUPHALLCALLS. AndPoint3isON,thecarisNEXTintheUPPERZONE. AndPoint4isON,thecarisNEXTintheLOBBYZONE. AndPoint5isON,thecarhasNOCALLSBEHINDIT(BackCalls). AndPoint6isON,thecarisatLanding1(Binary). AndPoint7isON,thecarisatLanding4(Binary). AndPoint8isON,thecarisrunningonEmergencyPower. IfPoint1isOFF... AndPoint2isON,thecarisCANCELINGDOWNHALLCALLS. AndPoint3isON,thecarisonFIRESERVICEPHASE2. AndPoint4isON,thecarisHOMING,RUNNINGDOWN,attheMAINLDG,orNEXTintheLobby Zone. AndPoint5isON,thecarisINSERVICE. AndPoint6isON,thecarisatLanding2(Binary) AndPoint7isON,thecarisatLanding8(Binary) AndPoint8isON,thecarwantstorunonEmergencyPower. NOTE:TheCarPosition,Points67,isinBinarycode.(Point8isusedwithmorethan 15 landings.) To determine the car position, add the landing values together. For example,ifthecarcommunicationlightsforBinary1andBinary2arebothon,then thecarisatthe3rdlanding. NOTE:IftheDatalight(Points28)isflashinginsequencewithPoint1,thentheData fromtheFIRSTGROUPistrue.IftheDatalight(Points28)isflashingoutofsequence fromPoint1,thentheDatafromtheSECONDGROUPistrue.IftheDatalight(Points 28)isonallthetime,thentheDatafromthefirstandsecondgroupsistrue.


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NOTE: This description applies totheoperationoftheInputsandtheOutputs.The Outputs will show the status oftheMicroprocessorforthatElevator,andtheInputs willshowthestatusfortheotherElevator. ExampleOfCommunicationData InitialConditions:Therearenocarcallsregistered.Bothcarsareatrest. ElevAisattheMain(2nd)Landing,ElevBisatthe4thlanding. ElevACommunicationOutputs #1=flashing #2=off #3=off #4=on #5=on #6=flashingoppositefrom#1 #7=off #8=off A"1U"HallCallisregistered. ElevAwillanswerthiscall,sinceitistheLobbyZoneNextcar. CommunicationOutputchanges: ElevB:Thereshouldbenochanges,sincethiscarisnottomove. ElevA:#6willflashwith#1whenthecarchangestothe1stfloor. #2willflashwith#1whenthecaranswersthecallatthe1stlanding. ElevBCommunicationOutputs: #1=flashing #2=off #3=flashingwith#1 #4=off #5=on #6=off #7=flashingwith#1 #8=off

Note:WhileElevAisrespondingtothecall,thefollowingshouldNOToccur. (Ifanyoftheseconditionsoccur,thenElevBwillstarttowardthecall) #2shouldonlystartflashing1secondafterthecargetstothe1stfloor. #3shouldnotcomeonatall. #4shouldremainONatalltimes. #5shouldremainONatalltimes. #6,#7,#8arenotcritical.

TotesttheHallCallHelpOuttimer,putElevBoutofservicewhileitisintheUpperZone,butjumpElev BCommunicationOutputPoint#5ON.ElevAwillthinkthatElevBisstillinservice.Nowregisterahall callintheUpperZone,andseehowlongElevAtakestoleavetheMainLandingtorespondtothecall. Thefactorytimeis30seconds.


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4.9 FailureTimers4.9.1 StuckButtonTimerIfacarorhallcallbuttonremainsonforanadjustabletime,andothercallsareregistered,thestuck buttoncallwillbeignored,andthecarwillanswertheothercall(s).Thecarwillreturntothestuck buttoncallasitanswersothercalls,andthestuckbuttontimersequencewillberepeated.

4.9.2 RunningTimersTractionsystemsIfthecarrunsforanadjustabletime,withoutchangingfloors,thenrunning shutdownoperationwillbeinitiated.Theshutdowncouldbecausedbyaproblemwiththemotor startercircuit(s);oraproblemwiththedrivesystem;oraproblemwiththeselector.Thecarwilldrop thefastspeedoutputs,thenstop.Itwillthenbeshutdown,withonlytheDoorOpenButtonanddoor protectivedevicesbeingoperational.ThefaultcanberesetbycyclingtheMainLineDisconnectSwitch, orbyputtingthecaron"Inspection"thenbackto"Automatic". NOTE: If a Reverse Phase Relay or Emergency Power circuitry is supplied, these will alsoinitiateashutdownsignaliftheinputsarenotenergized. Asequencefaulttimermonitorskeyinputsfromthedrivesystem,suchasDriveEnabled,BrakeMicro Switch,andcontactsofthekeydrivecontactors.Ifthesefailtochangestateproperlyasthecarstartsor stops,thenthecarwillbeshutdown.ThefaultcanberesetbycyclingtheMainLineDisconnectSwitch, orbyputtingthecaron"Inspection"thenbackto"Automatic". Alevelingtimerisprovidedthatwillcutoutlevelingifthecarhasbeenlevelingforover15seconds. Thispreventsthecarfromstallinginleveling.Thecarwillnotbeshutdown,butwillnotbeallowedto releveluntilthecarhasruntoanotherfloor.

4.9.3 DoorFaultTimersIfthedoorsfailtoopenfullyafteranadjustabletime,theopencyclewillbecanceled.Thedoortimewill expireasnormal,thedoorswillclose,andthecarwillcontinuetoanswercalls. Ifthedoorsfailtocloseafteranadjustabletime,thedoorswillreopen,andattempttocloseagain.The doorswillbeheldopenanadjustabletime(factorysetat15seconds)whichallowsthedoormotorto remaincool.Theclosecyclewillberepeateduntilthedoorsclose.

4.9.4 DoorCheckCircuitryDoorCheckcircuitryisanoptionalfeaturethatisprovidedasrequiredbytheappropriatecodes.ADoor ContactfaultconditionisrecognizedifALLthefollowingconditionsexist: 1. The"DC"or"DG"relayInputisenergized(thecarorhalldoorsareclosed),AND 2. TheDoorCloseLimitInputisenergized(thecardoorisnotfullyclosed),AND 3. TheUpLevelandDownLevelInputsarebothoff(thecarisnotleveling). 4. Thedoorsarenotopeningorclosing.


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Iftheabovefaultconditionexiststhenthefaultwillbeinitiatedafter0.1seconds.WhenaDoorFaultis initiated,theDoorFaultOutputwillenergizeandthedoorswillbeheldopen.Thefaultisclearedwhen thedoorcontactsrelayinput(s)gooff. Whenthedoorsarefullyopen,andthecarisnotleveling,theDOLXoutputwillenergize.Thiswill changetheconnectionsofthecardoorandhalldoors,sothatthePLCcanmonitorthecarandhall doorsindependently.

