J.31_Cargo_Elevator_Tech_Manual.pdf

· TECHNICAL MANUAL

AGOR-23 AND FOLLOWSHIPS

CARGO ELEVATOR MODEL 503f-1

OPERATION AND MAINTENANCE

CRANE DEFENSE SYSTEMS

ROUTE 20, BOX 1126

CONROE, TEXAS n301

CAGE CODE - ODHG4

CONTRACT N0002~C;.2223

HMI P.O • . M2510

II /01

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REVISION 1 - 19 SEPTEMBER 1994

TECHNICAL MANUAL

AGOR-23 AND FOLLOWSHIPS

CARGO ELEVATOR MODEL 5031-1

OPERATION AND MAINTENANCE

CRANE DEFENSE SYSTEMS

ROUTE 20, BOX 1126

CONROE, TEXAS 77301

CAGE CODE - ODHG4

CONTRACT N00024-88-C-2223

HMI P.O. Ni"2510

REVISION 1 - 19 SEPTEMBER 1994

REVISION

DESCRIPTION

ORIGINAL PUBLICATION

REVISION STATUS

UPDATED FIGURE 6, CDS DRAWINGS, AND VENDOR DATA

DATE

9-19-94

Chapter

SECTION I.

1-1 1-2 1-2.1 1-2.2 1-2.3 1-2.4 1-2.5

CDS 5031-1

Table of Contents

Page

PHYSICAL AND PERFORMANCE CHARACTERISTICS ...... . ............ 1-1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

SYSTEM COMPONENTS .................................. 1-1

ELEVATOR CAR .................... ....... ............ 1-1

MACHINERY PACKAGE .................................. 1-1

HOISTWAY DOORS ..................................... 1-1

CONTROL SYSTEM ..................................... 1-1

ASSOCIATED SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 1-2

SECTION II. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1 SAFETY PRECAUTIONS .......... ............ ......... ... 2-1

SECTION III.

3-1 3-2 3-3 3-4 3-5 3-6 3-7

INSTALLATION INSTRUCTIONS AND PREPARATION FOR USE .......... 3-1

INTRODUCTION .............. ...... ................... 3-1

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 .

UNCRATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PRE-INSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 POST-INSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .. . . 3-3 SYSTEM CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

SECTION IV. OPERATING INSTRUCTIONS ................................... 4-1

4-1 INTRODUCTION ....................................... 4-1

4-2 NORMAL OPERATION ................. ............... ... 4-1

SECTION V.

5-1 5-2 5-3 5-3.1 5-3.2 5-3.3 5-3.3.1 5-3.3.2 5-3.3.3 5-3.3.4 5-3.3.5 5-3.3.6 5-3.3.7 5-3.3.8 5-3.3.9 5-4 5-4.1 5-4.2 5-4.3 5-4.4 5-4.5

TROUBLESHOOTING INSTRUCTIONS .. ..... .... .... .............. 5-1

INTRODUCTION ................ ... ......... ........... 5-1

GENERAL FUNCTIONAL DESCRIPTION ...................... 5-1

CONTROL SYSTEM FUNCTIONAL ELEMENTS . . . . . . . . . . . . . . . . . . 5-1

HALL PUSHBUTTON STATION ....................... ...... 5-1

SLOW UP, SLOW DOWN SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

INTERLOCKS ......................................... 5-2

Phase Protection Relay .................................... 5-2 Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Slack Rope Switch . . ................ ... .................. 5-2 Governor Overspeed Switch ......... ....... ...... .. .... . .... 5-2 Final Tenninal Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Door Locked Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Zone Switch ........................................... 5-2 Door Closed Switch ...................................... 5-2 Pit Switch ............................................ 5-2 SYSTEM CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 CALL INITIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 SEND-TO INITIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 LEVEL (CAR LOCATION) SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 DIRECTION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Chapter

5-5 5-5.1 5-5.1.1 5-5.1.2 5-5.1.3 5-5.1.4 5-5.2 5-5.2.1 5-5.2.2 5-5.2.3 5-5.2.4 5-5.2.5 5-5.2.6 5-5.2.7 5-5.2.8

SECTION VI.

6-1 6-1.1 6-1.2 6-1.2.1 6-1.2.2 6-1.2.3 6-1.2.4 6-1.2.5 6-1.2.6 6-1.2.7 6-1.2.8 6-1.2.9 6-2 6-2.1 6-2.2 6-2.3 6-2.4 6-2.5 6-2.6 6-3

APPENDIX A

APPENDIX B

ii

CDS 5031-1

Table of Contents (Continued)

CIRCUIT DESCRIPTION

POWER SUPPLIES

460-Vac 3-Phase System Power 120-Vac Control Power 120-Vac Operate Power +5 V de Logic Power

CONTROL CIRCUITS

Level Sensing Call/Send Initiation Direction Control Level Comparator Speed Control Interlocks Monitor Motor Drive Select Motor Control

MAINTENANCE INSTRUCTIONS

PREVENTIVE MAINTENANCE

ROUTINE CARE

INSPECTION REQUIREMENTS

System Inspection Wire Rope Inspection Inspect Guide Rails Inspect Hoistway Switches Cabling and Conduit Inspect Hoist Sheaves Inspect Governor Inspect Motor Controller Hoistway Pit Area Components Lubrication

ADJUSTMENTS AND ALIGNMENT

GUIDE SHOE CLEARANCE

HOIST ROPE ADJUSTMENT

GOVERNOR ROPE ADJUSTMENT

BRAKE ADJUSTMENT

RESETTING GOVERNOR OVERSPEED SWITCH

RESETTING CAR SAFETIES

CORRECTIVE MAINTENANCE

Page

5-3 5-3 5-3 5-3 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-6 5-6 5-6 5-6

6-1 6-1 6;1 6-1 6-1 6-1 6-1 6-1 6-1 6-1 6-2 6-2 6-2 6-2 6-2 6-2 6-2 6-2 6-2 6-3 6-3

PARTS LISTS AND DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-i

VENDOR DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-i

CDS 5031-1

SECTION I. PHYSICAL AND PERFORMANCE CHARACTERISTICS

1-1 GENERAL

Cargo Elevator Model 5031-1 is an electric winding drum system designed for installation on the AGOR-23 vessel. It has a rated capacity of 3,000 pounds and operates at an average speed of approximately 50 feet per minute. The car travels a distance of approximately 36 feet to serve 5 stops. The machinery package is located at the 02 level, overhead sheaves are located in the hoistway just below the 03 level and projecting into the hoistway at the 02 level.

