4B W4005V46-SYS/B Series User manual

ORIGINAL INSTRUCTIONS
W4005V46-SYSx /B (BÜHLER)
Elevator Monitoring System
OPERATION MANUAL
MODELS: W4005V46-SYS1 /B
W4005V46-SYS2 /B
Hardware Version: R4
Software - Main Processor: 4.2.x; Ethernet Processor: 3.1.x
www.go4b.com
INSTALLATION INSTRUCTIONS
R9.6 –22 May 2020

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TABLE OF CONTENTS
1. ABBREVIATIONS AND NOTATIONS USED........................................................................................................................... 4
2. WARNINGS........................................................................................................................................................................ 4
3. SYSTEM INTRODUCTION ................................................................................................................................................... 4
4. SYSTEM APPROVALS AND COMPLIANCE ........................................................................................................................... 4
4.1 W4005V46-SYS1 /B DECLARATION OF CONFORMITY .................................................................................................................... 6
4.2 W4005V46-SYS2 /B DECLARATION OF CONFORMITY .................................................................................................................... 7
5. TRANSPORTATION ............................................................................................................................................................ 8
6. SYSTEM COMPONENTS ..................................................................................................................................................... 8
6.3 SYSTEM COMPONENTS INTRODUCTION.......................................................................................................................................... 8
7. SPECIFICATIONS ................................................................................................................................................................ 9
7.1 OVERALL PACKAGING ................................................................................................................................................................. 9
7.2 AIRBORNE NOISE....................................................................................................................................................................... 9
7.3 W4005NV46AI /B –W400 SERIES ELEVATOR CONTROLLER ........................................................................................................ 10
7.4 TS1V4AI /B –TOUCHSWITCH™ALIGNMENT SENSOR ................................................................................................................... 10
7.5 P300V34AI /B –PROXIMITY SPEED SENSOR............................................................................................................................... 11
7.6 WG4A-BR /B –WHIRLIGIG®SPEED SENSOR MOUNTING.............................................................................................................. 11
7.7 ADB910V3AI /B -ADJUSTABLE DEPTH BEARING TEMPERATURE SENSOR......................................................................................... 11
8. MECHANICAL INSTALLATION............................................................................................................................................12
8.1 TS1V4AI /B –TOUCHSWITCH™ALIGNMENT SENSOR ................................................................................................................... 12
8.2 WG4A-BR /B AND P300V34AI /B –PROXIMITY SPEED SENSOR AND BRACKET INSTALLATION ............................................................ 15
8.3 ADB910V3AI /B -ADJUSTABLE DEPTH BEARING TEMPERATURE SENSOR......................................................................................... 16
8.4 W4005NV46AI /B –W400 SERIES ELEVATOR CONTROLLER ........................................................................................................ 17
9. ELECTRICAL INSTALLATION AND WIRING .........................................................................................................................17
9.5 WARNINGS............................................................................................................................................................................. 18
9.6 TS1V4AI /B –TOUCHSWITCH™ALIGNMENT SENSOR ................................................................................................................... 18
9.7 P300V34AI /B –PROXIMITY SPEED SENSOR............................................................................................................................... 21
9.8 ADB910V3AI /B -ADJUSTABLE DEPTH BEARING TEMPERATURE SENSOR ........................................................................................ 21
9.9 W4005NV46AI /B –W400 ELEVATOR CONTROLLER.................................................................................................................. 22
10. W4005NV46AI /B CONTROLLER OPERATION DESCRIPTION..............................................................................................26
10.10 OVERALL OPERATION DESCRIPTION........................................................................................................................................ 26
10.11 W4005NV46AI /B CONTROLLER LEDS................................................................................................................................. 26
10.12 W4005NV46AI /B CONTROLLER BUTTONS ........................................................................................................................... 27
10.13 SETTINGS SWITCHES............................................................................................................................................................ 28
10.14 W4005NV46AI /B CALIBRATION ........................................................................................................................................ 30
10.15 ALARMS AND SHUTDOWN .................................................................................................................................................... 30
10.16 TEST FUNCTIONALITY........................................................................................................................................................... 32
10.17 NORMAL MACHINE START /STOP.......................................................................................................................................... 32
10.18 ALARM SHUTDOWN RESTART................................................................................................................................................ 33
11. COMMON MISUSE WARNINGS.........................................................................................................................................33
12.COMMUNICATION OPTIONS ............................................................................................................................................33
IMPORTANT: THE LATEST VERSION OF THIS MANUAL AS WELL AS ALL THE
AVAILABLE TRANSLATIONS CAN BE FOUND AT:
http://www.go4b.co.uk/buhler