4.10 FieldAdjustableFeaturesRefertothesectiononchangingSettingsandFeaturestoseethefeaturesthatareadjustable. ThecontrollerisalreadysetupforthespecificjobwhenitisshippedfromVirginiaControls.Itis recommendedthatthe"FactoryReset"sequencebeperformedwhenthecontrollerisfirstpoweredup. Thiscanbedoneby(1)Turningoffthepower;(2)Putthecaroninspection;(3)Jumpterminals1to21 and1to22;(4)TurnonthepoweruntiltheRunlightonthePowerSupplyhascomeon;(5)Turnoff thepower,andremovethejumpers,andcontinueasnormal.

4.11 TypicalTractionAdjustments1. ESTEMERGENCYSTOPSWITCHTIMEDRELAY.(HIGHSPEEDTRACTIONELEVATORS)Energizedwhen theEmergencyStopSwitchinthecarisinthe"On"or"Run"position.Itisatimedelaydropoutrelay, andallowsthecartoslowdowniftheStopSwitchisthrownwhilethecarisrunning."ES"willde energizethespeedrelaysorspeedcircuits,causingthecartostarttoslowdown,but"EST"willhold thedirectionrelays,allowingthecartoslowdownnormally,beforeapplyingthebrake.Thisprovidesa smootherstop,withlessstrainontheequipmentthananimmediatestopwould.Thetimeon"EST" shouldbeadjustedbymeansofthemultipositionswitch"EST",whichchangestheamountof capacitanceinparallelwiththerelaycoil. 2. UDTandUDTXCARRUNNINGTIMEDRELAYS.(SomeTRACTIONELEVATORS)Energizedwhenthecar isrunning,andheldforashorttimeafterthecarstops.OnM.G.setsystems,itallowstheElectricStop toholdthecarbeforetheBrakesets,andthesuicidecircuitcloses.OnSCRDrivesystems,itallowsthe Drivetoholdthecaratzerospeedwhilethebrakesets. 3. RUXPorTRUPM.G.SETRUNTIMER.(UsedwithM.G.setsonly.)EnergizedpresettimeaftertheM.G. setstartstorun.Itwillchangetheconnectionofthemotorfrom"Y"to"Delta".Recommendedsetting is4.8seconds,noadjustmentisnecessary. 4. GENERATORSERIESFIELDSHUNTWIRE.(UsedwithsomeM.G.setsonly.)Adjusttogiveproper compounding.TheShuntWireisacoilof1014gaugewire,approximately6feetlong,locatedinthe Generatorjunctionbox(shortenorlengthenwiretochangecompounding).TheShuntWireisatthe sametemperatureasthegenerator,thuscompensatingforanyresistancechangeduetotemperature changeofthegenerator. RefertotheSchematicforspecificinformationonthespecificdrivesystemusedwitheachinstallation. Referalsotothemanufacturer'sinstructionsfortheregulatorordrivesystemused.


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5. HardwareDescriptionThecontrollerconsistsoftheProgrammableLogicController(PLC)Microprocessorsystem,Power Supplysection,andRelayInterface. TheMicroprocessorsystemconsistsoftheCentralProcessorBoard(CPU),whichhastheMicroprocessor centralprocessingunit(theCPUmaybemountedinthebackplane,ormaybeaseparatemodule),the EPROMmemorychip(whichislocatedintheCPU),thePowerSupply,andtheInput/Outputboards. TheprogramisinEPROM(ElectricallyProgrammableReadOnlyMemory).Thefloorrelaysandfire servicerelaysaremaintainedintheMicroprocessorRAMmemoryandareheldthroughpowerlossby thebatteryinthePowerSupply.Thefloorrelaysmayneedtoberesetwhenthecontrollerisinitially installed. ThePowerSupplysectionincludestherequiredtransformersandfusestopowertheMicroprocessor systemandtheRelayInterface. TheRelayInterfaceincludestherequiredrelaysandcontactorstointerfacethefieldsignalsanddevices totheMicroprocessor.Thisusuallyincludesaprintedcircuitboardfornormalsignals,aswellasother relaysorcontactorsforsignalsrequiredforeachspecificjob.

5.1 MicroprocessorSystemThePLCMicroprocessorsystemcontainsthehardwarethatcontrolstheinputsandoutputswhich controltheelevator.ThissectiondescribesthemajorcomponentsoftheMicroprocessorsystem.The systemismodular,andeachmodulecanberemovedfromtherackbypressingintheleveronthe bottomofthemodule,thenswingingthemoduleupandoutoftherack. WARNING: Modules should only be removed and replaced with power to the PLC turnedOFF.

5.1.1 GESeries9030FormostlowriseelevatorapplicationswithlowI/Ocounts,theCPUis embeddedintothebackplaneallowingallslotsavailableforI/O.The backplaneswiththeembeddedCPUarenotexpandable. Forhigherriseelevatorapplications,ahighperformanceCPU (CPU350),whichisbasedontheIntel386EXprocessor,isutilized.The CPUisalwayslocatedinthefirstslotafterthepowersupply.

Figure1GESeries9030System


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5.1.1.1 GESeries9030CPUTheCPU(CentralProcessingUnit)isbuiltintothebaseon5slotand10slotsystems,andisaseparate modulelocatedontherightofthePowerSupplyonmultiracksystems.Therearenoadjustmentsor connectorsdirectlyontheCPU.

Figure2Models311and313(5Slot)EmbeddedCPUBaseplates

Figure3ModelIC693CPU323(10slot)EmbeddedCPUBaseplate


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Figure4IC693CHS3975SlotModularCPUBaseplate

Figure5IC693CHS39110SlotModularCPUBaseplate


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5.1.1.2 GESeries9030PowerSupplyThePowerSupplyplugsintothebaseonthefarleftofeachrack.Itispoweredby115VAC,and providesthenecessaryvoltagestotherestofthePLCsystem.Thereisabatterylocatedonthefront lowersectionofthePowerSupplythatmaintainsthestatusofcertainregistersintheCPUduringa powerloss.RefertothemaintenancesectionortheGEmanualforinstructionsonchangingthebattery. ThePowerSupplyhasaterminalstrip ontheleftforpowerconnections, anda15pinconnectorinthemiddle foracommunicationsportthatcan beusedwithahandheld programmerorcomputerfor programmingormonitoring functions. ThePowerSupplyhasasetofLED lightsontheupperfrontsection. WhenpowerisappliedtothePower Supply,thePOWERLEDwillcomeon immediately.TheOKLEDshould comeonaftertheCPUperformsa selfcheck.Ifitfailstocomeon,then checktheEPROMtomakesureitis insertedproperly.TheRUNLED shouldflashthenstayonafterthe CPUfinishestheselfcheckandgoes intotherunmode.Ifitfailstocome Figure6StandardAC/DCInputPowerSupplyIC693PWR321 on,theremaybeafaultwiththe system.Thiscouldbecausedbyabadcomponent(PowerSupply,CPU,InputorOutputBoard,or EPROMchip)orbyhavingtheInput/Outputboardsinthewrongslotsintherack. CAUTION:IftheI/OmodulesareswitchedsothatanInputmoduleisinsertedwhere anOutputModulewaslocated(orviceversa)thenthesystemwillnotcomeupinthe Run Mode. A handheld programmer or computer running GE Logicmaster software mayberequiredtogettheCPUbackintotheRunMode. ThereisafuselocatedinthePowerSupply,behindthefrontcover.Thisfusewillnotnormallyblow,but shouldbecheckedifthereispowerattheterminalsofthePowerSupply,butnoneoftheLEDsonthe frontofthePowerSupplyareon(TheremaybeaslightdelayonpowerupbeforetheLEDscomeon. Thisisnormal.)