EQUIPMENT SPECIFICATIONS

Power requirement

Hoist Type Drive Capacity Car size (inches)

Interior (Entrance)

Travel Stop Stations Hoistway doors

Average speed Control system

460-Volt, 60-Hertz, 3-Phase supply Winding drum Electric 3,000 pounds

32-1/2 D X 50 w 36 w X 72-3/16 H 36 feet 5, manual, swing, 36 x 72 clear 50 feet per minute Automatic call/send

1-2 SYSTEM COMPONENTS

Principal system components are described in the following paragraphs.

1-2.1 ELEVATOR CAR. The elevator car is a welded steel assembly with a rated capacity of 3,000 pounds. Upper and lower rail guide shoes are provided on the two sides of the car to maintain alignment during travel. The car is equipped with safeties which are designed to stop and hold the car in the event of an overspeed in the down direction. They are mounted beneath the car. Fixed mechanical and magnetic cams are also mounted on the car to unlock the hoistway doors and to trip the electrical zone and level switches located in the hoistway. The car is enclosed on three sides by wire mesh. A collapsible steel gate extends across the front of the car.

1-2.2 MACHINERY PACKAGE. The machinery package provides the driving forces to lift and lower the elevator car. It consists of a dual winding drum machine driven by a 10-horsepower, 2-speed, dripproof motor which requires a 460-Volt, 3-phase power source. The unit is equipped with a disc brake which is solenoid-released when the motor is energized and spring-set when the motor is deenergized. The motor drives the drums through a worm gear reducer. Slack rope switches are employed to open the control circuit and de-energize the electric motor should a slack rope condition be sensed at either hoist rope. All components are located on a single bedplate which is bulkhead mounted in a 02 level machinery compartment adjacent to the hoistway. The ma~hinery is isolation mounted to reduce noise and vibration transmission.

1-2.3 HOISTWAY DOORS. Five manually operated hoistway door assemblies with frames are provided. Each is a single panel swing type fire door. Each door is interlocked to prevent opening unless the elevator car is at the level.

The interlocks also prevent elevator operation while any door is open. A special key can release an interlock to enable a door to be opened for maintenance or emergency. All doors have a two inch sill to allow clearance for the two-inch deck coaming at each stop level. When open, a door provides a 36- by 72-inch clear passage to the elevator car. An automatic door closer is provided for each door.

1-2.4 CONTROL SYSTEM. The control system is a call/send system which accepts a command from any of its five hall control stations and completes that command before accepting another signal. The system is fused and interlocked for equipment protection and personnel safety. IN USE and ELEV HERE lamps located on each of the five hall control stations indicate system status.

1-1

System control is by means of a hall control station at each level, proximity and zone switches located in the hoistway at each level and actuated by magnetic cams on the elevator car, and the logic control panel. These elements function together to control the motor controller up/down contactor and fast and slow starter assemblies (contactors with overload relays). This process applies power to the appropriate motor windings to transport the elevator car to the calling station or to the send-to station. Other motor controller equipment includes a line disconnect (master) switch and overload resets. The unit is fused, provides protection from low voltage, phase loss and reversal, and contains the necessary transformer and terminal boards.

1-2.5 ASSOCIATED SYSTEM COMPONENTS.

Other elevator system components include an overspeed governor and tension weight, buffer

1-2 assemblies, guide rails, and wire ropes. The overspeed governor is a centrifugally-activated device located in the upper end of the .hoistway, provided to monitor car speed and to react to engage the safeties, shutoff the motor, and set the brake if the preset trip speed (140 feet per minute) is reached. The unit operates in conjunction with an endless 3/8-inch diameter wire rope which is connected to the car safety device and a tension weight assembly located below the governor in the hoistway pit.

Buffer assemblies are located at the bottom of the hoistway and are designed to stop and support the car should it be lowered to that point.

The guide rails are standard elevator T-rails which weigh about 8 pounds per foot. There are two hoisting wire ropes, each of which is 1/2-inch in diameter and has a breaking strength of 22,000 pounds.

SECTION II. SAFETY PRECAUTIONS

2-1 SAFETY PRECAUTIONS

The Model 5031-1 Cargo Elevator is an inherently safe system when used as design intended.

Following are p ecautions which must be observed to ensure tha t operation and maintenance activities remain safe:

1. Do not ride in or allow anyone else to ride in the elevator car.

2. Do not override or bypass any interlocks.

3. Do not enter the elevator hoistway for .

maintenance unless the 460-volt power control switch (ON-OFF switch on motor controller) is OFF and WARNING tagged.

2-1/(2-2 blank)

SECTION III. INSTALLATION INSTRUCTIONS AND PREPARATION FOR USE

3-1 INTRODUCTION

This section provides information for installation of Crane Defense Systems shipboard elevator Model5031-1. The equipment has been assembled and tested as a system before shipment from the factory. The installation task is to assemble the system in the hoistway and machinery room in the vessel for which it was intended, and to verify its correct operation.

