Brake Board Manual

Revision Date: Aug 20, 2010

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

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 Safety during normal operation. ..................................................................................5
1.2.5 Hazards caused by electric power...............................................................................5
2.1 Product Overview ....................................................................................................6
2.2 Contents of the Brake Board Kit..............................................................................6
2.3 Connection of ECD Brake Board ............................................................................6
2.3.1 24VDC ............................................................................................................................6
2.3.2 BKSIGNAL ...................................................................................................................7
2.3.3 AC SUPPLY..................................................................................................................7
2.3.4 VAC BRAKE ................................................................................................................7
2.3.5 NO NC C ........................................................................................................................7
2.3.6 SIN 1 ...............................................................................................................................8
2.3.7 Brake Coil and Rectifier Connections......................................................................9
2.4 Setup of Brake Board .............................................................................................10
2.4.1 Vmax Adjustment...................................................................................................... 10
2.4.2 V1 Adjustment ........................................................................................................... 10
2.4.3 T1 .................................................................................................................................. 11
2.4.4 T2 .................................................................................................................................. 11
2.4.5 T3 .................................................................................................................................. 11
2.4.6 T4 .................................................................................................................................. 11
2.5 LED Sequence of Operation ..................................................................................12
3. Specifications ...........................................................................................................13
3.1. AC SUPPLY input voltage range............................................................................. 13
3.2.1 VAC BRAKE output current capable ratings. .................................................... 13
3.3. 24VDC brake board power supply........................................................................... 13
3.4. REL (NO NC C) contact ratings............................................................................... 13
4 Example Connection .................................................................................................14

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 equipment 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.
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.

1.2.4 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.

1.2.5 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.

2.1 Product Overview

The brake board is specifically designed to control elevator machine brakes across a wide
range of voltages and loads. It may also be used to control door lock cams to ensure smooth
and quiet cam operation.
The following of user adjustable parameters ensures smooth and quiet brake operation and
reduction of back EMF surges;
Brake lift time and voltage
Brake cooling time and voltage. (reduced holding voltage once brake has lifted)
Brake drop time

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
BKSIGNAL
AC SUPPLY
VAC BRAKE
NO NC C
SIN1

Brake board power supply

Brake lift input
Brake coil supply AC voltage only. Min 80VAC. Max 240VAC.
Brake coil connection
Loss of AC output relay
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.

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.

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.

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

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%. The minimum allowed
setting is 10% and the maximum setting is 100%.
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.

10

2.4.3 T1
This setting is used to control how fast the brake coil will get to full voltage (v max).
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 1500ms.
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.

11

2.5 LED Sequence of Operation

Fitted to the Brake Board are 3 LEDs which can be used to follow the sequence of operation
of the board. The LEDs are red, green and yellow.
During standby state both the red and yellow LEDs 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 LEDs are illuminated.
During T4 operation no LED is illuminated.
During V1 operation all LEDs 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.

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3. Specifications
3.1. AC SUPPLY input voltage range
80VAC 240VAC @50Hz
For AC SUPPLY input voltage less than 80VAC contact ECD for resistor upgrade.
3.2.1 VAC BRAKE output current capable ratings.
Output current ratings reduce as V Max reduces.
Eg. (with 240VAC input);
10 Amps @ 120VAC (V max = 50%)
20 Amps @ 240VAC (V max = 100%)
(with 110VAC input);
10 Amps @ 55VAC (V max = 50%)
20 Amps @ 110VAC (V max = 100%)

3.3. 24VDC brake board power supply

24 VDC
3.4. REL (NO NC C) contact ratings
0.5 @ 60VDC/125VAC

3.5. Setting Values

Default:
Vmax
V1
T1, T3 & T4
T2

35%
25%
500ms
1500ms

Minimum

Vmax
V1
T1 to T3
T4

10%
10%
100ms
0ms

Vmax
V1
T1 to T3
T4

100%
100%
5000ms
3000ms

Maximum

13

14

GRD

C2

L2

L3

L3

MOTOR 3

PE

PE

PE

KEB
COMBIVERT

L2

OH

Interference
suppression filter.