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5.1.1.3 GESeries9030InputandOutputModulesTheInputandOutputmodulesareusedtoconnectthePLCwiththefielddevices.Theinputandoutput modulesareavailableinavarietyofvoltagesandconfigurationstomeettheneedsofthesystem.The mostcommonlyusedmodulesare115VACInputsandRelayOutputs.

Figure7IC693MDL940StandardDensityDiscreteOutputModule EachmodulehasLEDindicatorstoshowthestatusofeachInputorOutputpoint.Thesearelocatedon thefrontofthemoduleatthetop.TherearetworowsofLEDs,withthetoprowindicatingthestatusof thefirst8points(GroupA)andthelowerrowindicatingthestatusofthesecond8points(GroupB). Whenapointison,theLEDwilllight,andwillshowupasanumberbetween1and8,toindicatewhich pointison. NOTE: If trouble shooting assistance is required from Virginia Controls, it is very importanttogetthestatusofallInputandOutputpointstohelpidentifyanypossible problems.


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ConnectionstotheInputandOutputmodulesaremadebymeansoftheremovableterminalstripon thefrontlowerhalfofthemodule.Checktheschematiccarefullybeforewiringtothemodule,asthe locationofthecommonsmayvaryfromonetypeofmoduletoanother.Theterminalblocksare removable,soBEFOREpowerisapplied,removetheterminalblocksandcheckforgroundsatthe terminalblocks. CAUTION:Beverycarefulnottojumptoacommonwhenyouintendedtojumptoan inputoroutput,asthiscoulddamagethecontrollerorotherequipment. FusesareprovidedontheI/Oboard.Thefusesarelocatedontheprintedcircuitboardsinsidethe modules.Theoutputsalsohaveexternalfusesthatareratedbelowthefusesonthemodules,sothe externalfusewillblowfirst.Checktheschematicforthesizeandnameofthefusesforeachoutput module. Theaddressingfortheboardsishandledinthesoftware,andispreprogrammedbyVirginiaControls. CAUTION: Be very careful not to insert an Input Module in a slot allocated for an Output Module, or to insert an Output Module into a slot allocated for an Input Module.Ifthisisdone,theCPUwillregisterafault,andwillnotcomeupintheRun Mode.AhandheldprogrammerorcomputerrunningGELogicMastersoftwarewillbe requiredtoclearthefault,andgettheCPUbackintotheRunMode.

5.1.1.4 GESeries9030Connections5.1.1.4.1 GESeries9030IncomingPowerTerminalsTheIncomingPowerConnectorisaterminalblocklocatedontherightfrontofthePowerSupply module.Theincomingpoweris115VAC.

5.1.1.4.2 GESeries9030ProgrammingPortTheProgrammingPortislocatedonthefrontofthePowerSupply.TheHandheldProgrammeris pluggedinhere.Alsothisportisusedtocommunicatewithcomputersormodemsforprogrammingor monitoringapplications.TheportsupportsRS422communications,throughaD15connector.

5.1.1.4.3 GESeries9030InputandOutputTerminalsConnectionstotheInputandOutputmodulesarebymeansofaremovableterminalblockmountedon thefrontofeachmodule.Refertotheschematicforthewiringdiagramforeachmodule. Toremovetheterminalblock,firstpresstheleveratthetopoftheterminalblockbehindtheswing cover.Thiswillpushthetopoftheblockout.Thenpullonthesmalltabatthetopoftheterminalblock toswingtheterminalblockoutanddown.


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Figure8Removing20pinterminalassemblyfrommodule Toreplacetheterminalblock,lineupthebottomoftheblockthenswingitupandontothemodule.

Figure9Installing20pinterminalassemblyontomodule

5.1.1.4.4 GESeries9030RackConnectorInmultiracksystems,eachrackisconnectedtotherackbelowusingaspecialcable.Thiscableis factoryinstalled,andispluggedintotheconnectoratthefarrightoftherack.


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5.1.2 AllenBradleySLC500MicroprocessorSystemTheAllenBradleySLC500isasmallchassisbased familyofprogrammablecontrollers,discrete,analog, andspecialtyI/O,andperipheraldevices. TheSLC500familydeliverspowerandflexibilitywith awiderangeofcommunicationconfigurations, features,andmemoryoptions. Atminimum,amodularhardwareSLC500control systemconsistsofaprocessormoduleandI/O modulesinasingle1746chassiswithapowersupply. Asystemcanbemadeupofone,two,orthreelocal chassis,foramaximumtotalof30localI/Oor communicationmodules.Multiplelocalchassis connecttogetherwithchassisinterconnectcablestoextendthebackplanesignallinesfromonechassis toanother. Figure10AllenBradleySLC500System Morecomplexsystemscanuse: distributedI/O. multiplecontrollersjoinedacrossnetworks. I/OinmultipleplatformsthataredistributedinmanylocationsandconnectedovermultipleI/O links.


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5.1.2.1 AllenBradleySLC500CPUTheSLC5/03processorsuppliessystemthroughputtimesof1msforatypical1Kuserprogramand onlineediting.TheSLC5/03processorprovides: Totalmemorysizeof8Kor16K Onlineprogramming(includesruntimeediting) Controlofupto4096inputandoutputpoints BuiltinDH485channel

BuiltinRS232channelsupportingDF1Fullduplex, RemoteI/Opassthroughfromchannel0(DF1)or DF1HalfDuplexMaster/SlaveforSCADA,DH485 channel1(DH485)usinga1747SNor1747BSN usinga1761NETAICwitha1747CP3cable,and remoteI/Oscannermodule ASCIIprotocols DeviceNetpassthroughusing1747SDNDeviceNet scannermodule 2msSelectableTimedInterrupt(STI) Advancedmathfeaturestrigonometric,PID, exponential,floatingpoint,andthecompute instruction FlashPROMprovidesfirmwareupgradeswithout physicallychangingEPROMS KeyswitchRUN,REMote,PROGram Builtinrealtimeclock/calendar 0.50msDiscreteInputInterrupt(DII) Indirectaddressing

OptionalflashEPROMmemorymoduleavailable BatterybackedRAM

Figure11SLC5/03Processors(1747L531and1747L532)