Included in this section are safety precautions, uncrating instructions, and sequenced installation instructions. Installation drawings are included in Appendix A to this document. Before any installation is attempted, this section should be reviewed and the drawings studied carefully so that installation personnel will become familiar with the equipment and installation requirements.

An overhead crane, suitable fork lift truck, work scaffolding, and standard power and hand tools (normal shipyard equipment) are necessary to accomplish this task.

3-2 SAFETY PRECAUTIONS

Observe the following general safety precautions during installation of the elevator equipment:

WARNING

The electrical input to the system at the motor controller is 460 V AC. Extreme care must be exercised when working with and about voltage of this magnitude.

WARNING

DO NOT wear loose clothing, especially neckties. Buttons should be buttoned at all times, and steel-toe type shoes and safety glasses should be worn at all times.

Wear a hard hat while working in the hoistway.

3-3 UNCRATING

The elevator system is shipped in three segments:

the machinery package, the guide rails, and the elevator car which carries the motor controller and the remaining components and parts.

Uncrate the system as follows:

1. Remove wooden crating from packaged elements.

2. Remove barrier material and plastic covering.

3. Cut banding straps.

4. Discard strapping, packing material, blocking, etc.

5. Transport equipment to shipboard installation site.

6. Carefully remove components and parts shipped in elevator car.

7. Discard any remaining dunnage.

3-4 PRE-INSTALLATION INSPECTION

After unpacking equipment, inspect for in-transit damage and any other obvious defects. Verify that all equipment is present by checking the packing list (remember that some equipment elements were pre-assembled before shipment).

Report any damage or discrepancy immediately.

3-5 INSTALLATION PROCEDURE

The following procedures should be followed using standard shipyard tools and equipment while observing normal shipyard practices and precautions. Installation should, in general, be in the sequence given. Some non-interfering tasks may be performed simultaneously if sufficient skilled manpower is available.

Remember, however, that the elevator car assembly is completely assembled and must be placed in the hoistway before it is closed off.

3-1

Normal car installation is thru the top of the hoistway.

While referring to Cargo Elevator General Arrangement drawing 5031 and other drawings as may be referenced, proceed as follows:

1. Install guide rails the length of the hoistway using brackets and hardware provided.

Use a guide wire, stretched taut from top to bottom of hoistway on centerline of clear opening to be sure rails are straight. Adjust position as necessary to bring car sill distance within tolerance when checked at intermediate levels.

2. Install car buffer assemblies, and governor tension weight bracket and governor tension weight.

3. Install machinery package (dwg 50311200) in machinery compartment.

4. Install motor controller (50311205) and logic controller (50311206). Install cables CA2 and CA4 between motor controller and electric motor, and cable CAl from motor controller to a 460-V 60-Hz 3-ph supply. Connect per 50318020.

5. Cut hoist wire rope into two pieces (one about eight feet longer than the other) and install a socket bolt on one end of each rope.

Attach ropes to restraint brackets on bottom of car. Run each rope onto its rope guide and install rope retainers on rope guides. Secure rope coils temporarily at top of car.

6. Install car assembly (50311000) in hoistway, engaging forward and aft guide rails, then lower car assembly to rest on the buffers, taking care that ropes are not snagged in the process.

7. Install sheaves at top of hoistway and at 02 level in machinery compartment.

8. Reeve hoist ropes up over sheaves and secure to machinery package hoist drums. Be sure there is 1-1/2 to 2 wraps on each drum with car on buffers.

3-2

NOTE

The system installation task can be .made easier if a temporary platform is put on the car top and the car used as a moveable work station. Connect a temporary control pendant to the up/down contactor and to the slow starter assembly to enable car control -- extreme care must always be use when operating in this mode, there are no interlocks or safeties.

9. Install hoistway door frames and doors (5), and interlock assemblies. Adjust interlock roller arms so the rollers are displaced 1 to 1-3/8 inch when the car cam operates them.

10. Install hall control stations (5).

11. Install hoistway level switch assemblies (5), zone switch assemblies (5), final terminal switch assemblies (2), and the pit switch.

12. Install governor assembly near top aft side of hoistway. Be sure that it is oriented correctly so the bail will swing toward the center of the hoistway when actuated.

13. Install governor rope:

a. Reeve rope over governor rope sheave and allow both rope ends to hang to bottom of hoistway.

b. Run inboard end of rope between two screw projecting from roller arm on side of car base.

c. Block governor tension weight so that it is one inch below its full up position (at sheave centerline).

d. Reeve outboard end of rope around governor tension weight sheave and up between two screws on roller arm (adjacent to other end of rope), then install keeper and hold with two nuts finger tight.

e. While pulling both ends of the rope to remove slack, tighten nuts holding rope keeper then cut off excess length and tie ends to the adjacent rope.

f. Remove blocking from beneath governor tension weight.

14. Install electrical conduit and cables and make connections per AGOR-23 Running List of Electrical Cable Terminations drawing 50318020. Before removing temporary control arrangement, ensure all in-hoistway conduit and cabling is secure and out of harms way and move car the length of the hoistway checking clearances and adjustments.

15. Carefully remove work platform from the car assembly and clear hoistway.

3-6 POST-INSTALLATION INSPECTION

Make visual inspection of elevator system per table 3-1.

3-3

Table 3-1. Post-Installation Checklist

NOTES: 1. Verify that all mounting bolts, screws, nuts are in place and tight on every component examined.

