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LD-16 Door Operator - Modernization

Clutch Assemblies

October 2021 - 88420 v.1.0

A-1

Clutch Assemblies

GAL ENGAGED

Front View Isometric View

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Front View Isometric View

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GAL Interlock Rollers (364AG_)

Summary of Contents for LD-16

Page 1: ...LD 16 Door Operator FOR MODERNIZATION ...

Page 2: ... resulting from any error or omission The material contained herein is subject to revision Please report any problems with this manual to Vertical Express P O Box 2019 Memphis Tennessee 38101 Vertical Express P O Box 2019 Memphis Tennessee 38101 2021 Vertical Express All rights reserved Published October 2021 First Edition Printed in the United States of America Manual Number 88420 v 1 0 ...

Page 3: ...er Installation 27 Overview 27 Universal MOD Kit 200CJD 28 Separate Header Installation 35 New Existing Car Door Panel Installation 44 Car Door Panel Adjustment 47 Set Eccentrics on the Car Door Hanger 48 Clutch Installation and Adjustment 49 Adjust Door Contacts and Door Lock Contact Relating Cable Adjustment 53 Adjust Car Door Interlock Restrictor 54 Verify Running Clearances 55 Block LD 16 Clut...

Page 4: ...Interface Setup 74 I O Signal Definitions 75 I O Wiring Diagram 76 Calculate Minimum Door Closing Times 77 Based on Kinetic Energy 77 Car or Hoistway Door Weight 78 Maintenance 82 Replace the Door Operator Control Board 82 Replace the Drive Belt 83 Replacement Parts 84 APPENDIX Clutch Assemblies A 1 GAL Interlock Rollers 364AG_ A 1 MAC Interlock Rollers 364AG_ A 2 TKE Interlock Rollers 364AG_ A 3 ...

Page 5: ... controller check that all manufacturing wire connections are tight on relays contactors fuse blocks resistors and terminals on boards and DIN rail terminals Connections loosened during shipment may cause damage or intermittent operation Other specific warnings and cautions are found where applicable and do not appear in this summary See the Employee Safety and Accident Prevention Program Manual a...

Page 6: ...turers instruction book for proper test equipment operation and adjustments Buzzer type continuity testers can damage electronic components Connection of devices such as voltmeters on certain low level analog circuits may degrade electronic system performance Always use a voltmeter with a minimum imped ance of 1 M Ohm Volt A digital voltmeter is recommended Mechanical Safety See the Employees Safe...

Page 7: ...ions on the guidelines below Handling Store boards in separate sealed anti static bags until time for installation When handling boards wear an anti static wrist strap with ground wire Acceptable straps are available through local electronics parts suppliers Typical anti static wrist straps are intended for applications below 240 VAC Do not place boards on any surface without adequate static prote...

Page 8: ...cessing the car top place the stop switch in the STOP position and confirm the proper operation Locate a safe refuge area Always maintain control of the hoistways doors during access egress Fall protection is to be used when a fall hazard exists The only exception to this is when routine maintenance is being performed on top of complete operational elevator cars Do Not use fall protection where th...

Page 9: ...ng a pit ensure that every employee is aware of the hazards Some common hazards are Recognized refuge space Inadequate lighting Improper access Tripping hazards Improper use of pit ladders Moisture water fluid Moving equipment Safety Precautions Before Entering a Pit Take appropriate steps to minimize the following hazards and any others that are identified such as Locate the position of the car b...

Page 10: ... the pit hoistway until authorization is received Safety Precautions When Working In Pits Before entering a pit test and verify the door lock circuit and stop switch circuit Ensure that all portable lights and tools are connected through a ground fault GFCI Take care to protect all lighting from damage DO NOT work in a pit with standing water Before climbing always examine shoes for fluid grease U...

Page 11: ...ctober 2021 88420 v 1 0 3 Overview Integral Cab Header Center Opening Two Speed Assembly 3002BJ Center Opening Single Speed Assembly 3002BF Side Opening Two Speed Assembly 3002BH Side Opening Single Speed Assembly 3002BG Cimarron Assembly 3002BN ...

Page 12: ...ee Universal MOD Kit 200CJD Installation on page 28 Mount Door Operator on this Side End Clip Rear Support Kit To obtain clearance with existing equipment use the proper door angle for the job installation or Door Mounting Angle and Strut 1Ƽ X 1Ƽ 20 Door Mounting Formed Angle Center Opening 32 60 shown ...

Page 13: ...C Humidity range 98 maximum 40 C Regulations and codes ASME A17 1 CSA B44 EN81 Electromagnetic compatibility Immunity and emission protection EN12015 16 Maximum movable masses 600 lbs 270 kg 1322 lbs 600 kg Estimated lifetime More than 3 million cycles More than 5 million cycles Safety device for cab egress Car door interlock Door operator noise level sound levels in a stopped car Average 55 dBA M...

Page 14: ... dBA 50 avg 55 max 45 avg 50 max Door Cycles Lifetime 7 000 000 10 000 000 Hours Lifetime Hours 12 000 20 000 NR Pole 4 4 Rated Voltage V 36 42 Rated Speed rpm 4000 3300 Rated Torque Nm 0 22 0 41 Nominal Current A 3 45 4 Rated Output Power W 92 142 Efficiency 84 5 Overload Imax Irated 5 7 DC Link Voltage V 18 to 42 18 to 75 Rotor Inertia gcm 119 760 Max Cogging Force Ncm 85 9 85 9 Cogging Torque M...

Page 15: ...ed head Allen key Flat Phillips screwdrivers Torpedo or tool box level Tape measure or folding ruler Door pressure gauge 1 4 cordless impact with 12 extension Sawsall with metal cutting blades MOD applications Pallet jack Hand trucks Tin snips Pry bar Claw hammer Tri square Small plumb bob Large channel locks 5 16 nut driver for impact 3 8 impact gun adapter Wire strippers Scribe Electrical tape S...