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TheSLC5/04processorprovidesthebaselinefunctionalityoftheSLC5/03processorplusDH+ communication.Inaddition,theSLC5/04processorrunsapproximately15%fasterthantheSLC5/03 processor.TheSLC5/04processorprovides: Programmemorysizesof16K,32K,or64K Controlofupto4096inputandoutputpoints BuiltinDH+channel,supporting: Highspeedcommunication(57.6K,115.2K,and 230.4Kbaud)andMessagingcapabilities Channeltochannel(DH+toDH485)passthrough capability RemoteI/Opassthroughfromchannel0(DF1)or channel1(DH+)usinga1747SNor1747BSN remoteI/Oscannermodule Builtinrealtimeclock/calendar 0.50msDiscreteInputInterrupt(DII) Indirectaddressing OptionalflashEPROMmemorymodule BatterybackedRAM Highspeedperformance0.90ms/Ktypical Onlineprogramming(includesruntimeediting) BuiltinRS232channelsupportingDF1Fullduplex, DF1HalfDuplexMaster/Slave,DH485usinga 1761NETAICwitha1747CP3cable,andASCII protocols Channeltochannel(DF1FullDuplextoDH+) passthrough DeviceNetpassthroughusing1747SDNDeviceNet scannermodule 1msSelectableTimedInterrupt(STI) Advancedmathfeaturestrigonometric,PID, exponential,floatingpoint,&computeinstruction FlashPROM KeyswitchRUN,REMote,PROGram(clear faults)

Figure12SLC5/04Processors(1747L541,1747L542,or1747L543)


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TheSLC5/05processorprovidesidenticalcontrolfunctionalityastheSLC5/04processorusingstandard EthernetcommunicationsinsteadofDH+.Ethernetcommunicationtakesplaceat10Mbps,providinga highperformancenetworkforprogramupload/download,onlineediting,peertopeermessaging,data acquisition,andoperatorinterface(e.g.RSView32).TheSLC5/05provides: Programmemorysizesof16K,32K,or64K Controlofupto4096inputandoutputpoints Builtin10BaseTEthernetchannel,supporting: HighspeedcommunicationusingTCP/IP, Messagingcapabilities,SNMPforstandard EthernetnetworkmanagementandBOOTPfor optionaldynamicIPaddressassignment EthernettoDH485,channeltochannel passthrough RemoteI/Opassthroughfromchannel0(DF1or DH485)orchannel1(Ethernet)usinga1747SNor 1747BSNremoteI/Oscannermodule Builtinrealtimeclock/calendar 0.50msDiscreteInputInterrupt(DII) Indirectaddressing OptionalflashEPROMmemorymoduleavailable BatterybackedRAM Highspeedperformance0.90ms/Ktypical Onlineprogramming(includesruntimeediting) BuiltinRS232channelsupportingDF1Fullduplex, DF1HalfDuplexMaster/Slave,DH485usinga 1761NETAICwitha1747CP3cable,andASCII

EthernettoDF1,channeltochannelpassthrough DeviceNetpassthroughusing1747SDNDeviceNet scannermodule 1msSelectableTimedInterrupt(STI) Advancedmathfeaturestrigonometric,PID, exponential,floatingpoint,&computeinstruction FlashPROM KeyswitchRUN,REMote,PROGram(clearfaults)


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Figure13SLC5/05Processors(1747L551,1747L552,and1747L553)

Figure14SLC500ProcessorComponentLocations PLCTractionControllerUserManual Page30

5.1.2.1.1 AllenBradleySLC500CPUBatteryTheSLC5/03,SLC5/04,orSLC5/05processorprovidesbackuppowerforRAMthroughareplaceable lithiumbattery.Thisbatteryprovidesbackupforapproximately2years.ABATTLEDonthefrontofthe processoralertsyouwhenthebatteryvoltagehasfallenbelowathresholdlevel. Toreplacethelithiumbattery,followthesesteps: CAUTION: Do not remove the processor from the SLC 500 chassis until all power is removedfromtheSLC500powersupply. 1. RemovepowerfromtheSLC500powersupply. 2. Removetheprocessorfromthechassisbypressingtheretainerclipsatboththetopandbottomof themoduleandslideitout. CAUTION:Donotexposetheprocessortosurfacesorotherareasthatmaytypically holdanelectrostaticcharge.Electrostaticchargescanalterordestroymemory. 3. Unplugthebatteryconnector.Refertothefigurebelowforbatteryconnectorlocation.

Figure15SLC500ProcessorBatteryLocation NOTE:TheSLC5/03,SLC5/04,andSLC5/05processorshaveacapacitorthatprovides atleast30minutesofbatterybackupwhilethebatteryisdisconnected.DatainRAM isnotlostifthebatteryisreplacedwithin30minutes. 4. Removethebatteryfromtheretainingclips.


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5. Insertanewbatteryintothebatteryretainingclips. 6. Plugthebatteryconnectorintothesocketasshownintheabovefigure. 7. ReinsertthemoduleintotheSLC500chassis. 8. RestorepowertotheSLC500powersupply.

5.1.2.2 AllenBradleySLC500PowerSupplyThepowersupplymountsontheleftsideofeachchassiswithtwoscrews.ForACpowersupplies, 120/240voltselectionismadebyplacingthejumpertomatchtheinputvoltage.SLCpowersupplies haveanLEDthatilluminateswhenthepowersupplyisfunctioningproperly. CAUTION: Excessive loading of the power supply outputs can cause a power supply shutdownorprematurefailure. Powersuppliesaredesignedtowithstandbriefpowerlosses. NOTE:Powerlossdoesnotaffectsystemoperationforaperiodbetween20msand 3s,dependingontheload.

Figure16AllenBradleySLC500PowerSupplies


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5.1.2.3 AllenBradleySLC500InputandOutputModulesTheInputandOutputmodulesareusedtoconnectthePLCwiththefielddevices.Theinputandoutput modulesareavailableinavarietyofvoltagesandconfigurationstomeettheneedsofthesystem.The mostcommonlyusedmodulesare115VACInputsandRelayOutputs. DigitalI/Omodulesareavailablewith4,8,16,or32channelsandinawidevarietyofI/Ovoltages (includingAC,DC,andTTL).Combinationmoduleswith2inputs/2outputs,4inputs/4outputs,and6 inputs/6outputsarealsoavailable. Terminalsonthe4,8,12,and16channelmoduleshaveselfliftingpressureplatesthataccepttwo14 AWG(2mm2)wires.LEDindicatorsonthefrontofeachmoduledisplaythestatusofeachI/Opoint. 32channelI/Omodulesareequippedwitha40pin,MILC83503typeheaderandaremovablewiring connector(1746N3). OutputmodulesareavailablewithsolidstateAC,solidstateDC,andrelaycontacttypeoutputs.High currentsolidstateoutputmodules,catalognumbers1746OBP16,OVP16,andOAP12,havefused commonswithablownfuseLEDindication.The1746OB16E,OB6EI,andOB32Emodulesprovide electronicprotectionfromshortcircuitandoverloadconditions. EachmodulehasLEDindicatorstoshowthestatusofeachInputorOutputpoint.Thesearelocatedon thefrontofthemoduleatthetop.Whenapointison,theLEDwilllightandwillshowupasanumber toindicatewhichpointison. NOTE: If trouble shooting assistance is required from Virginia Controls, it is very importanttogetthestatusofallInputandOutputpointstohelpidentifyanypossible problems. ConnectionstotheInputandOutputmodulesaremadebymeansoftheremovableterminalstripon thefrontlowerhalfofthemodule.Checktheschematiccarefullybeforewiringtothemodule,asthe locationofthecommonsmayvaryfromonetypeofmoduletoanother.Theterminalblocksare removable,soBEFOREpowerisapplied,removetheterminalblocksandcheckforgroundsatthe terminalblocks. CAUTION:Beverycarefulnottojumptoacommonwhenyouintendedtojumptoan inputoroutput,asthiscoulddamagethecontrollerorotherequipment. Theaddressingfortheboardsishandledinthesoftware,andispreprogrammedbyVirginiaControls. CAUTION: Be very careful not to insert an Input Module in a slot allocated for an Output Module, or to insert an Output Module into a slot allocated for an Input Module.Ifthisisdone,theCPUwillregisterafault,andwillnotcomeupintheRun Mode. A computer running AllenBradley RSLogix 500 software will be required to clearthefault,andgettheCPUbackintotheRunMode.