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12.19 ETHERNET DATA ALLOCATION ............................................................................................................................................... 34
13. TROUBLESHOOTING GUIDE ..............................................................................................................................................40
14.MAINTENANCE PROCEDURE.............................................................................................................................................41
15. COMMISSIONING .............................................................................................................................................................42
16. SYSTEM BREAKDOWN PROCEDURE..................................................................................................................................42
17. MANUFACTURER INFORMATION .....................................................................................................................................42
17.20 MANUFACTURER DETAILED INFORMATION .............................................................................................................................. 42
18. REVISION HISTORY ...........................................................................................................................................................43

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1. Abbreviations and Notations Used
Abbreviation
Meaning
SUD
Start Up Delay
HBS
Hot Bearing Temperature Sensor
ETH
Ethernet
NTC
Negative Temperature Coefficient –temperature bead type
PPM
Pulses per Minute (Speed)
RPM
Revolutions per Minute (Speed)
BYTE
8-bit wide variable
WORD
16-bit wide variable
Table 1 –Document Abbreviations
2. Warnings
DANGER: EXPOSED BUCKETS AND MOVING PARTS WILL CAUSE SERIOUS
INJURY OR DEATH. THE OPERATOR MUST ALWAYS LOCKOUT POWER
BEFORE REMOVING COVER OF THE INSPECTION DOOR OF THE ELEVATOR
OR PERFORMING ANY INSTALLATION OR MAINTENANCE WORK.
DANGER: ALL ELECTRICAL POWER TO THE SYSTEM AND WIRING MUST BE ISOLATED
PRIOR TO STARTING ANY INSTALLATION OR MAINTENANCE WORK. WORKING ON
OPEN LIVE CIRCUITS IN ATEX ZONES IS PROHIBITED AND CAN LEAD TO AN EXPLOSION.
IMPORTANT: MAKE SURE THAT THE VERSION OF THE CONTROLLER AND THE ONE
STATED ON THE FRONT OF THIS MANUAL MATCH. MAKE SURE THE LATEST MANUAL
FOR THE VERSION OF THE CONTROLLER IS OBTAINED ONLINE. THE CONTROLLER
VERSION INFORMATION CAN BE FOUND ON THE INSIDE OF THE LID OR VIA INDUSTRIAL
ETHERNET CONNECTION.
3. System Introduction
The W4005V46-SYSx /B is a fully automated elevator dust explosion hazard prevention system. All the major
elevator explosion hazard conditions are constantly monitored and the elevator is stopped when it is unsafe
to carry on the operation. No PLC or other control intervention is needed to provide the safety of operation.
4. System Approvals and Compliance
Approvals information may change due to the standards changing from time to time and due to 4B constantly
expanding the portfolio of international certifications that the system components are approved to. The
information given below is correct at the time of release of this manual it may become out of date from time
to time though. Please refer to an approvals information addendum sheet (if one has been included in this
manual) for the latest information.