2. On each electrical component, be sure that stuffing tube/pass thru is tight and that cable run to it is secure.

ITEM

1. Pit stop switch

2. Buffer -- forward -- aft

3. Governor tension weight:

Bracket Tension weight

4. Final terminal switch (down limit)

5. Car rail guides

6. Level switch assy (5)

7. Zone switch assy (5)

8. Door intlk mechanism (5)

CONDITION

per dwg 5031, sht 2 & 4 per dwg 5031, sht 2 per dwg 5031, sht 2 per dwg 5031, sht 2 Load carried by governor rope --about one inch below top travel limit.

per dwg 5031, sht 2 & 4

Free on rails, no binding. (Adjust hoist ropes or rail shims as appropriate.)

per dwg 5031, sht 4 per dwg 5031, sht 4 per dwg 5031, sht 3

9. Level control station (5) (hall per dwg 5031, sht 3 pushbutton sta)

10. Final terminal switch (up limit) per dwg 5031, sht 2 & 4

11. Top hoist sheave per dwg 5031, sht 2

12. 02 level hoist sheave per dwg 5031, sht 2

13. Governor per dwg 5031, sht 2

14. Logic controller per dwg 5031, sht 2 & 4

15. Motor controller per dwg 5031, sht 2 & 4

16. Machinery package per dwg 5031, sht 2

17. Hoistway access door and door per dwg 5031, sht 3 closer

3-4

VERIFIED

3-7 SYSTEM CHECKOUT

At least three people are needed for initial checkout of this system. One safety watch must remain at the motor controller at all times and two people are required to operate and verify system response. Good, reliable communications must be available at all hall stations and the machinery compartment (motor controller).

Proceed as follows:

WARNING

Initial operation of an elevator system can be unpredictable and very hazardous because of the possibility of incorrect connections or hidden shipping damage.

Follow the procedure as given.

1. Verify that the hoistway above and below the car, and the car are clear of tools, equipment, and personnel. Set pit switch to ON.

2. Verify that hoistway access doors are closed at all levels (5).

3. After verifying that all test personnel are safe, apply ship source power to elevator system, then at motor controller, set system power ON/OFF switch to ON.

4. At tank top level, CALL the car -- the car should travel from its initial location and stop at tank top level, and ELEV HERE lamp should light.

5. Open hoistway access door, then attempt to send car to each of the other levels -the car should not move. Access doors at other levels cannot be opened.

6. Close hoistway access door, send the car to the next lowest level, and then CALL it back (after interlock and lamp are checked).

When car reaches the commanded level the ELEV HERE lamp lights and the hoistway access door can be opened (and closed).

7. Repeat step 6., sending the car, in turn, to each of the remaining untested levels -work from the lowest level upward.

8. Repeat steps 4. thru 7. at each of the remaining levels. After checking tank top level, it is unnecessary to check hatchway access door interlocks anymore.

9. Check down final terminal switch:

WARNING

Be extremely careful when operating relays and contactor manually, 460-Vac power is active in the motor controller.

a. With car at tank top level and hoistway access door closed, have person stationed at machinery compartment carefully lower car by opening the motor controller door, holding slow speed starter closed manually, and operating the down contactor briefly manually to jog the car down four to five inches -- car does not respond to CALL and hoistway door (tank top level) cannot be opened.

b. Return car to its normal opera~ing range by holding slow speed relay closed manually, and operating the up contactor briefly manually to jog the car up clear of the down final terminal switch.

10. Check up final terminal switch:

a. CALL/send car to 01 level, open 01 level hoistway access door, and open car gate.

b. Working thru car overhead, tape/tie back actuating arm of up final terminal switch (at 02 level, aft).

c. Exit car, close gate, and close hatchway access door.

d. Attempt to send car to any other level -car should not respond to any send or CALL command.

e. Open 01 level hoistway access door and car gate.

f. Working thru car overhead, remove tape/ties from up final terminal switch actuator arm and be sure it operates freely.

3-5

g. Exit car, close car gate, and close hoistway access door.

h. Send car to any other level -- it should respond normally.

3-6

11. An elevator capacity overload test should be accomplished per procedures set forth in ANSI-17 by qualified personnel.

SECTION IV. OPERATING INSTRUCTIONS

4-1 INTRODUCTION.

The Model 5031-1 Cargo Elevator is designed for continuous service, and once energized may be left in the operating mode indefinitely. Should circumstances so warrant (eg. test or maintenance procedures), the system can be easily shutdown and re-energized when ready for use again.

4-2 NORMAL OPERATION

Following is the normal operating scenario for the cargo elevator (the system is assumed to be energized (ON/OFF switch on motor controller set to ON) and the car not at your level):

1. If IN USE lamp is lit, standby until it goes off.

2. Press CALL pushbutton at your level.

(The car will leave the other level, travel to your level, and stop.)

3. When ELEV HERE lamp lights, open hoistway door.

4. Open car gate and load car as .

required.

WARNING

Personnel must not ride in car, there are no in car controls or emergency exit provisions.

5. Ensure no one is in car, then close car gate.

6. Press appropriate level send-to button.

(The car will leave your level, travel to the directed level, and stop.)

4-1/(4-2 blank)

SECTION V. TROUBLESHOOTING INSTRUCTIONS

5-1 INTRODUCTION.

Trouble diagnostic techniques require that maintenance personnel be aware of the locations of all system controls and indicators, and sensing and interlock devices, and know the functions of each of these components. Typical elevator problems (trouble symptoms) are as follow:

1. Inability to keep the system running.

2. Inability to CALL or SEND the car at one station.

3. Inability to CALL or SEND the car at more than one station.

4. Inability to operate at rated load capacity.

5. Inability to operate at rated speeds.

6. Malfunction of a safety device.

The troubleshooting guide (table 5-1) will aid the technician who is unfamiliar with the system. It is a guide to localizing a fault and defining the corrective action that should be taken.

You are most effective troubleshooting when you know how the system functions. The following paragraphs explain how the components function, their relationships, and system operation.