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Figure17FeaturesofanAllenBradleySLC500I/OModule


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5.1.2.4 AllenBradleySLC500Connections5.1.2.4.1 AllenBradleySLC500IncomingPowerTerminalsTheIncomingPowerConnectorisaterminalblocklocatedunderthecoverofthePowerSupplymodule. Theincomingpoweris115VAC.

5.1.2.4.2 AllenBradleySLC500ProgrammingPortTheProgrammingPortislocatedonthefrontoftheCPU.Thisportisusedtocommunicatewith computersormodemsforprogrammingormonitoringapplications.

5.1.2.4.3 AllenBradleySLC500InputandOutputTerminalsConnectionstotheInputandOutputmodulesarebymeansofaremovableterminalblock(some exceptionsarepossible)mountedonthefrontofeachmodule.Refertotheschematicforthewiring diagramforeachmodule. Toremovetheterminalblock: 1. IftheI/Omoduleisalreadyinstalledinthechassis,removepowertotheSLC. 2. Unscrewtheupperrightandlowerleftterminalblockreleasescrews. 3. Grasptheremovableterminalblockwithyourthumbandforefingerandpullstraightout. 4. Labeltheremovableterminalblockwithslot,rack(chassis)&moduleidentification.

Toreplacetheremovableterminalblock: 1. Besurethecoloroftheremovableterminalblockmatchesthecolorbandonthemodule. CAUTION: Inserting a wired removable terminal block on an incorrect module can damagethemodulescircuitrywhenthepowerisapplied. 2. Writetheappropriateslot,chassis,andmoduletypeontheremovableterminalblocklabel. CAUTION: Disconnect power before attempting to install or remove I/O modules or theirterminalblocks. 3. Disconnectpower. 4. Aligntheterminalblockreleasescrewswiththematingconnectorinthemodule. 5. Presstheremovableterminalblockfirmlyontotheconnectorcontacts. 6. Tightentheterminalblockreleasescrews.Toavoidcrackingtheterminalblock,alternatethe tighteningofthescrews.


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5.1.3 AllenBradleyMicroLogix1500MicroprocessorSystemTheMicroLogix1500isaprogrammablelogiccontrol platformthatfeaturesatwopiecedesignwithasmall footprint.Theprocessorandbaseunitsslidetogether toformthecompletecontroller.Theprocessorand baseareindependentlyreplaceable. TheMicroLogix1500usesCompactI/Omodulesto expandtheembeddedI/O,aswellastoprovide additionalflexibility. Figure18AllenBradleyMicroLogix1500 System TheMicroLogix1500systemalsoutilizesRockwell SoftwareRSLogix500programmingsoftware,and featuresaninstructionsetcommontotheMicroLogix 1000,MicroLogix1200andSLCfamiliesofcontrollers.

Programportabilityofuserprograms(upload,downloadandtransport)isaccomplishedviaMemory Modules.RealTimeClock(RTC)modulesprovideschedulingofcontrolcapability. TheoptionalDataAccessTool(DAT)plugindeviceofferstheabilitytodigitallymonitorandadjust48 integerand48bitlocationsforontheflyadjustment.Twoadditionalfunctionkeyseachactas momentaryandtogglepushbuttons. Securityfeaturesmaybeusedtoprotectdatafromoperatorchanges.

5.1.3.1 AllenBradleyMicroLogix1500CPUThe1764LSPprocessorfortheMicroLogix1500 controlleristhebaseprocessorintheMicroLogix 1500family. The1764LSPprocessorisprogrammedwithRSLogix 500softwareandhasaninstructionsetwhichis compatiblewiththeMicroLogix1000,and1200 products,aswellasallSLC500processors. Itprovideslargememorysize(greaterthan7Kuser programcapacity)with100%retentativedatawhich ensuresdataintegrityevenduringpowerloss. Theprocessorofferscommunicationssupportfora Figure19AllenBradleyMicroLogix1500 varietyofprotocolsincludingDF1FullDuplexand 1764LSPCPU HalfDuplexSlave,DH485,ModbusRTUSlaveand ASCII.Staticdatafileprotectionpreventsuserdata frombeingalteredviacommunication.ASCIIread/writecapabilitiesaresupported. Theprocessorprovidesinterfacingtothefollowingadvancedfeaturesandfunctionality: Optionalmemoryandrealtimeclockmodules Optionaldataaccesstool(1764DAT) Builtinanalogtrimpotentiometers Battery(builtinandreplacement)


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1msSelectableTimedInterrupt(STI) Highresolutiontimers Latching(pulsecatch)inputs Communicationtogglepushbutton ModeswitchforRun/Remote/Program Fieldupgradeableflashoperatingsystem

The1764LRPprocessorfortheMicroLogix1500 controllerisamoreadvancedalternativetothe1764 LSPprocessor.The1764LRPhasmorememory,data loggingcapabilities,andasecondcommunication port. The1764LRPprocessorisprogrammedwithRSLogix 500softwareandhasaninstructionsetwhichis compatiblewiththeMicroLogix1000,and1200 products,aswellasallSLC500processors. Figure20AllenBradleyMicroLogix1500 1764LRPCPU(shownwithoptionalData AccessTool)

5.1.3.2 AllenBradleyMicroLogix1500BaseUnitsMicroLogix1500baseunitshouseembeddedinputs,outputs,powersupplyandthechannel0port. TheyalsoprovidetheinterfacetoexpansionI/Owhenrequiredbyanapplication.Threebaseunitsare availablewiththefollowingelectricalconfigurations. 120/240Vacpoweredbaseunits o 176424AWA(12)120Vacinputsand(12)relayoutputs o 176424BWA(12)24Vdcinputsand(12)relayoutputs 24Vdcpoweredbaseunit o 176428BXB(16)24Vdcinputsand(6)24VdcFETand(6)relayoutputs

TheembeddedinputsandoutputsareusedtoconnectthePLCwiththefielddevices. EachinputandoutputhasanLEDindicatortoshowthestatusofeachInputorOutputpoint.Theseare locatedonthefrontofthebaseunit.Whenapointison,theLEDwilllightandwillshowupasanumber toindicatewhichpointison. NOTE: If trouble shooting assistance is required from Virginia Controls, it is very importanttogetthestatusofallInputandOutputpointstohelpidentifyanypossible problems.