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Part Number
ATEX
IECEx
NEPSI (China)
EAC Ex
W4005NV46AI
DE/COSC/101214
Ex II 3D Ex tc IIIC T125°C
Dc IP66 Tamb -20°C to
+45°C
Not Approved
NEPSI Ex
GYJ16.1486X
Ex tD A22 IP66 T125°C
Ex tc IIIC T125°C
Dc X
TS1V4AI
Baseefa14ATEX0015X
Ex II 2D Ex tb IIIC T80°C
Db IP66 Tamb -20°C to
+40°C
IECEx BAS13.0116X
Ex tb IIIC T80°C Db
IP66 Tamb -20°C to
+40°C
NEPSI Ex
GYJ16.1482X
Ex tD A21 IP66 T80°C
Ex tb IIIC T80°C
Db X
ADB910V3AI
Baseefa09ATEX0231X
Ex II 1D Ex ta IIIC T125°C
Da IP65 Tamb -40°C to
+60°C
IECEx BAS 09.0111X
Ex ta IIIC T125°C Da
IP65 Tamb -40°C to
+60°C
NEPSI Ex
GYJ16.1484X
Ex tD A20 IP65 T125°C
Ex ta IIIC T125°
C Da X
P300V34AI
Baseefa12ATEX0226X
Ex II 1GD Ex ma IIC T4 Ga
Ex ma IIIC T200 110°C Da
Tamb -15°C to +50°C
IECEx BAS12.0118X
Ex ma IIC T4 Ga
Ex ma IIIC T200 110°C
Da
Tamb -15°C to +50°C
NEPSI Ex
GYJ16.1483X
Ex maD 20 T100°C
Ex 0 Ex ma IIC T4
Ga X
Ex ma IIIC
T200110°C Da X
WG4A-BR
Baseefa03ATEX0675X
Ex II 1G Ex h IIC T5 Ga
Ex II 1D Ex h IIIC T100°C
Da
(Tamb -15°C to +50°C)
Not Approved
NEPSI Ex GYJ16.1487
Ex c IIIC T100°C Da
Ex II Ga c IIC T5 X
Ex III Da c IIIC
T100°C X
Table 2 - Explosive Atmosphere Certification Information

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4.1 W4005V46-SYS1 /B Declaration of Conformity
DECLARATION
OF CONFORMITY
Note: This is an example of the declaration of conformity. The correct and signed version is included as an
insert within the printed manual together with the delivered product.
I, the undersigned, on behalf of Don Electronics Limited, hereby declare that the Assembly listed below
conforms to the relevant provisions of the 2014/34/EU ATEX (Atmosphères Explosibles) Directive and
2006/42/EC Machinery Directive and other normative documents mentioned herein.
ASSEMBLY: W4005V46-SYS1
TYPE OF PRODUCT: SENSOR MONITORING SYSTEM
INTENDED USE: ELEVATOR MONITORING
DIRECTIVE: DIRECTIVE: 2014/34/EU ATEX and 2006/42/EC Machinery (Article 12, 3 (a))
W4005V46-SYS1 SYSTEM
Qty
Equipment
Code
Equipment Description
Manufactured By
Certificate No’s
1
W4005NV46A
W400 Elite 24V Controller
Don Electronics Ltd
DE/COSC/101214
4
TS1V4AI
Cable Entry TouchSwitch 24V
Don Electronics Ltd
IECEx BAS13.0116X /
Baseefa14ATEX0015X
1
P300V34AI
P300 30mm Sensor
Synatel Ltd
IECEx BAS12.0118X /
Baseefa12ATEX0226X
1
WG4A-BR
Whirligig Pulse Generator
Synatel Ltd
Baseefa03ATEX0675X
We declare that we have followed the ATEX Guidelines on the Application of Directive 2014/34/EU
concerning equipment and protective systems intended for use in potentially explosive atmospheres (4th
Edition). As per as per section 3.7.5 (Assemblies) of the above guidelines, we declare that we have carried out
an ignition risk assessment of this system and state that this assembly has not altered the explosion
characteristics of the products with respect to the Essential Health & Safety requirements of the above
Directive.
Name: David Wheat
Position: Managing Director
Date: 13th May 2020
Don Electronics Ltd
Westfield Industrial Estate

