Brake Board Manual

Revision Date: Dec 21, 2009

ECD System
Manual
 ELECTRONIC CIRCUIT DESIGNS PTY. LTD.

Operation Guide

This manual covers all versions of Brake Board

hardware and software, although some features
mentioned in this manual might not be available on
earlier versions

 Electronic Circuit Designs Pty. Ltd.

Factory 11/30 Perry Street • Matraville • NSW • Australia • 2036
Phone 61 2 9316 6909 • Fax 61 2 9316 6797
Email sales@ecd.com.au Web www.ecd.com.au

2
Table Of Contents

Section 1.1 Safety Regulations......................................................................................4

Section 1.2 Obligations & Liability ...............................................................................4
1.2.1 Following operating instructions....................................................................................4
1.2.2 Obligations of operator. ..................................................................................................4
1.2.3 Obligations of personnel.................................................................................................4
1.2.4 Hazards associated with the equipment........................................................................5
1.2.5 Warranty and liability. ......................................................................................................5
1.2.6 Organisational measures..................................................................................................5
1.2.7 Protective equipment. ......................................................................................................5
1.2.8 Informal safety measures.................................................................................................6
1.2.9 Training of personnel.......................................................................................................6
1.2.10 Machine controls. ...........................................................................................................6
1.2.11 Safety during normal operation....................................................................................6
1.2.12 Hazards caused by electric power................................................................................6
2.1 Product Overview ....................................................................................................7
2.2 Contents of the Brake Board Kit..............................................................................7
2.3 Connection of ECD Brake Board ............................................................................7
2.3.1 24VDC .............................................................................................................................7
2.3.2 BKSIGNAL ....................................................................................................................8
2.3.3 AC SUPPLY....................................................................................................................8
2.3.4 VAC BRAKE..................................................................................................................8
2.3.5 NO NC C ........................................................................................................................8
2.3.6 SIN 1 ................................................................................................................................9
2.3.7 Brake Coil and Rectifier Connections ...................................................................... 10
2.4 Setup of Brake Board .............................................................................................11
2.4.1 Vmax Adjustment........................................................................................................ 11
2.4.2 V1 Adjustment............................................................................................................. 11
2.4.3 T1................................................................................................................................... 11
2.4.4 T2................................................................................................................................... 12
2.4.5 T3................................................................................................................................... 12
2.4.6 T4................................................................................................................................... 12
2.5 LED Sequence of Operation ..................................................................................13
3 Specifications ............................................................................................................14
3.1. AC SUPPLY input voltage range................................................................................ 14
3.2. VAC BRAKE output ratings ....................................................................................... 14
3.3. 24VDC brake board power supply ............................................................................. 14
3.4. REL (NO NC C) contact ratings ................................................................................ 14
4 Example Connection .................................................................................................15

3
Section 1.1 Safety Regulations
• Installation of this equipment shall be done in accordance with all applicable local
codes

• Elevator controllers and other electrical components can cause serious harm or
death if installation guides are not met. It is the responsibility of the installer of our
equipment to ensure that once installed, the equipment does not pose any threat,
danger or hazard.

Section 1.2 Obligations & Liability

1.2.1 Following operating instructions.

• In order to ensure safe handling and problem free operation of this
equipment, it is absolutely essential for the relevant personal to be fully
acquainted with the relevant safety regulations.
• These operating instructions contain the most important information for
operating the machine correctly and safely.
• These operating instructions, in particular the safety regulations, must be
observed by all those persons who work on the equipment.
• Furthermore, all locally applicable rules and regulations relating to accident
prevention and installation must be observed.

1.2.2 Obligations of operator.

The operator undertakes to allow only those persons to work on the equipment
who
• Are fully acquainted with the basic regulations relating to safety in the
workplace and accident prevention and to have been trained in handling the
equipment.
• Have read the safety regulations and the warning notices contained in these
the operating instructions.
• Regular checks are conducted to ensure that personnel perform their duties
with safety considerations foremost in their minds.

1.2.3 Obligations of personnel.

All personnel charged with working on the machine undertake prior to starting
work to
• Observe the basic regulations relating to safety in the workplace and
accident prevention.
• Read the operating instructions, in particular the safety regulations, and
confirm by way of their signature that they have understood them.

4
1.2.4 Hazards associated with the equipment.
The equipment is built with state-of-the-art technology and recognized safety
regulations. Nevertheless, use of the equipment can result in dangers to life and
limb for the installer, user or a third party and in impairments to the equipment or
to other material property. The equipment must only be used
• For its intended purpose.
• In perfect condition in terms of safety requirements.