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5.1.3.3 AllenBradleyMicroLogix1500InputandOutputExpansion ModulesHighdensityBulletin1769CompactI/Orackless expansionmodulescomplementandextendthe capabilitiesoftheMicroLogix1500controllerby maximizingflexibilityoftheI/Ocountandtype.Upto eightexpansionCompactI/Omodulescanbe connectedtoaMicroLogix1500controllerdependent onpowerrequirements. WithMicroLogix1500OperatingSystemRevision Number(FRN)3orlater,youcanconnectan additionalbankofI/O. InaMicroLogix1500system,amaximumof one1769Expansioncablecanbeused, allowingfortwobanksofI/Omodules(one connecteddirectlytothecontrollerandthe otherconnectedviathecable).EachI/O bank(1)requiresitsownpowersupply(Bank0 usesthecontrollersembeddedpowersupply). Onlyonepowersupply(embeddedor expansion)maybeusedonanI/Obank.The expansionpowersupplycannotbeconnected directlytoacontrollerthathasanembedded powersupply,suchastheMicroLogix1500.It mustbeconnectedusingoneoftheexpansion cables. Figure23AllenBradleyMicroLogix1500Expansion (HorizontalOrientation) Figure22AllenBradleyMicroLogix1500Expansion (VerticalOrientation) Figure21CompactI/OExpansionModules


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5.1.3.4 AllenBradleyMicroLogix1500DataAccessToolTheDataAccessToolprovidesdirectaccessto48bitelements and48integerelements.Thetoolhastwofunctionkeysand canbeusedtodisplaycontrollerfaults.Itcanberemovedor insertedunderpower.

Figure24AllenBradleyMicroLogix 1500DataAccessTool


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5.1.4 AllenBradleyCompactLogixMicroprocessorSystemAllenBradleyCompactLogixisamemberoftheLogix familyandprovidesasingleintegratedcontrol architectureforsequential,drives,motion,and processcontrol. TheLogixplatformsprovideacommoncontrol engine,programmingsoftwareenvironment,and communicationsupportacrossmultiplehardware Figure25AllenBradleyCompactLogixSystem platforms.AllLogixcontrollersoperatewitha multitasking,multiprocessingoperatingsystemand supportthesamesetofinstructionsinmultipleprogramminglanguages. OneRSLogix5000programmingsoftwarepackageprogramsallLogixcontrollers.And,aspartofthe IntegratedArchitecture,allLogixcontrollersofferthebenefitsoftheCommonIndustrialProtocol(CIP) tocommunicateviaEtherNet/IP,ControlNet,andDeviceNetnetworks.

5.1.4.1 AllenBradleyCompactLogixControllersCompactLogixcontrollerscanmonitorandcontrolI/Oacrossthe1769 CompactBus,aswellasoverremoteI/Olinks.CompactLogixcontrollerscan communicatewithcomputersorotherprocessorsacrossRS232C(DF1/DH 485protocol),DeviceNet,ControlNet,andEtherNet/IPnetworks. Themultitaskingoperatingsystemsupportsconfigurabletasksthatcanbe prioritized.Onetaskcanbecontinuous.Theothersmustbeperiodicorevent tasks.Eachtaskcanhaveasmanyas32programs,eachwithitsownlocal dataandlogic. Thecontrollershipswithoutworkingfirmware.Thecurrentfirmwaremustbe downloadedbeforeusingthecontroller.Toloadfirmware,use: ControlFlashutilitythatshipswithRSLogix5000programmingsoftware. AutoFlashthatlaunchesthroughRSLogix5000softwarewhenyoudownload aprojecttoacontrollerthatdoesnothavethecurrentfirmware. a1784CF64CompactFlashcardwithvalidmemoryalreadyloaded. Figure26Allen BradleyCompactLogix Controller


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Figure27AllenBradleyCompactLogixControllersSpecifications


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5.1.4.2 AllenBradleyCompactLogixCompactFlashCardThe1784CF64CompactFlashcardprovidesnonvolatilememorystorageforthe1769L3xxcontroller. Thecardstoresthecontentsofthecontrollermemory(programlogicandtagvalues)andthecontroller firmwareatthetimethatyoustoretheproject.StoringinformationtotheCompactFlashcardislike storingasnapshotofcontrollermemoryatagiventime. Thisisanoptionalfeatureandisnotrequiredtooperatethecontroller. CAUTION:DonotremovetheCompactFlashcardwhilethecontrollerisreadingfrom orwritingtothecard,asindicatedbyaflashinggreenCFLED.Thiscouldcorruptthe data on the card or in the controller, as well as corrupt the latest firmware in the controller. Toinstallthecard,dothefollowingsteps: 1. Pushthelockingtabtotheright. 2. Insertthe1784CF64IndustrialCompactFlashcard intothesocketonthefrontofthecontroller.The labeloftheCompactFlashcardfacestowardstheleft. Matchtheorientationarrowonthecardwiththe arrowonthefrontofthecontroller. NOTE:TheCompactFlashcardsupportsremovalandinsertionunderpower. WARNING:WhenyouinsertorremovetheCompactFlashCardwhilepowerison,an electrical arc can occur. This could cause an explosion in hazardous location installations. ToremovetheCompactFlashcard,pushthelockingtabawayfromtheCompactFlashcardandpullthe CompactFlashcardfromthesocket.

Figure28AllenBradleyCompactLogix CompactFlashCardInstallation


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5.1.4.3 AllenBradleyCompactLogixBatteryTheCompactLogixcontrollercomeswithone1769BAlithiumbattery. CAUTION: The 1769BA battery is the only battery you can use with the 1769L31, 1769L32C, 1769L32E, 1769L35CR and 1769L35E CompactLogix controllers. The 1747BAbatteryisnotcompatiblewiththeseCompactLogixcontrollersandmaycause problems. NOTE: Do not remove the plastic insulation covering the battery. The insulation is necessarytoprotectthebatterycontacts. Toconnectthebattery: 1. Insertthebatteryintothebatteryport.

2. Insertthebatteryconnectorintotheconnectorport.Theconnectoriskeyedtoengagewiththe correctpolarity.


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3. Slidethesidecoverbackuntilitclicksintoposition.

5.1.4.4 AllenBradleyCompactLogixPowerSupplyCompactI/Opowersuppliesdistributepowerfromeithersideofthepowersupply.Forexample,a2A at5Vdcpowersupply(1769PA2,PB2)canprovide1Atotherightsideofthepowersupplyand1Ato theleft.A4Aat5Vdcpowersupply(1769PA4,PB4)canprovide2Atotherightsideofthepower supplyand2Atotheleft.