Page 16: ...w equipment 5 Remove part of the header for clearance of the mounting angles so that it is even with the top of the header See Figure 2 on page 9 6 Use the included hardware to install the mounting angles See Figure 3 on page 9 for Dimension C Other Installation Configurations Starts on Single Speed Center Opening Doors Integral Cab Header page 21 Two Speed Side Opening Doors Integral Cab Header p...

Page 17: ...pening 0ȻōȚ Strike End of the Header C Ʉ ŎȚ Mounting Angles Remove Part of the Header if necessary for Clearance of the Mounting Angles C C 1 Clear Opening ŐƽȚ B C Primary location for keyslots used to brace the door operator back to the cab start at 1 from the clear opening and spaced at Dimension C inches See Chart for Dimension C right hand shown left hand opposite DOW B C 32 23 27 34 25 29 36 ...

Page 18: ... hardware to attach the adapter angle to the header but do not tighten leave hardware loose to allow adapter alignment with track keyslots a Use low profile bolts at the following locations When looking from the strike end of the side opening Small Hole Slot Right Hand Openings No Hole Slot Left Hand Openings b Use push nuts to help position the low profile bolts Figure 4 Adapter Angle Installatio...

Page 19: ...tallation continued Figure 5 Adapter Angle Installation 2 of 2 C B Clear Opening Clear Opening Door Lap standard door lap 6 3 right hand shown Top of Door Panel qô AáČ ZðáĦÔ áÔûôǎ Small Hole Slot RH Opening No Hole Slot LH Opening From strike end of side opening Use Push Nuts To Position AáČ ZðáĦÔ áÔûô Push Nut Push Nut right hand shown ŐƽȚ ŐƽȚ ƜƭƂƇ ...

Page 20: ...ator to the adapter angle See Figure 6 below and Figure 7 on page 13 a Align the door track bolts with the keyslots in the track and attach the door operator to the adapter b Verify that the door operator is level c Verify that there is 51 4 between the clear opening and the B dimension d Use a 3 16 Allen wrench to tighten down the bolts 11 Install the door operator mounting angles 12 Add bolts to...

Page 21: ...021 88420 v 1 0 13 Single Speed Side Opening Doors Integral Cab Header Installation continued Figure 7 Door Operator Machine Installation 2 of 2 Side Opening Operator The Mounting Angle Toe is Facing the Motor Front View Top View Almost Flush with Top of Operator Mounting Bolt ...

Page 22: ...door operator See Figure 8 17 Route the wiring harness through the 11 2 flex conduit and then install the 11 2 flex and straight connectors 18 Install the wiring harnesses through the flex conduit insert the OPERF or OPERR plug into the COP harness end 19 Install the CTS to the top of the junction box See Figure 8 20 Before routing cable tie the CTS wiring 21 Proceed to New Existing Car Door Panel...

Page 23: ...ipment 5 Remove part of the header for clearance with mounting angles so that it is even with the top of the header See Figure 10 on page 16 6 Use the included hardware to install the mounting angles See Figure 11 on page 16 for Dimension C Other Installation Configurations Starts on Single Speed Side Opening Doors Integral Cab Header page 8 Single Speed Center Opening Doors Integral Cab Header pa...

Page 24: ...Keyslots and Door Operator Machine to Clear Opening 0ȻōȚ Strike End of the Header C Ʉ ŎȚ Mounting Angles Remove Part of the Header if necessary for Clearance of the Mounting Angles 1 3 D D D E Clear Opening 2SP Clear Opening E D 21 23 24 26 27 29 30 32 33 24 25 27 28 30 31 33 34 36 36 38 40 42 44 46 48 50 52 2SP Clear Opening E D 35 36 38 39 41 42 44 45 47 48 37 39 40 42 43 45 46 48 49 51 54 56 58...

Page 25: ...ded hardware to attach the adapter angle to the header but do not tighten leave hardware loose to allow adapter alignment with track keyslots a Use low profile bolts at the following locations When looking from the strike end of the side opening Small Hole Slot Right Hand Openings No Hole Slot Left Hand Openings b Use push nuts to help position the low profile bolts Figure 12 Adapter Angle Install...

Page 26: ...ab Header Installation continued Figure 13 Adapter Angle Installation 2 of 3 9 Route the door operator harness to the Car Operating Panel COP See Maintenance on page 82 and the Generic Wiring Diagrams on page A 16 Do not install the plugs on the operator door card or on the COP Before moving the car replace the door card cover ...

Page 27: ...rack bolts with the keyslots in the track and attach the door operator to the adapter b Verify that the door operator is level c Verify that there is 51 4 between the clear opening and the B dimension d Use a 3 16 Allen wrench to tighten down the bolts 11 Install the door operator mounting angles 12 Add bolts to brace the cab to the door operator back 13 Check for plumb 14 Verify that the track to...

Page 28: ...r operator See Figure 15 17 Route the wiring harness through the 11 2 flex conduit and then install the 11 2 flex and straight connectors 18 Install the wiring harnesses through the flex conduit insert the OPERF or OPERR plug into the COP harness end 19 Install the CTS to the top of the junction box See Figure 15 20 Before routing cable tie the CTS wiring 21 Proceed to New Existing Car Door Panel ...

Page 29: ... header of all door operator parts and components that may interfere with new equipment 5 Remove part of the header where necessary for clearance with mounting angles located 21 from the center See Figure 17 on page 22 6 Use the included hardware to install the mounting angles See Figure 18 on page 22 Other Installation Configurations Starts on Single Speed Side Opening Doors Integral Cab Header p...

Page 30: ...nting Angles 21 2 Mounting Angle 21 from Center of Opening Center of Door Opening Mounting Angle 21 from Center of Opening 21 32 for door widths up to 60 42 for door widths up to 60 Keyslots shown at 42 are primary locations to brace the operator back to the cab Other keyslot locations may be used where interference prohibits mounting angles 2 2 B A Clear Opening B A 32 64 63 34 68 67 36 72 71 38 ...