5-2 GENERAL FUNCTIONAL DESCRIPTION

The Model 5031-1 Cargo Elevator is a call/send system serving five levels. The car is suspended in the hoistway by two half-inch wire ropes.

Each rope is routed up thru a sheave and to a rope drum on which it is wound. The rope drums are on a common shaft thru a worm drive, speed reducer gearbox. The gearbox is driven by a ten horsepower, reversible, ac electric motor with brake. This arrangement pays out or reels in rope to lower or raise the car.

A hall pushbutton station is located at each level adjacent to, to the right of the hoistway access door. Each station shows system status and allows the car to be called to that level or to send the car from that level to any other level. The car is available to command anytime the IN USE lamps are not lit. (They light simultaneously on all levels.) The ELEV HERE lamp lights at a level when the car enters within 18 inches of the level whether stopping or passing to another level. This lamp stays lit until the car enters the adjacent level sensing zone.

5-3 CONTROL

ELEMENTS

SYSTEM FUNCTIONAL

5-3.1 HALL PUSHBUTTON STATION. The five hall pushbutton stations are functionally the same. Each has a CALL button and four send to buttons which are described in paragraphs 5-

4.1 and 5-4.2 respectively. Two status lamps are on each station, ELEV HERE and IN USE. The ELEV HERE lamp lights when the car enters within 18 inches of the level of the station and remains lit until the car travels to within 18 inches of an adjacent station.

The IN USE lamps on all hall pushbutton stations operate simultaneously. When the car is CALLed or is in motion, and when a hoistway access door is open (for loading/unloading), these lamps are lit. There is also a ten-second delay after the car stops at a level during which the circuit remains active. This delay prevents the car from being CALLed away before the hoistway access door can be opened at the stopped level.

5-3.2 SLOW UP, SLOW DOWN SWITCHES.

The slow up and slow down switches are magnetic proximity switches. A pair of these switches is installed in the hoistway on the forward side at each level. The slow down switch is installed about nine inches above door sill level and the slow up switch is about 18 1/2 inches below the slow down switch. They are positioned so they are adjacent to a magnetic cam on the car when the car is at level. A magnetic cam is a vertical steel bracket 18 inches long welded to the forward side of the car. It is centered on the car floor and has a magnet mounted at each end.

The presence of the steel surface alone is

5-1 sufficient to activate an adjacent proximity switch, however, the addition of the magnets improves switch response.

5-3.3 INTERLOCKS. Interlocks are included in the system to prevent or stop system operation when an unsafe condition is detected (50318010, sheet 2). This minimizes the potential for personal injury or equipment damage.

5-3.3.1 Phase Protection Relay. The phase protection relay in the motor controller monitors the ship source 460-Vac, 3-phase supply. It senses the presence of all three phases and the proper phase rotation. When all three phases are present and in correct rotation, the relay is energized.

5-3.3.2 Overload Relay. An overload relay is a part of each starter assembly (slow, fast) in the motor controller. Heater coils sense the current in each phase passing thru the starter assembly.

Excess current flow in any phase causes its coil to overheat and it trips the relay to open the K3 interlock, removing power from the electric motor.

The reset button on the motor controller/starter assembly (overload relay) must be pushed to return the starter assembly to operating status.

5-3.3.3 Slack Rope Switch. A slack rope switch is mounted on the machinery package (50311200) adjacent to each hoist rope. The switch actuator is positioned so that if the cable sags, it will cause the switch to open to stop the motor.

5-3.3.4 Governor Overspeed Switch. This switch on the governor is actuated when the governor trips because of a car downward overspeed condition. It causes power to be removed from the electric motor. This switch remains open until the governor is reset.

5-3.3.5 Final Terminal Limit Switch. Final terminal limit switches (50311013) are installed in the hoistway just above and just below the normal travel range of the car. These switches shut off the system if the car fails to stop normally at the 02 level or the tank top level.

The upper switch operates when the car travels about two inches above 02 level and the lower switch operates when the car is about four inches

5-2 below tank top level. They are operated by a cam on the aft side of the car.

5-3.3.6 Door Locked Switch. A switch in the interlock assembly (GAL Type M) senses when the interlock actuator is displaced by the cam on the car. When this actuator is operated, the latch at that level is unlocked and the switch is opened. As the car moves from the level, the actuator rolls off the car cam, the interlock assembly returns to the locked condition, and the switch closes. Identical interlock assemblies are at each level.

5-3.3. 7 Zone Switch. The zone switches, in the hoistway at each level, are proximity switches.

They are to the right of the level switches at door sill height. They are operated by a magnetic cam identical to and adjacent to that which operates the level switches. A zone switch is activated when the car is within nine inches of the access door sill level. This switch functions to momentarily bypass the door locked switch at that level to enable uninterrupted operation of the car to an address beyond that level, and it enables normal stopping and leveling at the 02 level and the tank top level.

5-3.3.8 Door Closed Switch. A second switch in the interlock assembly (paragraph 5-3.3.6) opens when the hoistway access door at that level is opened. This open condition prevents the electric motor from being started as long as the door is open.

5-3.3.9 Pit Switch. The pit switch is near the bottom of the hoistway in the pit area, clear of all moving parts. It is a maintenance safety switch and is opened when personnel enter the pit for any purpose. As long as it is open, the electric motor start circuit is disabled.

5-4 SYSTEM CONTROL OPERATION

5-4.1 CALL INITIATION. As long as the IN USE lamp is not lit, pressing the CALL button sets up circuits in the logic controller to cause the car to travel to that level. If the IN USE lamp is lit, CALL signals are ignored. If the CALL button is pressed while the car is at the level, the IN USE lamps will light for about ten seconds.