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Kirk Lane, Yeadon LS19 7LX,
United Kingdom
4.2 W4005V46-SYS2 /B Declaration of Conformity
DECLARATION
OF CONFORMITY
Note: This is an example of the declaration of conformity. The correct and signed version is included as an
insert within the printed manual together with the delivered product.
I, the undersigned, on behalf of Don Electronics Limited, hereby declare that the Assembly listed below
conforms to the relevant provisions of the 2014/34/EU ATEX (Atmosphères Explosibles) Directive and
2006/42/EC Machinery Directive and other normative documents mentioned herein.
ASSEMBLY: W4005V46-SYS2
TYPE OF PRODUCT: SENSOR MONITORING SYSTEM
INTENDED USE: ELEVATOR MONITORING
DIRECTIVE: DIRECTIVE: 2014/34/EU ATEX and 2006/42/EC Machinery (Article 12, 3 (a))
W4005V46-SYS2 SYSTEM
Qty
Equipment
Code
Equipment Description
Manufactured By
Certificate No’s
1
W4005NV46AI
W400 Elite 24V Controller
Don Electronics Ltd
DE/COSC/101214
4
TS1V4AI
Cable Entry TouchSwitch 24V
Don Electronics Ltd
IECEx BAS13.0116X /
Baseefa14ATEX0015X
4
ADB910V3AI
100mm Adjustable NTC Bearing Sensor
Don Electronics Ltd
IECEx BAS 09.0111X /
Baseefa09ATEX0231X
1
P300V34AI
P300 30mm Sensor
Synatel Ltd
IECEx BAS12.0118X /
Baseefa12ATEX0226X
1
WG4A-BR
Whirligig Pulse Generator
Synatel Ltd
Baseefa03ATEX0675X
We declare that we have followed the ATEX Guidelines on the Application of 2014/34/EU concerning
equipment and protective systems intended for use in potentially explosive atmospheres (4th Edition). As per
section 3.7.5 (Assemblies) of the above guidelines, we declare that we have carried out an ignition risk
assessment of this system and state that this assembly has not altered the explosion characteristics of the
products with respect to the Essential Health & Safety requirements of the above Directive.
Name: David Wheat
Position: Managing Director
Date: 13th May 2020
Don Electronics Ltd

4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM R9.6 –22 May 2020
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Westfield Industrial Estate
Kirk Lane, Yeadon LS19 7LX,
United Kingdom
5. Transportation
The system is securely packaged in a specially designed carton box with custom inserts. Nevertheless, care
must be taken during the transportation of the system as the carton contains sensitive electronic components.
If any mechanical or water damage is noticed the electronics inside the box should not be used and the end
user must contact the seller immediately to arrange for a replacement.
6. System Components
System Component
Qty
Description
W4005NV46AI /B
1
W400 Series Elevator Controller
TS1V4AI /B
4
TouchSwitch Belt Alignment Sensor
P300V34AI /B
1
Speed Sensor
WG4A-BR /B
1
Whirligig Speed Sensor Mount
ADB910V3AI /B *
4*
Adjustable Depth Bearing Temperature Sensor
W400-CG-KIT /B**
0**
1 x 25mm Diameter Dual-entry ATEX Approved Cable Gland
2 x 25mm Diameter ATEX Approved Cable Gland
1 x 20mm Diameter ATEX Approved Cable Gland
3 x 25mm Gland Weather Seals
1 x 20mm Gland ATEX Weather Seal
W400-BSA-KIT/B
1*
4 x 1/8” Female to M6 Male Thread Adapters
4 x M6 Seal-tights
2 x 1/8” Rp Female to 1/4" Rc Male Thread Adapters
Table 3 - System Components
* NB! This item is only included in the W4005V46-SYS2 /B system model. These can be added at a later date,
please contact your local 4B representative.
** This is an optional component and needs ordering separately
6.3 System Components Introduction
6.3.1.W4005NV46AI /B –W400 Series Elevator Controller
The W4005NV46AI /B is a standalone controller unit which operates by reading up-to: four NTC Temperature
inputs, two Misalignment Zones (possible to add more than two sensors, see Belt Alignment Sensor section).
It can operate in a single speed mode or with two speed inputs, i.e. differential speed mode. It also has a
Motor Run input. When the motor run signal is applied to the W4005NV46AI /B, it monitors all its sensor
inputs for any fault conditions and if needed shuts down the elevator/conveyor when any of the dangerous
conditions are detected. The unit is fitted with MUTE and TEST buttons. The unit is equipped with an Ethernet
port and supports ProfiNet and Ethernet /IP protocol support for easy integration with the Siemens and
Rockwell PLCs.
6.3.2.TS1V4AI /B –TouchSwitch™Alignment Sensor