Operate the equipment in technically perfect condition and for its intended use only
while bearing in mind all safety and hazard considerations and following the
operating instructions. In particular, faults which restrict safety must be rectified
immediately after they have been identified and at the latest before the equipment is
started up.

1.2.5 Warranty and liability.

Our “Sales terms and conditions” apply. These terms and conditions will have been
available to the purchaser at time of sale. Warranty and liability shall be limited to
repairs and replacement to the equipment purchased from us. Warranty and liability
claims shall not be entertained if they can be traced back to one or more of the
following causes.
• Equipment not used for its intended purpose.
• Improper installation, startup, operation and maintenance of the equipment.
• Operation of the equipment with faulty safety devices or improperly
installed or non-operational safety and protective equipment.
• Failure to observe the information, instructions and notices contained in the
operating instructions relating to transportation, storage, installation,
startup, operation, maintenance and setting up of the equipment.
• Inadequate monitoring of the equipment parts which are subject to wear.
• Improperly conducted repairs.
• Catastrophes caused by the influence of foreign bodies and force majeure.

1.2.6 Organisational measures.

• The installer and or maintainer shall provide the necessary protective
equipment for the personnel
• All existing safety equipment must be checked at regular intervals.

1.2.7 Protective equipment.

• At all times, prior to putting the machine into operation, all protective
equipment must be correctly installed and in proper working condition.
• Protective equipment may only be removed
- after the machine has come to a complete stop and the machine has
been disabled to ensure it cannot be started up again.
- if subcomponents are delivered, the operator must install the
protective equipment in accordance with regulations

5
1.2.8 Informal safety measures.
• Keep the operating instructions and circuit diagrams permanently at the
site where the equipment is installed.
• In addition to the operating instructions, the generally valid and local
regulations relating to accident prevention and environmental protection
must be provided and observed.
• Maintain all safety and danger notices on/next to the machine in legible
condition and comply with them.
• If the equipment is sold or transferred, the operating instructions must be
included with the equipment.

1.2.9 Training of personnel.

• Only personnel who have been trained and instructed are allowed to work
on the machine.
• The responsibilities of the personnel must be clearly defined for the
machine/controller installation, startup, operation, setting-up, maintenance
and repairs.
• Personnel still in the process of being trained are only permitted to work at
the machine under the supervision of an experienced person.

1.2.10 Machine controls.

• Under no circumstances carry out any program modifications to the
software!
• Only properly instructed personnel are permitted to operate the controls.
• The machine must not be operated if potential electromagnetic interference
sources are acting on the machine. Interference sources are e.g. welding
equipment, portable phones.

1.2.11 Safety during normal operation.

• Only operate the machine when all protective equipment is fully
operational.
• Prior to switching on the machine, ensure that the startup can cause no
harm to personnel.
• Regularly maintain and check machine for externally identifiable damage
and check that all the safety devices are operational.

1.2.12 Hazards caused by electric power.

• Work on the electric power supply may only be carried out by a qualified
electrician.
• Check the electrical equipment of the machine at regular intervals.
Repair loose connections and scorched cables immediately.
• Keep the control cabinet locked at all times. Access is only permitted to
authorized personnel with a key or tool.
• If work has to be carried out on live parts, do this only in the presence of a
second person who can switch off the master switch in an emergency.
• The machine causes electromagnetic interference sources. For this reason,
do not use any sensitive equipment in its vicinity.

6
2.1 Product Overview
The brake board is specifically designed to control elevator machine brakes across a wide
range of voltages and loads.
With the aid of user adjustable parameters, brake lift, brake drop and brake cooling voltages
and times can be set to ensure smooth and quiet brake operation and reduce back emf surges.
The brake board can also be used to control door lock cams to ensure smooth and quiet cam
operation

2.2 Contents of the Brake Board Kit.

1 brake board
1 ferrite core
1 1000v 35A bridge rectifier
4 crimp lugs for rectifier
1 power diode for brake coil back EMF protection
1 system manual

2.3 Connection of ECD Brake Board

Below is a list of the connection terminals on the brake board.

24VDC Brake board power supply

BKSIGNAL Brake lift input
AC SUPPLY Brake coil supply AC voltage only
VAC BRAKE Brake coil connection
NO NC C Loss of AC output relay
SIN1 Spare input (not used)

For diagrams of the following terminals refer to see Section 4, Fig.6 & 7.