5-4.2 SEND-TO INITIATION. Four send-to buttons are located on each hall pushbutton station (50318010, sheet 3). These buttons are enabled only when the ELEV HERE lamp on that station is lit. At the car-here level, the send-to buttons are used to address the car to any other level. These selection circuits are not inhibited by the IN USE signal. Once a send-to button is pressed, that address is held in memory until the car reaches that address, all subsequent inputs are ignored. The system can respond to drive the car to the addressed level only when all interlocks are satisfied.

5-4.3 LEVEL (CAR LOCATION) SENSING.

Proximity switches located at each level sense the presence of a magnetic cam on the forward side of the car as the car travels to that level.

Depending on the direction of car travel, either, a slow down switch or a slow up switch located at the level being approached is activated by the magnetic cam about 18 inches before the car reaches the level. This initiates a signal which causes the ELEV HERE lamp to light and, if the level is the destination level, it causes the drive motor to shift to slow speed (paragraph 5-5.5).

Because of a logic latching circuit, the current level ELEV HERE lamp will remain lit until the car presence is sensed at another level. At this time, the departed level ELEV HERE lamp goes off and the current level ELEV HERE lamp lights.

5-4.4 DIRECTION CONTROL. Direction control is a function of the logic system. It uses the CALL or send-to signal as compared to the ELEV HERE level signal to determine which direction to run the electric motor to move the car to the addressed level. The level sensing switches at the addressed level tell the system when the car arrives and when it should stop. A two-second delay timer allows the car to stabilize before the car here control signal is removed (this is not the level indicating signal). If the car should overshoot the level (more than one-half inch) for any reason, before the two seconds has elapsed, the logic output stops the timer and reverses the motor at slow speed to return the car to level until told to stop. The two-second timer starts again when the stop signal is triggered. Removal of the car here control signal clears the logic system to enable a CALL from another station

(paragraph 5-4.6) or insertion of a send-to command.

5-4.5 SPEED CONTROL. Speed control is an automatic function of the logic system. When an address is in the system and all interlocks are satisfied (50318010, sheet 3), the motor controller · is caused to run the electric motor up or down, as necessary, at fast speed (50 feet per minute).

When the presence of the car is sensed approaching the addressed level (paragraph 5-4.3) by the slow up (or slow down) switch, the logic controller causes the fast starter to be deenergized and the slow starter to be energized.

The electric motor rpm drops to slow speed. As the car continues toward the addressed level at slow speed (19 feet per minute), the magnetic cam activates the slow down (or slow up) switch simultaneously with the slow up switch to produce a stop signal to shut off the electric motor. The switch and magnetic cam physical geometry is devised to align the car deck with the hoistway access door sill when the stop signal is triggered. Initial operation is alw~ys at fast speed, slow speed is used for level approach and leveling (paragraph 5-4.4).

5-5 CIRCUIT DESCRIPTION

5-5.1 POWER SUPPLIES. Ship source 460-V 60-Hz 3-phase power is the only external power required for this system (50318010, sheet2).

5-5.1.1 460-Vac 3-Phase System Power. The ON/OFF switch on the motor controller applies ship source power to the elevator circuits thru fuses F1, F2, and F3. This 460-Vac 3-phase system power is used to drive the ten-horsepower electric motor (via a contactor and starter assemblies) and energizes the 460 V to 120 V stepdown transformer Tl.

5-5.1.2 120-Vac Control Power. Stepdown transformer T1 is connected across phases A and C of 460-V 3-phase system power, its output is 120 Vac. Fuses F4 and F5 in the outputs of transformer T1 provide overload protection. This supply is used to operate the interlock relays K2 and K3, and the IN USE and ELEV HERE lamps, and to energize the +5 Vdc logic power supply.

5-3

5-5.1.l 120-Vac Operate Power. This is a limited segment of the 120-Vac circuitry. Operate power is available when interlock relays K2 and K3 are energized, it is used to energize interlocks satisfied relay K4 to enable the logic control module, and to operate the motor up/down contactor and the starter assemblies.

5-5.1.4 +5-Vdc Logic Power. The +5-Vdc supply located in the logic controller is always energized when 120-Vac control power is available. This supply is used to power the level encoder, the control module, and the solid state relays (SSR1 thru SSR10) in the logic controller. Also, this supply is used by the hall pushbutton stations and the slow up and slow down switches to generate command signals (call, send-to, slow, and stop).

5-5.2 CONTROL CIRCUITS. Elevator control circuits (figure 5-1) determine car direction and speed in response to CALL or SEND-TO commands entered at hall pushbutton stations.

To accomplish this, circuits must sense car location, command required direction, prevent car operation if an unsafe condition exists, turn on drive motor, and slow and stop drive motor when the car arrives at destination level.

5-5.2.1 Level Sensing. Whenever the car is within 18 inches of a level, a slow up or slow down magnetic proximity switch at that level sends a ground signal (logic low) to the level encoder. The level encoder then generates a three-bit code corresponding to the car position.

This code is immediately stored in memory and remains there until the car activates another slow up or slow down switch on a different level. At that time, the new car position code is entered in memory.

The three-bit memory output drives the level decoder. The level decoder produces a discrete output for each level. These discrete car level signals supply the level comparator and direction control circuits with car location. The car level signals also drive solid state car here relays (SSR6 thru SSR10 in local controller) to light the ELEV HERE lamp on the appropriate hall pushbutton station.

5-4

5-5.2.2 Call/Send Initiation. Pressing a CALL button on a hall pushbutton station applies +5 V de to memory circuits. If the systeJll is not currently in use, this +5 Vdc signal latches the call level address in address memory until the car arrives at that level and clears the memory.

With a call address in memory, any subsequent call or send command is rejected. When the hoistway door is open to access the car, all call command inputs are disabled.