Page 31: ...ation continued 7 Use included hardware to attach the adapter angle to the header but do not tighten leave hardware loose to allow adapter alignment with track keyslots See Figure 19 Figure 19 Adapter Angles Installation Detail AáČ ZðáĦÔ áÔûô Û ZĀôÀ HĀûô 32 Door Lap láí áº ááð Z Û Ô 3 ð ºǌ 6 ð ºǌ qô ZĀôÀ HĀûô ûá ZáôÃûÃáÛ AáČ ZðáĦÔ áÔûô ZĀôÀ HĀû ƼȚ ZĀôÀ HĀû ...

Page 32: ...gle See Figure 20 below and Figure 21 on page 25 a Align the door track bolts with the keyslots in the track and attach the door operator to the adapter b Verify that the door operator is level c Verify that there is 21 2 from the center of the door opening d Use a 3 16 Allen wrench to tighten down the bolts 10 Install the door operator mounting angles 11 Add bolts to brace the cab to the door ope...

Page 33: ... Header Installation continued Figure 21 Door Operator Machine Installation 2 of 2 Angles are Almost Flush with Top of Door Operator Add Mounting Bolts to Brace the Cab to the Door Operator Back Attach These Angles if not already on header 9 Position the Angle with the Bolt Loose Enough to Adjust the Height when Setting the Operator in Place ...

Page 34: ...door operator See Figure 22 16 Route the wiring harness through the 11 2 flex conduit and then install the 11 2 flex and straight connectors 17 Install the wiring harnesses through the flex conduit insert the OPERF or OPERR plug into the COP harness end 18 Install the CTS to the top of the junction box See Figure 22 19 Before routing cable tie the CTS wiring 20 Proceed to New Existing Car Door Pan...

Page 35: ...t Door LD 16 Door Operator Single Speed RH shown Clutch and Linkage Rear Header Support Junction Box End Clip Overview Installation Steps 1 Remove existing door operator 2 Install bottom strut 3 Install door mounting angle 4 Install header plate 5 Install header support 6 Install fixing brackets 7 Install LD 16 door operator 8 Install wiring harness and CTS 9 Install doors 10 Install clutch and li...

Page 36: ... applies to all parts in the Universal MOD Kit The dimensions shown in the following drawings are reference points and apply to TKE or Dover equipment ONLY a Place the strut above the cab transom face or the return per the applicable dimensions Single Speed and Center Opening 11 16 Two Speed and Two Speed Center Opening 5 8 b Cut off the excess material Figure 23 Strut Installation Cab Transom Fac...

Page 37: ... to have 5 16 door panel to cab running clearance Two Speed and Two Speed Center Opening 5 8 4 Use the included hardware to install the door operator header to the mounting angle See Figure 24 on page 29 For side opening align one end of the header plate with the clear opening Figure 24 Mounting Angles and Header Installation For Side Opening Align One End of the Header Plate with the Clear Openin...

Page 38: ...th the strut at the first set of slots on the strike side Side opening distance 311 16 33 4 c Use the included hardware to attach the end clips to each end of the strut d Install the rear header support brackets Figure 25 Header Support Installation Strut First Set of Slots on Side with Strike 3ƣƣƭƍƒ 3 Side Opening Clear Opening End Clip Rear Header Support Strut Āû Nģ Excess Dimensions shown are ...

Page 39: ...pening Figure 28 on page 33 Figure 26 Single Speed Fixing Brackets SS Clear Opening Dim B 32 34 36 38 40 42 44 46 48 32 СШМ 47 СШМ 51 СШМ 55 СШМ 59 СШМ 63 СШМ 67 СШМ 71 СШМ 75 СШМ B Clear Opening 5ƤƧƭЈЇ for door lap 13ƠƭЈЇ for door lap Top of Clear Opening 3ϻШІЋ 3 2Ûôû ÔÔ ĦđÃÛ ð Ò ûô ÃÛ ºðáÛû áº ûð ÛôáÚ to give ƧƭІЋ slow door ðĀÛÛÃÛ Ô ð Û ǥ ííðáđǌǦ ǥ ÔÔ ÃÚǌ ÃÛ ÃÛ À ôǦ Dimensions shown are referenc...

Page 40: ...f Header with Clear Opening Back of slow door track is mounted ħĀôÀ ČÃûÀ ûÀÃô ôĀðº 2SP Clear Opening B 36 38 40 42 44 46 48 50 52 31 33 35 37 39 41 43 45 47 54 56 58 60 62 64 66 68 70 72 49 51 53 55 57 59 61 63 65 65 2SP Clear Opening B 2Ûôû ÔÔ ĦđÃÛ ð Ò ûô in front of cab transom to give ƧƭƂƇ slow door ðĀÛÛÃÛ Ô ð Û ǥ ííðáđǌǦ ǥ ÔÔ ÃÚǌ ÃÛ ÃÛ À ôǦ Dimensions shown are reference points and apply to TK...

Page 41: ... Universal MOD Kit continued Figure 28 Center Opening Fixing Brackets CO Clear Opening B 32 54 56 60 31 ƞƭІЋ 41 ƞƭІЋ all dim in inches Center of Clear Opening B Clear Opening 13 ƠƭЈЇ for door lap 5 ƤƧƭЈЇ for door lap Dimensions shown are reference points and apply to TKE or Dover equipment ONLY ...

Page 42: ...ontinued 7 Install the door operator See Figure 29 8 Install the junction box to the door operator 9 Install the CTS and the wiring harness to the COP 10 Proceed to New Existing Car Door Panel Installation on page 44 Figure 29 Door Operator CTS and Wiring Harness Installation Install CTS and Wiring Harness ...

Page 43: ... Remove the Header Angle See Figure 30 Door operator Tracks Hangers Figure 30 Remove Door Operator and Equipment Do Not Remove the Header Angle s 2 Install the door operator mounting per the applicable application Single Speed Figure 31 on page 36 Center Opening Figure 32 on page 37 Two Speed Figure 33 on page 38 Do Not Remove the Header Angle s Side View ...

Page 44: ...ary location for keyslots used to brace the door operator back to the cab start at 1 from the clear opening and spaced at Dimension C inches See Chart for Dimension C right hand shown left hand opposite DOW B C 32 23 27 34 25 29 36 27 31 38 29 33 40 31 35 42 33 37 44 35 39 46 37 41 48 39 43 Dimension C 2 all dim in inches Dimensions shown are reference points and apply to TKE or Dover equipment ON...