5.1.4.5 AllenBradleyCompactLogixInputandOutputModulesTheInputandOutputmodulesareusedtoconnectthePLCwiththefielddevices.Theinputandoutput modulesareavailableinavarietyofvoltagesandconfigurationstomeettheneedsofthesystem.The mostcommonlyusedmodulesare115VACInputsandRelayOutputs. The1769CompactI/OmodulescanbeusedaslocalI/OforaCompactLogixcontroller.TheI/Omodules canbeinstalledonapanelwithtwomountingscrewsoronaDINrail.Themodulesmechanicallylock togetherbymeansofatongueandgrovedesignandhaveanintegratedcommunicationbusthatis connectedfrommoduletomodulebyamoveablebusconnector. EachI/Omoduleincludesabuiltinremovableterminalblockwithfingersafecover.Theterminalblock isbehindadooratthefrontofthemodule.I/Owiringcanberoutedfrombeneaththemoduletothe I/Oterminals. EachmodulehasLEDindicatorstoshowthestatusofeachInputorOutputpoint.Thesearelocatedon thefrontofthemoduleatthetop.Whenapointison,theLEDwilllightandwillshowupasanumber toindicatewhichpointison. NOTE: If trouble shooting assistance is required from Virginia Controls, it is very importanttogetthestatusofallInputandOutputpointstohelpidentifyanypossible problems. ConnectionstotheInputandOutputmodulesaremadebymeansoftheremovableterminalstripon thefrontlowerhalfofthemodule.Checktheschematiccarefullybeforewiringtothemodule,asthe locationofthecommonsmayvaryfromonetypeofmoduletoanother.Theterminalblocksare


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removable,soBEFOREpowerisapplied,removetheterminalblocksandcheckforgroundsatthe terminalblocks. WARNING:Beverycarefulnottojumptoacommonwhenyouintendedtojumpto aninputoroutput,asthiscoulddamagethecontrollerorotherequipment. Theaddressingfortheboardsishandledinthesoftware,andispreprogrammedbyVirginiaControls. Themodulescanbeseparatedintomultiplebanks.Ifseparated: Figure29AllenBradley CompactLogix(Vertical Orientation) thecontrollermustbeintheleftmostpositionofthefirst bank eachbankneedsitsownpowersupply useexpansioncablestoconnectthebanks thelastI/Obankrequiresanendcap

Figure30AllenBradleyCompactLogix(HorizontalOrientation) ThecontrolleristheleftmostmoduleintheCompactLogixsystem.Thecontrollerhasbuiltin termination,sotheleftmostendofthesystemisterminated.ThefinalI/ObankintheCompactLogix systemneedsanendcapontheendwithouttheexpansioncable. InadditiontolocalI/O,theCompactLogixcontrollercancontrolremote(distributed)I/Ovia: EtherNet/IPusinga1769L32Eor1769L35Econtroller ControlNetusinga1769L32Cor1769L35CRcontroller DeviceNetusinga1769SDNscannermodule


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5.1.5 AllenBradleyControlLogixMicroprocessorSystemAllenBradleyControlLogixisamemberoftheLogix familyandprovidessequential,process,motion,and drivecontroltogetherwithcommunicationsandI/O inachassisbasedsystem.AsimpleControlLogix systemconsistsofastandalonecontrollerandI/O modulesinasinglechassis. TheLogixplatformsprovideacommoncontrol engine,programmingsoftwareenvironment,and communicationsupportacrossmultiplehardware platforms.AllLogixcontrollersoperatewithamultitasking,multiprocessingoperatingsystemand supportthesamesetofinstructionsinmultipleprogramminglanguages. Figure31AllenBradleyControlLogixSystem OneRSLogix5000programmingsoftwarepackageprogramsallLogixcontrollers.And,aspartofthe IntegratedArchitecture,allLogixcontrollersofferthebenefitsoftheCommonIndustrialProtocol(CIP) tocommunicateviaEtherNet/IP,ControlNet,andDeviceNetnetworks.

5.1.5.1 AllenBradleyControlLogixControllersTheControlLogixcontrollerprovidesascalablecontrollersolutionthat iscapableofaddressingalargeamountofI/Opoints. TheControlLogixcontrollercanbeplacedintoanyslotofa ControlLogixI/Ochassisandmultiplecontrollerscanbeinstalledin thesamechassis.Multiplecontrollersinthesamechassis communicatewitheachotheroverthebackplane(justascontrollers cancommunicateovernetworks)butoperateindependently. ControlLogixcontrollerscanmonitorandcontrolI/Oacrossthe ControlLogixbackplane,aswellasoverI/Olinks.ControlLogix controllerscancommunicatewithcomputersorotherprocessors acrossRS232C(DF1/DH485protocol),DeviceNet,DH+,ControlNet, andEtherNet/IPnetworks. Themultitaskingoperatingsystemsupports32configurabletasksthat canbeprioritized.Onetaskcanbecontinuous.Theothersmustbe periodicoreventtasks.Eachtaskcanhaveasmanyas100programs, eachwithitsownlocaldataandlogic.

Figure32AllenBradley ControlLogixController


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Figure33AllenBradleyControlLogixControllersSpecifications

5.1.5.2 AllenBradleyControlLogixCompactFlashCardTheCompactFlashcardoffersnonvolatilememory(flash)topermanentlystoreauserprogramandtag dataonacontroller. 1784CF64has64MBofmemory. 1784CF128has128MBofmemory.

The1756L6xcontrollerssupportaremovableCompactFlashcardfornonvolatilememorythatis installedinasocketonthecontroller.TheCompactFlashcardstorestheuserprogram,tagdata,and controllerfirmwareandcanbeusedtoupgradefirmwareon1756L6xcontrollerswithoutusingRSLogix 5000softwareorControlFlashsoftware. CAUTION:DonotremovetheCompactFlashcardwhilethecontrollerisreadingfrom orwritingtothecard,asindicatedbyaflashinggreenCFLED.Thiscouldcorruptthe data on the card or in the controller, as well as corrupt the latest firmware in the controller.


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5.1.5.3 AllenBradleyControlLogixChassisTheControlLogixsystemisamodularsystemthatrequiresa 1756I/Ochassis.Chassisareavailableinsizesof4,7,10,13, and17moduleslots.Anymodulecanbeplacedintoanyslot. Thebackplaneprovidesahighspeedcommunicationpath betweenmodules.Multiplecontrollermodulesonthe backplanecanpassmessagesbetweenoneanother. Figure34AllenBradleyControlLogix Chassis

Figure35AllenBradleyControlLogix#1756A4Chassis(withPowerSupply)

PLCTractionControllerUserManual Page48






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5.1.5.4 AllenBradleyControlLogixPowerSupplyControlLogixpowersuppliesareusedwiththe1756chassistoprovide1.2V,3.3V,5V,and24Vdcpower directlytothechassisbackplane.Standard(1756PA72,1756PB72,1756PA75,1756PB75,1756PC75, 1756PH75)andredundant(1756PA75R,1756PB75R)powersuppliesareavailable. Thestandardpowersupplymountsdirectlyontheleftendofthechassis,whereitplugsdirectlyintothe backplane.