Pressing a send-to button on a hall pushbutton station applies +5 Vdc to enter an address in memory if the car here relay for the initiating level is energized and the address memory is clear. Whenever the car here relay for a level is energized, the ELEV HERE lamp for that level is lit. As with call commands, once a "send to" command is latched in memory, all subsequent commands are rejected.

The address memory produces a discrete address signal for each level when an address is latched in memory. The signal for that level becomes the address signal to the level comparator ·and direction control circuits. Whenever a call or send-to command is latched in memory, an address-in-memory signal lights the IN USE lamps on all levels.

5-5.2.3 Direction Control. Direction control circuits compare car level signal (from level decoder) to the address signal from address memory. If the address is a level above current level, direction control circuits generate an up command. When the address is a level below, a down command is generated. An address to current level results in no direction control response. Up and down commands are each discrete signals that provide direction input to motor drive select circuits.

5-5.2.4 Level Comparator. Level comparator circuits compare car level to the address level.

When the car level signal matches the address level, the comparator generates a car here signal (paragraph 5-5.2.1). The car here signal is routed to speed control circuits to initiate a slow speed command and then, when both proximity switches are activated simultaneously, a stop command.

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I SLOW DOWN J CAR LEVEL

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SPEED

CONTROL

DIRECTION

r:------1 CALl/SEND INITIATION - - - - - I

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1 HAll CALUSEND

I ADDRESS

LEI EVEL CONTROL UP/ UP/DOWN

1 PUSHBUTTON COMMAND ADDRESS

I STAT ION MEMORY

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L _____ _ _ _j

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INTERLOCKS

MONITOR

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t--INTERLOCKS _____.

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MOTOR

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DRIVE

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The car here signal is terminated two seconds after the stop command if both switches remain continuously activated (car floor remains level with sill, does not overrun).

5-5.2.5 Speed Control. Speed control circuits command fast speed until a car here signal indicates that address level has been reached.

The slow up or slow down proximity switch signal that registered car current level into level encoder/decoder memory is also applied to speed control circuits. This signal causes speed control circuits to terminate fast speed command and initiate a slow speed command. When slow up and slow down signals are present simultaneously, speed control initiates a stop command to motor drive select circuits and to interlock monitor circuits.

5-5.2.6 Interlocks Monitor. Interlocks monitor circuits disable elevator operation when an unsafe condition exists including an open hoistway access door. Interlock monitor circuits also function to clear address memory, disable call commands for a period after the car stops, and initialize control circuits when power is turned on and after an interlock is closed. A stop command from speed control circuits initiates a memory clear signal and a two-second delay for this signal. If the car remains at level (stop command uninterrupted) for the two-second delay period, address memory is cleared, motor drive select circuits are disabled, and a ten-second timer is started.

During this ten seconds, call inputs to address memory are disabled (a send-to input can be inserted). If the hoistway access door is not opened (or another interlock switch opened), the motor drive circuits are enabled (enable signal) at completion of the ten-second delay. The IN USE lamps remain lit during the delay period.

5-5.2. 7 Motor Drive Select. Motor drive select circuits are enabled by a signal from interlocks monitor and disabled by a stop command from

5-6 speed control. When the enable signal is present and a stop command is not present, direction (up/down) and speed (fast/slow) signals control solid state relays SSRl thru SSR4. An up or down command from direction control energizes either SSRl (up) or SSR2 (down) and a fast or slow signal from speed control energizes either SSR3 (fast) or SSR4 (down). When en~rgized, SSR1 thru SSR4 apply 120 Vac to the coils of the motor control contactors.

5-5.2.8 Motor Control. An up/down (reversing) contactor, a fast starter assembly (contactor with overload relay), and a slow starter assembly control 460-Vac 3-phase power to the ten horsepower motor. The up/down contactor controls motor direction by controlling 3-phase power direction of rotation. When the up coil is energized, A-B-C phase rotation will drive the motor to lift the car. When the down coil is energized, phase rotation is reversed (A-C-B) and the motor will turn in the opposite direction, lowering the car when it runs. The contactor up and down coils are interlocked thru no~ally closed contacts of the other section to prevent energizing both sections at the same time. A mechanical interlock also prevents simultaneous operation of both sections of the up/down contactor.

When the fast starter contactor is energized, 460- Vac power is applied to the motor fast windings, driving the motor at fast speed -- 1200 rpm.

When the slow starter contactor is energized, 460- Vac power is applied to the motor slow winding, driving the motor at slow speed -- 450 rpm. The fast starter assembly is interlocked with the slow starter assembly to prevent application of power to the motor fast windings at the same time the slow windings are energized. The fast command to the fast starter contactor is routed thru a normally closed contact in the slow starter contactor, thus when a slow command energizes the slow starter contactor, the fast starter contactor is disabled.

Table 5-l. Fault Isolation

WARNING: 460-Vac power is used in this system, be especially careful working in and around the motor controller and electric motor.

NOTES: 1. Refer to drawings 50318010, 50318035, and/or 50318036 as appropriate to identify pertinent test points (electrical terminals) for circuit segment isolation.

SYMPTOM

2. Use a meter with a 20K ohms per volt (or greater) input impedance for voltage measurements.

3. Be sure system power is shut off when resistance or continuity checks are made.

PROBABLE

CAUSE

IMMEDIATE

ACTION

REMEDY

Elevator does not move, no lamps lit.

Loss of 460-Vac, 3-ph power.

Access motor controller:

Loss of 120 Vac power.

Loss of +5 V de.

Verify ship supply thru fuses F1, F2, F3.

Verify 120 Vac thru fuses F4, F5.

Access logic controller:

Verify +5 Vdc out of power supply.

1. Turn on ship's supply.

2. Replace fuse(s) F1, F2, F3 -- why blown?

NOTE

Monitor system initial operation for mal function.