Page 45: ...e 32 Center Opening Door Operator Mounting L 2 2 15 15 32 42 A 6 5ƣƣƭƂƇ 1 Clear Opening C L A 32 64 63 34 68 67 36 72 71 38 76 75 40 80 79 42 84 83 44 88 87 46 92 91 48 96 95 50 100 99 52 104 103 54 108 107 56 112 111 58 116 115 60 120 119 all dim in inches Dimensions shown are reference points and apply to TKE or Dover equipment ONLY ...

Page 46: ...adjustment when setting the door operator in place 5 Install the door operator Figure 35 on page 40 a Align the door operator with the door track and the mounting angles b Verify that the door operator is level with the face of the door track c Tighten all hardware 1 3 D D D E Clear Opening 2SP Clear Opening E D 21 23 24 26 27 29 30 32 33 24 25 27 28 30 31 33 34 36 36 38 40 42 44 46 48 50 52 2SP C...

Page 47: ...Installation October 2021 88420 v 1 0 39 Separate Header Installation continued Figure 34 Door Track and Mounting Angles Installation 9 0 ȉ ƻ Door Track Gap Mounting Angles Dimensions shown are reference points and apply to TKE or Dover equipment ONLY ...

Page 48: ...Separate Header Installation LD 16 Door Operator Modernization 40 Vertical Express Separate Header Installation continued Figure 35 Door Operator Installation ...

Page 49: ...Installation October 2021 88420 v 1 0 41 Separate Header Installation continued 6 Install the junction box See Figure 36 Figure 36 Junction Box Installation Cover Shown Removed for installation and wiring CTS by others Junction Box TKE CTS Junction Box ...

Page 50: ...xpress Separate Header Installation continued 7 Install the CTS to the top of the junction box See Figure 37 8 Route the wiring harness from the junction box to the COP 9 Install the junction box cover Figure 37 CTS and Wiring Harness Installation Install CTS and Wiring Harness ...

Page 51: ...or Operator Modernization Separate Header Installation October 2021 88420 v 1 0 43 Separate Header Installation continued 10 Install the clutch See Figure 38 Figure 38 Clutch Installation clutch shown in green ...

Page 52: ...he 1 4 spacers on the sill 4 Use included hardware to install the door interface angle to the top of the existing car door 5 Shim as necessary to ensure that the interface angle is plumb to the car door 6 Install the car door on the two eccentrics and align the adapter slots with the holes in the hanger 7 Install and hand tighten the four 8 mm bolts Figure 39 Assemble and Align Door Panel and Angl...

Page 53: ... Door Panel and Angle 2 of 2 Typical Attachment Method Adapter to Door Finished Face Car Side Existing Tapped Pendant Bolt Holes HARDWARE INSTALLATION Existing Car Door Adapter Angle ƻȚ HARDWARE INSTALLATION Shim if needed to align plumb the car door Finished Face Car Side Existing Tapped Pendant Bolt Holes Adapter Angle Shim if needed to align plumb the car door Existing Car Door ...

Page 54: ...New Existing Car Door Panel Installation continued 8 Use a 6 mm T handle Allen wrench to rotate the eccentrics and align the car door panel with the return See Figure 41 9 Verify that there is 1 4 clearance from the door to the top of the sill Figure 41 Car Door Installation T handle Allen Wrench ...

Page 55: ...nter opening doors 3 Verify that the door to sill clearance is between 3 16 and 5 16 Figure 42 Door Hanger Fully Closed Position Against Bumper 4 Use a 13 mm wrench to tighten the eccentric bolt then tighten the mounting bolts See Figure 43 on page 48 5 Set a 1 4 3 8 required gap per code between the transom the returns and the door panel a Loosen the 1 2 bolts that attach the interface angle to t...

Page 56: ...ment continued Figure 43 Tighten Mounting Bolts Set Eccentrics on the Car Door Hanger 1 Verify that the gap between the upthrust roller and the rail is 1 64 2 If the upthrust roller needs adjustment loosen the nut and use the Allen wrench to turn the roller shaft 8 mm Hardware 8 mm Hardware Door Gibs Eccentric Bolts ...

Page 57: ...nd discard 4 shipping nuts from the clutch actuator restrictor assembly See Figure 44 3 Use included hardware to mount the clutch actuator assembly to the hanger plate 4 Check all clutch bolts and fasteners for tightness may be loose from shipping 5 Use 2 Allen screws to connect the clutch assembly to the drive belt Figure 44 Clutch Actuator Assembly Installation Drive Belt Attachment Opening for ...

Page 58: ... in the car door keyslots If existing keyslots do not exist scribe the elevation of rollers above the sill use the clutch baseplate as a drilling template 10 Use the supplied metric bolts to attach the clutch assembly See Figure 45 Clutch location the hatch door rollers are centered vertically in the clutch with the car at floor level 11 Verify that the running clearance is between 1 4 and 5 16 wi...

Page 59: ...ne the spacer width Distance of the squeezed pickup rollers Actual rollers TKE interlock rollers width 15 8 b Use a 5 mm hex key to adjust the linkage length until the lock hook is in the fully lifted position and tighten the linkage screws To extend the lengths of the push rod if needed use the linkage extensions Figure 46 Adjust Clutch and Linkage Short and Long Wittur Extensions HL 24 375 Max 1...

Page 60: ...ss Clutch Installation and Adjustment continued Figure 47 Adjust Clutch and Linkage 750 Door Lap 8 535 Top of Door Track Above Clear Opening When Using Car Door Adapter Angles 2 716 5 819 8 406 Location for 2SCO 13 151 8 151 1 161 Top of Door Panel Clear Opening HL 16 375 Max 11 375 Min ...

Page 61: ...relating cable rope guide b Move the car door hanger until the distance is equal for both pendants c Tighten the set screws on the rope guide All Other Doors 2 When the door lock pins are just touching the door contacts verify that the mea surement between the door hanger and the bumper is 1 8 See Figure 48 If the measurement is not 1 8 a Loosen the screws b Move the bracket s c Verify that the me...