Figure40AllenBradleyControlLogixPowerSupplyWiring


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Figure41AllenBradleyControlLogixPowerSupplySpecifications

5.1.5.5 AllenBradleyControlLogixInputandOutputModulesTheInputandOutputmodulesareusedtoconnectthePLCwiththefield devices.Theinputandoutputmodulesareavailableinavarietyofvoltages andconfigurationstomeettheneedsofthesystem.Themostcommonly usedmodulesare115VACInputsandRelayOutputs. EachmodulehasLEDindicatorstoshowthestatusofeachInputorOutput point.Thesearelocatedonthefrontofthemoduleatthetop.Whenapoint ison,theLEDwilllight,andwillshowupasanumbertoindicatewhichpoint ison. ConnectionstotheInputandOutputmodulesaremadebymeansofthe removableterminalstriponthefrontlowerhalfofthemodule.Checkthe schematiccarefullybeforewiringtothemodule,asthelocationofthe commonsmayvaryfromonetypeofmoduletoanother.Theterminalblocks areremovable,soBEFOREpowerisapplied,removetheterminalblocksand checkforgroundsattheterminalblocks.

TheremovableterminalblocksarenotincludedwiththeI/Omodules.They mustbeorderedseparately.Thetypeofmoduledetermineswhichremovableterminalblockyouneed. Screwclamporspringclampremovableterminalblocksareavailable. NOTE: If trouble shooting assistance is required from Virginia Controls, it is very importanttogetthestatusofallInputandOutputpointstohelpidentifyanypossible problems. CAUTION:Beverycarefulnottojumptoacommonwhenyouintendedtojumptoan inputoroutput,asthiscoulddamagethecontrollerorotherequipment. Theaddressingfortheboardsishandledinthesoftware,andispreprogrammedbyVirginiaControls.

Figure42Allen BradleyControlLogix I/OModule


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5.2 PowerSystem5.2.1 Transformers

Figure43ControlTransformers CCXFistheControlCircuitTransformer.Thiswillprovidethecontrollerwith115VAC.Theprimary connectionswillvarydependingontheBuildingPower.Seetheschematicforsizingandwiring information. DOXForDXFaretheDoorCircuitTransformer(s).Thesizeandquantityofthesetransformerswill dependonthetypeofdoorsused.Seetheschematicforsizingandwiringinformation.


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5.3 SafetyInterfaceBoard

Figure44VirginiaControlsT1AInterfaceBoard

5.3.1 DigisetTimersThisunitisauniversalvoltagesolidstatetimerthatwill operatefrom19VACupto265VACandfrom10VDCupto 120VDC.Anytimeperiodbetween0.1secondand102.3 secondsisavailablein0.1secondincrementsandcanbeset withthedipswitch. Applicationofinputvoltagetothetimerstartsthetime delay.Attheendofthedelayperiod,theloadisenergized. Toreset,removetheinputvoltagetothetimer. Toselectatimeperiod,simplyadduptheselectedswitches intheONpositionforthetotaltimedelayinseconds. ThistimerprovidesadelayintheUpRuncircuit.

Figure45DigisetTimer PLCTractionControllerUserManual Page53

5.3.2 BypassSwitchesTheBypassSwitchesbypasseithertheCarDoorContact(s)or theHallDoorContacts,asrequiredbytheappropriatecodes. TheymayonlybeusedonInspectionOperation. ThecoderequiresusingtheseswitchestorunthecaronTop ofCarInspectionwiththedoorsopen,insteadofputting jumpersaroundtheDoorContacts. MovingeitheroftheseswitchestotheBypasspositionwill forcethecarontoInspectionOperation.

Figure46T1ABoardBypassSwitches WARNING:Useextremecautionwiththeseswitches,andalwaysmakesureitissafe tooperatethecarwiththeseswitchesclosed.

5.3.3 InspectionSwitches

Figure47T1ABoardInspectionSwitches TheInspectionSwitchesallowtheelevatortoberunonInspection,inaccordwiththeappropriate codes. NOTE:TheControllerInspectionButtonsarenotactivewhenonCarTopInspection. Tooperatethecar,slidetheINSPECTIONSWITCHtoINSPECTION,thenpresstheENABLEandUP orENABLEandDOWNbuttonstogether. WARNING: Use extreme caution when operating the car from the machine room. Makesureitissafetomovethecar.


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5.3.4 CutoutSwitchesMovetheHALLCALLCUTOUTSWITCHtoCUTOUTtocutout hallcalls. MovetheDOOROPENCUTOUTSWITCHtoCUTOUTtocutout dooroperation. Figure48T1ABoardCutoutSwitches

5.3.5 UDTXPotentiometerTheUDTXpotentiometeradjuststhetimingofthedropoutof relayUDTX.Itshouldbeadjustedsothatthebrakedrops whentheelevatorreacheszerospeed. (Clockwise=longerdelay)

Figure49T1ABoardUDTX Potentiometer


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6. ControllerNomenclatureSYMBOL AF,BF,etc. BK1,BK2 C D/D12,DX DC DL DZ ES,EST ESB FL,FLR FS,FSX FSD FSU IAS LC LL LV MG,MG12 N O P,PX PM PMP RU RUX/RUXP SAF12 STR SU TRU TRUP U/U12,UX UD UDT,UDTX UL VR DESCRIPTION BINARYCODEDFLOORPOSITIONRELAYS BRAKECONTACTORS DOORCLOSERELAY(INMODSSONTOPOFTHECAR,IFUSED) DOWNRUNREVERSINGCONTACTOR/RELAYS DOORCLOSEDRELAY DOWNLEVELRELAY DOORZONERELAY EMERGENCYSTOPSWITCHRELAY(OPTIONAL) EMERGENCYSTOPSWITCHBYPASSRELAY FIELDLOSSRELAYS FASTSPEEDRUNCONTACTORORRELAYS FASTSPEEDDOWNRUNRELAY FASTSPEEDUPRUNRELAY INSPECTIONACCESSRELAY LEVELINGCUTOUTRELAY LOWLEVELINGSPEEDRELAY LEVELINGRELAY MOTORGENERATORCONTACTOR,RELAYS DOORCLOSENUDGINGRELAY DOOROPENRELAY(INMODSSONTOPOFTHECAR,IFUSED) POTENTIALCONTACTOR,RELAY STARTER(ACROSSTHELINESTART) PUMPMOTORPILOTRELAY(110VDC) MOTORRUNCONTACTOR(WYEDELTASTART) M.G.SETRUNNINGCONTACTOR/TIMER SAFETYCIRCUITRELAYS MOTORSTARTCONTACTOR(WYEDELTASTART) SUICIDECONTACTOR WYEDELTAMOTORRUNRELAY(WYEDELTASTART) WYEDELTAMOTORRUNTIMER(WYEDELTASTART) UPRUNREVERSINGCON

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VCI PLCTractionUserManual(Rev 2 00)