2.3.1 24VDC
The 24VDC input is the power supply to the microprocessor and as such should be as stable as
possible.
Supplied in the kit is a ferrite core that is to be installed on the 24Vdc supply. The wires for
this supply should be twisted together then looped once through the ferrite core (see fig.1).
Note this is particularly important if the board is being supplied from a switch mode power
supply.

7
Fig. 1

2.3.2 BKSIGNAL
The BKSIGNAL input is the signal from the lift controller to initiate the brake lift sequence.
This input only requires a voltage free contact.

2.3.3 AC SUPPLY
The AC SUPPLY terminal is used for the AC voltage @ 50Hz for the brake board.
This voltage is regulated by the brake board and output from terminal VAC BRAKE to control
the brake

Important Note: This voltage cannot exceed 240Vac and must be @ 50Hz

2.3.4 VAC BRAKE

The VAC BRAKE terminal is the AC output from the Brake Board to the Brake coil.
As a DC voltage is required for most brake coils, use the supplied rectifier on this output.

2.3.5 NO NC C
The NO NC C relay contacts are used to signal to the lift controller that a fault has occurred
with the brake board, inhibiting any further lift operation. See example Section 4, Fig. 6 & 7,
where the relay C & NO contacts are used for the controller PRV (prove) input.

When the brake board is functioning normally, the fault relay will be energized.

When any of the faults listed below are detected the fault relay will drop out:

• Loss of AC SUPPLY. “Loss of AC!” will be displayed on the LCD. (No AC voltage at
AC SUPPLY, Fig. 2). Brake board will remain inoperative until AC SUPPLY restored.

8
 Fig. 2

• Loss of 24VDC
• Triac shorted. “Triac damaged!” will be displayed on the LCD. (Fault detected with
Triac, Fig. 3).
This fault is a fatal error and requires a 24VDC reset. Note: If a triac fault is detected
while the brake board is operating, the brake board will finish the run and set the Triac
damaged fault when BK SIGNAL turns off.

Fig. 3

The relay contacts are rated as follows:

Max Voltage: 125 VAC or 60VDC
Max Current: 0.5A

Note: This relay is not rated for use in the Safety Circuit of most elevator controllers. If the
intend use of relay C and NO contacts is to open the Safety Circuit then an appropriately rated
slave relay must be used.

2.3.6 SIN 1
This terminal is currently not used and no wires should be connected.

9
2.3.7 Brake Coil and Rectifier Connections
The wiring from the VAC BRAKE output to the rectifier and brake should be sized according
to the load of the brake coil.

The supplied power diode needs to be connected “reverse biased” at the brake coil for back
EMF suppression.

+ BRAKE
COIL
-

10
2.4 Setup of Brake Board
The Brake Board has 6 adjustable parameters which can be adjusted to optimize the operation of
the brake:

Vmax
V1
T1 to T4

Vmax

V1

T1 T2 T3 T4
Fig. 4

Note: The graph show the sequence of operation from when BK SIGNAL is triggered

2.4.1 Vmax Adjustment

Vmax is used to set the maximum AC voltage output (VAC BRAKE) and is expressed as a
percentage value of the input voltage (AC SUPPLY)
Vmax is a code protected user adjustable setting. To adjust this setting, first go to LCK and set
to 6789.

E.g.1. Set to 50% if AC SUPPLY is 240VAC and you require 120VAC at VAC BRAKE.
E.g.2. Set to 100% if AC SUPPLY is 240VAC and you require 240VAC at VAC BRAKE.

The Brake Board is shipped with Vmax set at a default value of 35%.
After any adjustments to Vmax, it is recommended that LCK be changed to any value other
than 6789, so as to prevent an accidental vmax parameter change, which may cause an over
voltage supply to the brake coil.

2.4.2 V1 Adjustment
V1 is the holding voltage for the brake coil and is adjustable to a percentage of the input
voltage at the AC SUPPLY terminal; it is also interlocked to the Vmax setting so that it cannot
be set to a higher value than Vmax. The minimum allowed setting is 10% and the maximum
setting is 100% or Vmax whichever is the lesser.

The Brake Board is shipped with V1 set at a default value of 25%.

Once the lift is running this value can be adjusted either up or down to give the desired brake
hold voltage and thus cooling effect.

2.4.3 T1
This setting is used to control how fast the brake coil will get to full voltage (v max).
11
It is adjustable in steps of 50 ms.
The minimum allowed setting is 100ms and the maximum allowed setting is 5000 ms.
Default setting is 500ms.