1. Replace fuse(s) F4, F5.

2. Replace transformer Tl.

Replace +5 V de logic power supply.

5-7

SYMPTOM

When CALL or send is initiated, motor makes "straining" noise, then stops.

Car does not respond to CALL or send inputs, ELEV HERE lamp is lit (correctly).

5-8

CDS 5031-1

Table 5-l. Fault Isolation (Continued).

PROBABLE

CAUSE

Motor fault.

1. Motor fault.

IMMEDIATE

ACTION

1. Access motor controller:

a. Check fuses F1, F2, F3.

b. Check overload heater coil continuity.

2. Access hoistway:

Examine hoisting drive train and car to determine if there is a jammed or seized element.

1. Access motor controller:

a. Check for 460 Vac at fast starter assy. terminals Tll, T12, Tl3.

b. Check for 460 V ac at fast starter assy. terminals D, E, F (overload input).

REMEDY

Replace blown fuse(s).

1. Replace open overload heater coil.

2. If good, go to next step.

1. Correct mechanical problem if apparent.

2. Replace motor. ·

1. If present, replace motor.

2. If not present, reset overload relay and repeat step.

3. If not present on repeat, go to next step.

1. If present, replace fast starter assy.

2. If not present, go to step 2.a.

Table 5-l. Fault Isolation (Continued).

PROBABLE

CAUSE

2. Motor control interlock circuit open or fault.

IMMEDIATE

ACTION

a. Check for 120 V ac across TB 1- 16 and -2 (relay K2 coil).

b. Check for 120 Vac across TBl-1 and FOL-2 (relay K3 coil).

c. Check for 120 Vac across TB2- 14 and -13 (relay (LC) K4 coil).

d. Check for 120 V ac across relay K2 (or K3) terminals 7 and 9.

2. Access logic controller:

a. Check for 120 Vac across TBl-9 and -8.

b. Check for 0 Vdc at K4-7 (or PI- 55)

REMEDY

1. If present, go to next step.

2. If not present, isolate and close or replace interlock switch.

1. If present, go to next step.

2. If not present, isolate and close or replace interlock switch.

1. If present, go to step 2.a.

2. If not present, isolate next step.

1. If present, replace relay K3.

2. If not present, replace relay K2.

1. If present, go to next step.

2. If not present, isolate fault to motor controller TB2-14 and -13.

1. If 0 Vdc (ground), replace relay K4.

2. If not 0 Vdc, go to step 3.1.

5-9

5-10

CDS 5031-1

Table 5-l. Fault Isolation (Continued).

PROBABLE

CAUSE

3. Relay or contactor fault.

4. Logic control system fault.

IMMEDIATE

ACTION

Access motor controller:

1. Check for 460 V ac at fast start assy terminals A, B, and C.

2. Check for 120 Vac across TB2- 18 and -14.

3. Check for 120 Vac across TB2- 14 and fast starter assy terminal XL

4. Check for 120 Vac across TB2- 14 and -15 or TB2-14 and -16.

Access logic controller:

1. Check for logic low input (less than 1.5 Vdc) at SSR1-4 or SSR2- 4.

2. Check for logic low input at

SSR4-4.

REMEDY

1. If present, go to next step.

2. If not present, go to step 3.4.

1. If present, go to next step.

2. If not present, go to step 4.2.

1. If present, replace fast starter assy.

2. If not present, replace slow starter assy.

1. If present at either place, replace contactor.

2. If not present, go to step 4.1.

1. If at SSR1 or SSR2, replace that unit.

2. If not at either unit, replace control module (at P1).

1. If present, replace

SSR4.

2. If not present, replace control module (at Pl).

Car responds down but not up, ELEV HERE lamp lights (correctly).

Car responds up but not down, ELEV HERE lamp lights (correctly).

CDS 5031-1

Table 5-l. Fault Isolation (Continued).

PROBABLE

CAUSE

Contactor or control fault.

Contactor or control fault.

IMMEDIATE

ACTION

1. Access motor controller:

a. Check for 120 Vac across TB2- 14 and -15.

2. Access logic controller:

With car called/sent to upper level, check for logic low at

SSR1-4.

1. Access motor controller:

Check for 120 Vac across TB2-14 and -16.

2. Access logic controller:

With car called/sent to lower level, check for logic low at

SSR1-4.

REME:f?Y

1. If present, replace contactor.

2. If not present, go to next step.

1. If present, replace SSRl.

2. If not present, replace control module (at P1).

1. If present, replace contactor.

2. If not present, go to next step.

1. If present, replace

SSR1.

2. If not present, replace control module (at P1).

5-11

Table 5-l. Fault Isolation (Continued).

SYMPTOM PROBABLE IMMEDIATE REMEDY

CAUSE ACTION

Car stops about 18 1. Motor fault. Access motor inches short of level. controller:

1. Check for 460 1. If present, replace Vac at slow motor.

starter assy.

tenninals T1, T2, 2. If not present, T3. reset overload and repeat check.

3. If not present on repeat check, go to next step.

b. Check for 460 1. If present, replace Vac at slow slow starter assy.

starter assy.

tenninals D, E, F 2. If not present, go (overload input). to step 2.1.

2. Relay/control 1. Check for 120 1. If present, replace fault. Vac across TB2- slow starter assy.

17 and -14.

2. If not present, replace control module.

2. Check for logic 1. If present, replace low at SSR3-4. SSR3.

2. If not present, replace control module.

Car does not go to Control module Access logic Replace control correct level when fault. controller. module (at P1).

sent or called. ELEV HERE lamp lights (correctly).

5-12

ELEV HERE lamp does not agree with car location.

ELEV HERE lamp lit continuously at one level.

Car cannot be sent from one level, can be CALLed away, ELEV HERE lamp lights (correctly).

Car cannot be sent to a specific level from any…