Page 62: ... See Figure 49 Troubleshooting Figure 49 Adjust Car Door Interlock Restrictor Problem Reason Solution Car door interlock restrictor does not open Hoistway door is already closed Move car door interlock restrictor ramp in the Door Open direction Hoistway door is not locked and the car door is closed Hoistway door latch does not lock because of closing force wind or dirt in the sill Move car door in...

Page 63: ...d move the screw towards the Door Close direction Verify that there is a 3 8 running clearance for the following areas See Figure 50 1 Clutch to sill use the four bolts see below for adjustment 2 Stationary pickup roller to rear clutch cam after one pickup roller is adjusted transfer the roller position to the top of the LD 16 header and use this position to set the pickup rollers at all other ent...

Page 64: ...tch See Figure 51 2 Open the clutch vanes and install the screw in the lock position hole 3 Run the car on Inspection Operation and check the running clearance between the clutch and the hatch door rollers at each floor Adjust the hatch door rollers or clutch as required 4 After checking the running clearance remove the screw from the lock position hole and reinstall it in the parking position hol...

Page 65: ...dge Wiring Electronic Edge Wiring The electronic edge is wired to the X15 X16 plugs on the door board the quickest response to edge activation DIP SW 2 controls how the door board responds when the edge activates When DIP SW 2 is ON and the edge activates the door board will reopen the doors and the REOPEN relay output 3 at the X2 plug will also activate The REOPEN output can be wired to the contr...

Page 66: ...on page A 16 Appendix 1 Verify that the doors are mechanically adjusted for smooth movement with no binding or interference 2 Remove the cover from the Door Operator Control Board See Figure 53 on page 59 a If required move the car doors partially open b Loosen 4 screws slide the cover over and off of the screws and set the cover aside The Door Operator Control Board should not have power at this ...

Page 67: ...em remove the COP plugs from the 462AEMx harness and wire the harness directly to the COP terminals See also Harness Assembly diagrams start on page A 8 Serial Communications TKE Legacy Control Systems on page 71 Discrete Controller Interface on page 74 Loosen 4 Screws to Remove Cover Cover Ground Wires Ground Screws Cover Screw Door Control PC Board COP Extension 462AENx COP Adapter 462AEMx CWIx ...

Page 68: ...ctions PLUG AC FEMALE PLUG AC MALE L10 L20 GND GND LIGHT GRN 14 GA WHT 14 GA BLK 14 GA TSP4 GFCI RECEPTACLE GRN 14 GA BLU 14 GA BRN 14 GA LIGHT FAN 120 VAC NEUTRAL LIGHT FAN 120 VAC LINE CAR TOP STATION REAR COP SHIELD CAN Interface Board CON X16 Door Edge Emitter CON X15 Door Edge Detector Receiver CON X19 120VAC Power Input CON CAN Serial Communications to Controls Serial Interface Board in COP ...

Page 69: ...erify DIP Switch settings See Figure 55 below and Tables 1 and 2 on page 62 Figure 55 DIP Switch Default Settings CAN Interface Board Door Operator Control Board Serial Communications DIP Switch 2 8 ON All Others OFF Discrete Interface DIP Switch 2 ON DIP Switch 1 3 4 7 OFF DIP Switch 5 6 Desired Speed Pattern See Table 1 on page 62 DIP Switch 1 Front OFF Rear ON DIP Switch 2 OFF ...

Page 70: ...rete input I1 is active Open command COM connected I2 Discrete input I2 is active Close command COM connected I3 Discrete input I3 is active Nudging command COM connected I4 Discrete input I4 is active Inspection command COM connected I5 Discrete input I5 active Alt speed profile command COM connect IPD Input Passenger Detection Light curtain signal is active Doors are obstructed O1 Discrete Outpu...

Page 71: ...powered motion to learn the direction and the closed limit If the doors move open continue to press DOOR CLOSE until the doors move in the correct direction and 02 illuminates b Pick the Car Door Interlock CDI c Press and hold DOOR OPEN until the door is fully open on its door stop bumper and the 01 LED illuminates d Press DOOR CLOSE until the 02 LED light illuminates e Press DOOR OPEN until the 0...

Page 72: ...r Operator Modernization 64 Vertical Express Learn Door Travel continued Figure 56 LEDs and Test Buttons for Learn Door Travel LEDs LEARN Door Operator Control Board Door Operator Top View DOOR OPEN BUTTON DOOR CLOSE BUTTON TEST RUN SWITCH ...

Page 73: ...ling During Adjustment Procedure See Figure 57 on page 66 for all steps in this procedure 1 Place the car on Inspection Operation then power down and remove the X5 plug from the CAN Interface Card located on top of the door card Power back up and the Wittur tool communications and the X1 discrete door movement inputs are now enabled 2 Construct a reusable harness long enough to use the WPT and als...

Page 74: ...Electronic Setup Adjustment LD 16 Door Operator Modernization 66 Vertical Express Automatic Door Cycling During Adjustment Procedure continued Figure 57 X1 Inputs on Door Board 292PG6 Plug X1 ...

Page 75: ...ctive Use If the control system does not maintain the Open Command input when DOL is reached I2 CLOSE Command Drives the door in the closed direction until the closed position is reached Input must be maintained all the way to the mechanical close stop Automatic End Keeping DIP Switch 8 ON the door card and motor torque keeps doors closed with this commend being active Use If the control system do...

Page 76: ...CLOSE to close the doors Do not apply closing force for more than 10 seconds at a time See Figure 58 If required reduce the closing force by turning the CLOSE FORCE Potentiometer counterclockwise remeasure and repeat until the closing force is within limits To control kinetic energy reduce the door closing top speed to within the code requirements 4 Rotate the TEST RUN switch to the RUN position F...

Page 77: ...ture sensor NE Encoder not connected CF Closing force potentiometer defect ME Fault by motor or encoder SS Standstill fault door is blocked TH Temperature of the electronic or motor too high FE Set during manual change of coupler movement parameter ES Fault by encoder signals out of limits PI Position input ABSPOS Invalid BE Electrical error during rotor angle detection no current flowing motor no...