2.4.4 T2
This setting is used to control how long the brake coil will stay at full voltage.
It is adjustable in steps of 50 ms.
The minimum allowed setting is 100ms and the maximum allowed setting is 5000 ms.
Default setting is 500ms.

2.4.5 T3
This setting is used to control how fast the voltage will reduce to V1 level after the T2 time
expires.
It is adjustable in steps of 50 ms.
The minimum allowed setting is 100ms and the maximum allowed setting is 5000 ms.
Default setting is 500ms.

2.4.6 T4
This setting is used to set how fast the brake voltage will reduce to 0v after the BK SIGNAL is
switched off.
It is adjustable in steps of 50 ms.
The minimum allowed setting is 0ms and the maximum allowed setting is 3000 ms.
Default setting is 500ms.

12
2.5 LED Sequence of Operation
Fitted to the Brake Board are 3 LED’s which can be used to follow the sequence of operation
of the board. The LED’s are red, green and yellow.
During standby state both the red and yellow LED’s are illuminated.
During T1 operation only the red LED is illuminated.
During T2 operation only the green LED is illuminated.
During T3 operation the red and green LED’s are illuminated.
During T4 operation no LED is illuminated.
During V1 operation all LED’s are illuminated.

GREEN
Vmax

RED & GREEN

RED
RED,YELLOW and GREEN
ALL OFF
V1

T1 T2 T3 T4

Fig. 5 Note: The graph show the sequence of operation from when BK SIGNAL is triggered

Flashing yellow LED indicates the brake board is in the following fault state;
• Loss of AC SUPPLY. “Loss of AC!” will be displayed on the LCD. (No AC voltage at
AC SUPPLY). Brake board will remain inoperative until AC SUPPLY restored.

Flashing red LED and illuminated yellow LED indicates the brake board is in the following
fault state:
• Triac shorted. “Triac damaged!” will be displayed on the LCD. (Fault detected with
Triac). This fault is a fatal error and requires a 24VDC reset. Note: If a triac fault is
detected while the brake board is operating, the brake board will finish the run and set
the Triac damaged fault when BK SIGNAL turns off.

13
 3 Specifications
3.1. AC SUPPLY input voltage range
36VAC – 240VAC @50Hz

3.2. VAC BRAKE output ratings

6 Amps @ 36VAC
20 Amps @ 240VAC

3.3. 24VDC brake board power supply

18 VAC or 24 VDC +/- 10%

3.4. REL (NO NC C) contact ratings

0.5 @ 60VDC/125VAC

3.5. Setting Values

Default:
• Vmax 35%
• V1 25%
• T1 to T4 500ms

Minimum
• Vmax 10%
• V1 10%
• T1 to T3 100ms
• T4 0ms

Maximum
• Vmax 100%
• V1 100%
• T1 to T3 5000ms
• T4 3000ms

14
 1 2 3 4 5 6 7 8 9 10

Controller Terminals
Terminals on Circuit Boards
G Field Terminals

C/B5 6A
FAN
5

2 6

Therm. 7

F 1
R
C/B2 2A
TO MAIN S
LIFT C/B C/B1 16A
T

GRD
E C/B6A
2 4 6 N 240V
4 Example Connection

0v 24v T1 440 VA EARTH

C1 NE PH
EDP DOB
SIS 21 22 21 22
1 3 5 COL 4
SHAFT
INFORMATION CURTAIN 110V 4 SCHINDLER
SYSTEM OF LIGHT
10V 18V VF DOOR OP
C
DO NO
- 3
RCD 3
D L1 L2 L3 PE BR1 10 A C DC NO
Interference 2
suppression filter. L2A 2
+ SP4
F1 4A C NO X3.18 X3.19
C/B3 2A
1
L1 L2 L3 PE 24V 0V 100-174 KEB 1
0V 10V
++ CRAWL
100-174 TO SHEET 2
OH "10" G/1
SPEED
Brake Resistor OH1 KEB BRAKING CONTROLLER
- PULSE BOARD
RESISTOR