L1

L1

OH

C1

Isolate motor cables

from other wiring

Brake Resistor OH1

Temp Sw.
OH2

TO MAIN
LIFT C/B

BRAKING
RESISTOR

5v

31

32

EN

33

34

SUPPLY(VAC)

T1

240V

110V

NC

1000V 25A RECTIFIER

SUPPLIED BY ECD

L2A

14

13

BR2

SIGN:

18

21

SP4

DC

NO

NO

NO

PULSE

0V

24V

19

A+ (5V)

GND

PULSE BOARD

100-174

DO

22

EDP

Date 25-FEB-08

Control System

Job No:
KEB-1BrakeBoard-1SCHVF-PULSE BOARD

CBX

CBX

Rev:

DATE:

C2

14

TO SHHET 3
F/4

APP

NO

0V

TO SHEET 2
E/10

IMPORTANT.
TWIST THE 24VDC SUPPLY
WIRES TOGETHER AND LOOP
ONCE AROUND THE SUPPLIED
FERRITE CORE

TO SHEET 2
"10" G/1

C/B3 2A

CHANGES

BK

0V

RCD
10 A

Drawn

shield

BRAKE(VAC)

ECD BRAKE
BOARD

24V

F1 4A

100-174
CONTROLLER

10V

BR1

18V

BK SIGNAL 24V

11

C/B4 6A

0V

10V

440 VA

35

_
B GND

Revision:

_
A

"See Inst. Man.

6.3.1 for Conns."
CAUTION: Ensure any
unused conductors
within encoder cables are
terminated or islolated.

30

PB
X4

++

CURTAIN
OF LIGHT

PH

SHAFT
INFORMATION
SYSTEM

NE

COL

24v

C/B5 6A

Therm.

C/B1 16A

FAN

SIS

0v

C/B2 2A

X3.19

10

SCHINDLER
VF DOOR OP

SHEET

OF

100-174/1

c 1999-2006

CLOSE LIMIT

OPEN LIMIT

EARTH

C/B6A

Controller Terminals
Terminals on Circuit Boards
Field Terminals

100-174
POWER CIRCUIT

Drawing No:

0V

TO DFC
SHEET 5

0V

TO DFO
SHEET 5

TO ENCODER 5V
POSITIVE CHANNEL
AND ENCODER GND

KEB
CRAWL
SPEED

X3.18

22

DOB

VF100 KEB

21

4 Example Connection

Fig. 6.The diagrams below show an example of how to connect the Brake Board

14

SLACK
ROPE

TRAP
DOOR

TO SHEET 1
AREA D/6

L2A

TD

(if applies)

11

SR

SB

A1

A2

A1

A2

UDLR

47

46

DDLR

DN
DIR
LIMIT

A2

C1

A1

OT
14

D.O.T.
LIMIT

(if applies)

11

A2

CBX

A1

TR 15

12

MAINT. BOX
STOP

11/1

GOV
TENSION
WHEEL

UP
DIR
LIMIT

SG

PIT
LADDER
BOTTOM

SAFETY
GEAR

PIT
LADDER
TOP

13

14

LR

LR

16

BRK

J18

TO "C2-A1"
AREA D/9

A2

BK

21

24
(if applies) OT

14

J6
C

11

22

DF

M1

MSU

N/O C

UF

+24V

N/O C

J5

MSD

0V

SIGN:

N/O C

SP2

43

N Neutral

100-174

M4

0V

C2

N/O C

UP

44

1.2K 1W

DZ

M3

N/O C

DN

J29

1.2K 1W

24v

Date 24-JULY-07

Control System

Job No: KEB-BRAKEBOARD-1ECI

Rev:

DATE:

LR

M2

100-174

+24V

N/O C

SP1

MSU

MSD

KEB COMBIVERT

44

N/O C

SP3

41
LEV

1.2K 1W

BK

32

N/O

40

LANDING LOCKS

APP

0V

21

31

C2

+24V

BK. Use 2P
110vac relay

11

DZ

Drawn

CHANGES

SAF

39

LANDING LOCKS

DDLR UDLR

14

BRK-N/O

5
CAR DOOR
REAR

16/1

CAR DOOR
FRONT

COMMON
INSP BOX

TOP OF CAR
INSPECTION

Revision:

N Neutral

LRX

STOP
BUTTON
IN CAR

U.O.T.
LIMIT

0V
PRV

X3.17

X3.15
X3.16
X3.20
X3.21
Braking
control.
Main cont.
control.

X3.1
Cont. Control

X3.3
X3.4
X3.5
X3.6
X3.9
X3.10
X2.23
X2.11
X3.11
X3.12
Positioning/Relevelling VE
Rated/Max. speed VN
Insp. speed VI
Intermediate. speed V1
+24V
+24V
+24V
GND
GND
GND

X2.1
X2.2
X2.3
X2.4
Control release
Reset
Forward
Reverse

15

10

NB. SPD relay and OT contacts

for lifts with ETS. (above 1.0 m/s)

Controller Terminals
Terminals on Circuit Boards
Field Terminals

A2

C2

TO "X3.21"
AREA C/5

SHEET

OF

100-174/2

c 1999-2007

(if applies-see NB)

Drawing No:

A1

SPD

A2

21 C2 22 TO SHEET 1
B/6
BRAKE BOARD

100-174
CONTROL CIRCUIT

Decel Control

GOV
TO SHEET 1
OVER
AREA D/6
SPEED
ETS
10
10/1
11

Fig. 7

16

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

17