Page 78: ...WPT to read the faults switch OFF ON 6 Verify the DIP Switch settings The Door Does Not Reopen 1 When Automatic Reopen is selected DIP switch S1 2 is ON an Automatic Reopen pro cess is executed by the IPD input safety edge input or by the Close Force Limiter 2 Check the following reopen devices Curtain of Light not defected or dirty Close Force Limiter friction is not too high Faults Cause Reset o...

Page 79: ... Serial Interface Board Troubleshooting Guide on page 72 Serial Communications Troubleshooting Guide on page 73 Figure 59 Serial Interface Board 6300AFM JP4 FRONT OFF REAR ON F1 Fuse 1 2 amp Pico JP1 ON to apply a 121W CAN loading resistor to CON1 X1 Jumper on CAN Interface Board set X1 ON CAN port to CAN Interface Board RS485 to Legacy Control System connects to CON11 on Door Operator Control Boa...

Page 80: ...wing a 24VDC power input problems b F1 Fuse 1 2 amp Pico c Board replacement The RX_LEDs will not blink if communication is not established or if wiring is not correct The TX_LEDs may blink at first even with faulty wiring as the board attempts to establish communication Serial Interface Board stops trying to communi cate on one of the channels CAN or RS485 because the other channel cannot be esta...

Page 81: ...Systems Car CAN channel is fully functional the DCN Command shows the CWIx node online RS485 Systems 462AEM harness connections between CWIx in the COP and Serial Interface Board are correct 462AEN harness connections between CAN Interface Board and Serial Interface Board correct Wires are properly inserted in the OPERF plug and the OPERR plug RS485 Systems with Serial Interface Board in the COP D...

Page 82: ... present remove it to use the discrete interface ports Figure 60 Discrete Controller Interface X1 INPUTS enter the board here Do not wire any controller power supply to any pin Circuits designed for low current Suggested relays 100mA COM Common I1 OPEN I2 CLOSE I3 NUDGING I4 INSPECTION I5 ALT SPEED NO Normally Open O1 Door Open Limit NC Normally Closed O2 Door Close Limit O3 Reopening O4 SIX X2 OU...

Page 83: ...s the door operator test drive buttons same function as DIP Switch 1 The X2 outputs still functional when input is active I5 ALT SPEED Command Selects a higher Open or Close speed profile when active and used with an Open or Close Command input same function as DIP Switch 6 DIP Switches 5 6 OFF speed pattern 1 in effect input will select pattern 3 DIP Switch 5 ON 6 OFF speed pattern 2 in effect in...

Page 84: ...on Connector not used 1 2 3 LB Protection Device Supply REV Input Protection Device LB Protection Device Supply LB Protection Device Supply L junction terminal for LSE LB Protection Device Supply Note Do not connect any supply voltage to the inputs Open Input 1 Close Input 2 Nudging Input 3 Inspection Input 4 High Speed Input 5 Open End Close End Signals to lift control Signals to lift control Nor...

Page 85: ...eight of the car doors to weight of the heavier hoistway doors and enter the heavy door weight on the Total Door System Weight label 580AWP001 3 Install the Total Door System Weight label 580AWP001 per Figure 61 Figure 61 Door Labels HEAVY DOORS OPENING WIDTH _______ in OPENING HEIGHT _______ in NORMAL K E ___________ sec REDUCED K E __________ sec TYPICAL DOORS OPENING WIDTH _______ in OPENING HE...

Page 86: ...7 279 291 110 191 203 215 227 238 250 262 274 285 108 188 199 211 222 234 246 257 269 280 106 184 196 207 218 230 241 252 264 275 104 181 192 203 214 226 237 248 259 270 102 178 188 199 210 221 232 243 254 265 100 174 185 196 206 217 228 238 249 260 98 171 181 192 202 213 223 234 244 255 96 167 178 188 198 208 219 229 239 250 94 164 174 184 194 204 214 224 234 244 92 160 170 180 190 200 210 220 22...

Page 87: ...2 244 257 270 282 295 308 320 333 346 359 371 384 104 202 215 227 240 252 265 277 290 302 314 327 339 352 364 377 102 199 211 223 235 247 260 272 284 296 309 321 333 345 357 370 100 195 207 219 231 243 255 267 279 291 303 315 327 339 350 362 98 191 203 214 226 238 250 261 273 285 297 308 320 332 344 355 96 187 199 210 222 233 245 256 268 279 291 302 314 325 337 348 94 183 194 206 217 228 240 251 2...

Page 88: ...428 104 211 223 234 246 258 269 281 292 304 315 327 339 350 362 373 385 396 408 420 102 207 219 230 241 253 264 275 287 298 309 321 332 344 355 366 378 389 400 412 100 203 214 226 237 248 259 270 281 292 303 315 326 337 348 359 370 381 393 404 98 199 210 221 232 243 254 265 276 287 297 308 319 330 341 352 363 374 385 396 96 195 206 217 227 238 249 259 270 281 292 302 313 324 334 345 356 366 377 38...

Page 89: ... 557 569 104 350 362 373 385 396 408 420 431 443 454 466 477 489 501 512 524 535 547 559 102 344 355 366 378 389 400 412 423 434 446 457 468 480 491 503 514 525 537 548 100 337 348 359 370 381 393 404 415 426 437 448 459 471 482 493 504 515 526 537 98 330 341 352 363 374 385 396 407 418 429 439 450 461 472 483 494 505 516 527 96 324 334 345 356 366 377 388 398 409 420 431 441 452 463 473 484 495 5...

Page 90: ...oard DIP switches and jumpers to match the replaced unit 5 Attach the new door board box onto the door operator hanger and then install the 3 Allen bolts at the top to attach the unit to the door operator do not omit any spac ers that may be present 6 Verify that the REFRSW reference switch LED activates approximately 1 2 before the door is closed See Figure 62 Figure 62 Activated REFRSW reference...