15
C Temp Sw. OH2 OH COMBIVERT
24V
PB
W V U PE X4
"See Inst. Man. C/B4 6A 0V GND TO ENCODER 5V
6.3.1 for Conns." POSITIVE CHANNEL
CAUTION: Ensure any BK A+ (5V) AND ENCODER GND
5 3 1 11 14 IMPORTANT.
unused conductors TWIST THE 24VDC SUPPLY
within encoder cables are WIRES TOGETHER AND LOOP TO SHHET 3
PULSE
C2 ONCE AROUND THE SUPPLIED F/4
terminated or islolated. FERRITE CORE OPEN LIMIT
6 4 2 SUPPLY(VAC) BK SIGNAL 24V
B TO DFO
_ _
5v A A B B GND ECD BRAKE 0V SHEET 5
W V U BOARD
0V
Isolate motor cables BRAKE(VAC) NC NO C
from other wiring CLOSE LIMIT
30 31 32 33 34 35 shield
TO SHEET 2 TO DFC
E/10 SHEET 5
CBX
+

0V
MOTOR 3 1 2
C2
A 14 13 18 19
BR2
EN CBX
1000V 25A RECTIFIER 3 4

SUPPLIED BY ECD c 1999-2006

Job No:
Revision: Drawing No: 100-174/1
CHANGES DATE: SIGN: KEB-1BrakeBoard-1SCHVF-PULSE BOARD
Fig. 6.The diagrams below show an example of how to connect the Brake Board

A Drawn 100-174
Control System
B APP
POWER CIRCUIT

C Rev: Date 25-FEB-08 VF100 KEB SHEET 1 OF 5

 1 2 3 4 5 6 7 8 9 10
TO SHEET 1 GOV PIT PIT GOV
OVER LADDER LADDER TENSION D.O.T. U.O.T. Controller Terminals
AREA D/6 TOP BOTTOM WHEEL LIMIT LIMIT Terminals on Circuit Boards
SPEED TOP OF CAR CAR DOOR CAR DOOR LANDING LOCKS LANDING LOCKS
Fig. 7

ETS INSPECTION FRONT REAR Field Terminals

10 10/1 11 11/1 12 13 14 16
11 14
G
(if applies) OT 16/1 39 40 41 NB. SPD relay and OT contacts
11 14 COMMON for lifts with ETS. (above 1.0 m/s)
(if applies) INSP BOX
SB LEV

TRAP STOP
DOOR BUTTON
IN CAR MSD MSD

TD SR SG TR 15
SLACK SAFETY MAINT. BOX J6 DZ J5 MSU MSU J29
ROPE GEAR STOP SAF C N/O M1 M2 M3
F
100-174

J18
C
UP DN
DIR BRK DF UF SP3 SP1 SP2 DN UP 0V
DIR
LIMIT LIMIT
E BRK-N/O 24v PRV
C N/O C N/O C N/O C N/O C N/O C N/O C N/O C
21 C2 22 TO SHEET 1
B/6
46 47 1.2K 1W BRAKE BOARD

TO "X3.21"
AREA C/5

D 14 14
24
A1 A1
LRX LR (if applies) OT DDLR UDLR
DDLR UDLR 21 +24V
11 11
A2 A2
C2
LR C2
BK. Use 2P A2
BK 110vac relay 43 44
A2 44
N Neutral
+24V M4

16
C A1 A1
TO "C2-A1" +24V
C2 A2
C1 CBX AREA D/9 31 32 LR DZ
0V 100-174 (if applies-see NB)
A2 A2 SPD
BK A1
21 22 N Neutral
L2A
1.2K 1W 1.2K 1W
TO SHEET 1
0V 0V
B
AREA D/6

X3.15
X3.16
X3.20
X3.21
X3.6
X2.3
X2.4
X3.17

X3.1
X3.3
X3.4
X3.5
X3.9
X3.10
X2.23
X2.11
X3.11
X3.12
X2.1
X2.2 Reset

+24V
+24V
+24V
GND
GND
GND
Reverse
Forward

Cont. Control
Decel Control

Insp. speed VI
Control release

A
Rated/Max. speed VN

Braking
control.
Main cont.
control.
Intermediate. speed V1

KEB COMBIVERT
Positioning/Relevelling VE

c 1999-2007
Drawing No:
Revision: CHANGES DATE: SIGN: Job No: KEB-BRAKEBOARD-1ECI 100-174/2
A Drawn 100-174
Control System
CONTROL CIRCUIT
B APP

C Rev: Date 24-JULY-07 SHEET 2 OF 5

17
18
19
ELECTRONIC CIRCUIT DESIGNS PTY. LTD.

Operation Guide

 Electronic Circuit Designs Pty. Ltd.

Factory 11/30 Perry Street • Matraville • NSW • Australia • 2036
Phone 61 2 9316 6909 • Fax 61 2 9316 6797
Email sales@ecd.com.au Web www.ecd.com.au

20