Page 91: ... Pattern Adjustment with the Wittur Programming Tool WPT on page 65 11 Adjust the kinetic and closing force of the new door board See Closing Force Adjustment 30 lbs Maximum on page 68 12 Return the car to service Replace the Drive Belt 1 Remove the drive belt screws See Figure 63 2 Release the old belt from the bracket 3 Shorten the new belt to match the length of the old belt 4 Install the new b...

Page 92: ...5 9731325 Belt L 3900 mm All Others 46 16 9731428 Belt Diverting Pulley 17 9731726 Belt Diverting Pulley Left 18 9731829 Door Drive Control Box Standard 19 9731921 Door Drive Control Box with CAN Interface 20 9732123 Motor Unit Midi C O LH 21 9732226 Motor Unit Midi C O RH 22 9732329 Motor Unit Supra C O LH 23 9733127 Motor Unit Supra C O RH 24 9733220 Motor Unit Double Coupler Main LH 25 9731349 ...

Page 93: ...LD 16 Door Operator Modernization Replacement Parts October 2021 88420 v 1 0 85 Replacement Parts continued Wittur Programming Tool WPT Part No 9736918 ...

Page 94: ...Parts continued Door Operator Bolt Kit 200CHN001 Shim to Plumb Operator ƧƭƂƇ x ƧƭƂƇ ƧƭƂƇ Header and track are shown for installation detail only Use pushnuts to hold screw and nut in position to set operator in place ƧƭƂƇ Flat Head Screw ƧƭƂƇ Flat Head Screw ƧƭƂƇ Hex Nut ƧƭƂƇ Push Nut ...

Page 95: ...APPENDIX ...

Page 96: ...APPENDIX ...

Page 97: ...88420 v 1 0 A 1 Clutch Assemblies GAL ENGAGED Front View Isometric View ÔĀû À ô ôÀáČÛ ČÃûÀ ôí ðô ð áÛĦ Āð ºáð A 2Ûû ðÔá Ò áÔÔ ðôǌ l A ôÀáČÛǍ áííáôÃû ǌ ōǌŒōŐ A l l Front View Isometric View ŎǌŕōŐ GAL Interlock Rollers 364AG_ See also Clutch Operating Space on page A 7 ...

Page 98: ...xpress Clutch Assemblies continued MAC ENGAGED Front View Isometric View ÔĀû À ô ôÀáČÛ ČÃûÀ ôí ðô ð áÛĦ Āð ºáð G 2Ûû ðÔá Ò áÔÔ ðôǌ l A ôÀáČÛǍ áííáôÃû ǌ ŏǌŔŔŔ G l l Front View Isometric View őǌōŔŔ MAC Interlock Rollers 364AG_ See also Clutch Operating Space on page A 7 ...

Page 99: ... Clutch Assemblies continued TKE Dover ENGAGED Front View Isometric View ÔĀû À ô ôÀáČÛ ČÃûÀ ôí ðô ð áÛĦ Āð ºáð l Ǎ áċ ð 2Ûû ðÔá Ò áÔÔ ðôǌ l A ôÀáČÛǍ áííáôÃû ǌ l Ǎ áċ ð l l Front View Isometric View ōǌŒōŐ ŎǌōŕŐ TKE Interlock Rollers 364AG_ See also Clutch Operating Space on page A 7 ...

Page 100: ... using this clutch with side opening doors locate the door operator so that the center line of the door closed stop aligns with the strike side of the clear opening Dimensions to interlock rollers on this page are for reference only TKE RH shown LH opposite Isometric View 4 409 4 173 787 394 2982 4 173 CLUTCH RETRACTED Operator Hanger Plate CLUTCH ENGAGED Center Line of Door Closed Stop Daylight L...

Page 101: ...rator so that the center line of the door closed stop aligns with the strike side of the clear opening Dimensions to interlock rollers on this page are for reference only TKE LH shown RH opposite Isometric View 3 w 1 894 4 823 787 688 295 4 823 CLUTCH RETRACTED Operator Hanger Plate CLUTCH ENGAGED Center Line of Door Closed Stop Daylight Line for Side Opening Doors Car Sill Line 2 079 2 630 Car Si...

Page 102: ... operator so that the center line of the door closed stop aligns with the strike side of the clear opening Dimensions to interlock rollers on this page are for reference only TKE RH shown LH opposite Isometric View 2 2 ew 1 894 4 823 787 688 295 4 823 CLUTCH RETRACTED Operator Hanger Plate CLUTCH ENGAGED Center Line of Door Closed Stop Daylight Line for Side Opening Doors Car Sill Line 2 079 2 630...

Page 103: ...r To Car Sill For 375 Running Clearance For 250 Running Clearance 1 250 1 566 1 441 1 000 1 816 1 691 0 900 1 916 1 791 364AG Shown 375 typ 0 250 min Running Clearance 3 347 2 441 Clutch Height 2 441 Clutch Base 500 typ 0 400 min Engagement 375 typ 0 250 min Running Clearance 1 250 typ 0 900 min Sill to Sill 2 250 typ Car Door to Car Sill ...

Page 104: ...pter Harness 462AEM_ Door Control PC Board COP Extension 462AENx COP Adapter 462AEMx CWIx Board COP The 120VAC female plug receptacle powers the GFCI receptacle in the CTS Installation Overview 210B 220B 202 204 201 203 118 118A 12 OPERF OPERR PIN 1 PIN 1 PIN 1 PIN 1 PIN 1 FASTON FEMALE Gate Stop DO PWR Type Door Operator Use TAC32T Front 462AEM001 Rear 462AEM002 ...

Page 105: ...ams COP Adapter 462AEM_ continued 12 210B 220B 201 203 118 118A PIN 1 PIN 1 PIN 1 PIN 1 FASTON FEMALE OPERF OPERR Type Door Operator Use TAC32H Front 462AEM004 Rear 462AEM005 210B 201 118 PIN 1 PIN 1 PIN 1 PIN 1 FASTON FEMALE 12 PIN 1 PIN 1 118X 118X OPERF Type Door Operator Use Futura T TAC50 04 Front 462AEM006 ...

Page 106: ...agrams COP Adapter 462AEM_ continued 12 220B 203 118X OPERR PIN 1 PIN 1 PIN 1 PIN 1 FASTON FEMALE Type Door Operator Use Futura T TAC50 04 Rear 462AEM007 12 36 201 118X PIN 1 PIN 1 PIN 1 PIN 1 SIF CON1 118 118X PIN 1 PIN 1 OPERF Type Door Operator Use TAC22 ICON TAC20 03 TAC20 TAC50 03 Front 462AEM008 ...

Page 107: ...021 88420 v 1 0 A 11 Harness Assembly Diagrams COP Adapter 462AEM_ continued OPERR 12 36 203 PIN 1 PIN 1 PIN 1 SIR CON1 118X PIN 1 Type Door Operator Use TAC22 ICON TAC20 03 TAC20 TAC50 03 Rear 462AEM009 300 INS2 PIN 1 PIN 1 12 Type Inspection Use TAC32T Front 462AEM010 ...

Page 108: ...ontinued INS2 300 PIN 1 INNO INNC INCOM INUP INDN PIN 1 12 Type Inspection Use TAC32H Front 462AEM011 PIN 1 12 FASTON MALE ALRM PIN 1 BLK ALRM RED ALRM 210A Type Alarm Use TAC32T TAC32H Front 462AEM012 35 12 PIN 1 PIN 1 PIN 1 PIN 1 210 ALRM SIF CON11 SIF CON3 Type Alarm 485 Use TAC22 ICON TAC20 03 TAC20 TAC50 03 Front 462AEM0013 ...

Page 109: ...1 88420 v 1 0 A 13 Harness Assembly Diagrams COP Adapter 462AEM_ continued Type Alarm 485 Use TAC22 ICON TAC20 03 TAC20 TAC50 03 Rear 462AEM0014 PIN 1 PIN 1 PIN 1 SIR CON11 35 SIR CON3 220 FASTON MALE PIN 1 220A 12 Type Door Operator Ground Use TAC32T TAC32H Rear 462AEM016 ...

Page 110: ...ion 462AEN_ ALRM OPERF INS2 STOP GATE X19 CAN INS1 PIN 1 PIN 1 PIN 1 PIN 1 PIN 1 PIN 1 PIN 1 BLK BRN L10 WHT BLU L20 Type COP Use Front with Inspection Station Print No 462AEN001 OPERR CAN X19 GATE STOP BLK BRN L10 WHT BLU L20 PIN 1 PIN 1 PIN 1 PIN 1 PIN 1 Type COP CTB Use Rear No Inspection Station Print No 462AEN002 ...

Page 111: ... 0 A 15 Harness Assembly Diagrams COP Extension 462AEN_ continued OPERF CAN X19 STOP BLK BRN L10 WHT BLU L20 PIN 1 PIN 1 PIN 1 PIN 1 PIN 1 GATE Type CTB Use Front No Inspection Station Print No 462AEN004 X1 X2 Type Discrete Use Add On Print No Front 462AEN005 Print No Rear 462AEN006 ...

Page 112: ...FRONT 23 5 23 5 7 163 18 2 20 2 5 23 1 326 7 21 7 5 25 1 8 5 1 5 5 51 5 7 7 5 7 51 52 1 3 1 7 1 6 7 9 2 7 2 763 163 18 2 20 5 23 1 20 20 2 20 326 7 21 20 2 1 2 12 1 12 5 23 1 1 5 23 1 12 326 7 21 1 326 7 21 12 13876 2873876 COP 7 6 9 23 5 725 32 5 12 211 7 21 12 211 7 21 12 211 7 21 9 23 5 725 5 7851 7 6 5 029 211 725 520 51 66 1 211 7 5 6 72 335235 7 7 6 7 7 50 1 6 5 029 211 725 520 51 66 1 211 7...

Page 113: ...25 1 INSPECTION PENDANT 5 1 767 763 763 763 73 5 7 73 5 5 029 211 725 520 51 66 1 211 7 5 6 72 335235 7 5 723 6723 6 7 7 50 1 6 5 029 211 725 520 51 66 1 211 7 5 6 72 335235 7 163 7 21 7 50 1 6 50 251 6 86 5 029 211 725 520 51 66 1 211 7 5 6 72 335235 7 7 50 1 6 50 9 50 9 163 1 163 12 163 20 163 83 163 1 6723 6 6723 6 7 23 5 6723 6 6723 6723 211 725 6 3529 1 5 9 21 23 5 725 6 3529 12 VDC 2 1 3 1 1...

Page 114: ...PTACLE 51 8 51 7 1 9 1 875 7 1 9 1 CAR TOP STATION REAR 23 55 6723 STOP SWITCH 763 COP 5 7 6 6 6 5 7 21752 5 5 5 5 029 211 725 520 51 66 1 211 7 5 6 72 335235 7 5 723 6723 6 7 7 50 1 6 6723 6 6723 6 6723 211 725 6 3529 1 5 9 21 23 5 725 6 3529 6723 23 5 6 6723 7 6723 67 1 67 6723 1 1 675 675 3 8 0 1 3 8 0 ...

Page 115: ...9 www verticalxpress com All illustrations and specifications are based on information in effect at time of publication approval Vertical Express reserves the right to change specifications or design and to discontinue items without prior notice or obligation 2020 Vertical Express ...

Page 116: ... free Fax 901 877 8099 Ĩǌċ ðûÃ Ôđíð ôôǌ áÚ ÔÔ ÃÔÔĀôûð ûÃáÛô Û ôí ÃĦ ûÃáÛô ð ô áÛ ÃÛºáðÚ ûÃáÛ ÃÛ ģ û û ûÃÚ áº íĀ ÔÃ ûÃáÛ ííðáċ Ôǌ ðûÃ Ô đíð ôô ð ô ðċ ô ûÀ ðÃ Àû ûá À Û ôí ÃĦ ûÃáÛô áð ôÃ Û Û ûá Ãô áÛûÃÛĀ Ãû Úô ČÃûÀáĀû íðÃáð ÛáûÃ áð á ÔÃ ûÃáÛǌ ʌŎŌŎō ðûÃ Ô đíð ôô ...

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