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The TouchSwitch™ is an electronic limit switch with no moving parts. When a belt misaligns or a pulley moves
over and contacts the sensor, the built-in electronic circuitry detects the lateral force of the belt or pulley
and activates a voltage free relay contact. This relay contact is used to immediately generate an alarm. The
face of the sensor is made from hardened stainless steel, so that there is virtually no wear when a belt
contacts it. The sensor is not affected by dust or material build up and will still work when completelycovered
by material. Four sensors are provided in the kit and are expected to be installed in pairs –two sensors near
the top and two near the bottom pulleys.
6.3.3.P300V34AI /B –Proximity Speed Sensor
P300 is an inductive proximity sensor which is used to detect the speed of an elevator shaft. This sensor gives
an opto-isolated pulsed transistor output, which the W4005NV46AI /B controller uses to calculate the
current shaft speed. P300 sensor is designed to be mounted on to the shaft using the Whirligig mounting
bracket (WG4A-BR /B).
6.3.4.WG4A-BR /B –Whirligig® Speed Sensor Mounting
The Whirligig® is a fully guarded target for easy mounting of motion sensors. It is a target, bracket and guard
designed for the P300V34AI /B sensor included in the System. P300V34AI /B sensor is bolted to the Whirligig®
and the complete assembly either bolts to the machines shaft through a M12 tapped hole or is connected
magnetically using 4B’s patented Mag-Con™ adaptor (*not included in the System kit). Shaft or machine
vibration does not affect the performance of the sensor, as the whole assembly moves with the shaft. With
the Whirligig, installation of speed sensors is simple, safe and reliable.
6.3.5.ADB910V3AI /B * - Adjustable Depth Bearing Temperature Sensor
The ADB910V3AI /B bearing sensors are manufactured to screw directly into a bearing housing. Each sensor
is fitted with a grease nipple to allow lubrication of the bearing without the need for removal of the sensor.
The sensor is fitted with a mechanism to allow the temperature probe to be set at a variable depth to suit
your application. The temperature bead is of NTC (Negative Temperature Coefficient) response type. The
ADB910V3AI /B sensor cable has two cores. The connections are not polarity sensitive therefore special
connection requirements are eliminated. It is advisable however to connect all sensors in an identical
manner, this will reduce the risk of shorting.
7. Specifications
7.1 Overall Packaging
Overall Packaging Dimensions
Dimensions
323mm x 323mm x 315mm (L x W x H)
Weight
4.3kg (W4005V46-SYS1 /B); 5.0kg (W4005V46-SYS2 /B)
Table 4 - System Packaging Dimensions
7.2 Airborne Noise
This system is electronic with no major moving parts. The airborne noise of the system is below 70dB(A).
When a siren is connected to the controller alarm/fault relay, it is up to the end user to make sure that the noise
levels of the selected siren comply with the Machinery Directive.

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7.3 W4005NV46AI /B –W400 Series Elevator Controller
Controller Specifications
Supply Voltage:
24VDC OR 100-240VAC ±10% 50/60Hz
Power Dissipation:
25W Max
Alarm Relay Contacts:
1 Pole normally open 8A@ 250VAC AC1
Stop Relay Contacts:
Guided Relay Category B, 1 Pole normally open 8A@ 250VAC AC1
Sensor Supply:
24VDC; Current 800mA maximum (combined over F1 and F2)
Motor Run Input:
24VDC
Contactor Feedback Input
24VDC
Power Terminals:
4mm² 14 AWG max
Signal Terminals:
2.5mm² 16 AWG max
Protection:
IP66
Height:
246mm (9.7”)
Width:
188mm (7.4”)
Depth:
102mm (4”)
Fixing Centres:
222mm x 102mm (8.75”x 4”) (AutoCAD Drawing available)
Cable Entry:
3 x 25mm Dia Holes, 1 x 20mm Dia Hole
Weight:
1.3kg (3lbs)
Table 5 –W4005NV46AI /B Controller Specifications
7.3.1.W4005NV46AI /B Controller Fuses
The W400 series controller has three replaceable fuses. Please use the information below when ordering new
fuses.
Fuse Reference
Fuse Value
Fuse Type
4B Part Number
F1, F2, F6
2A; 250V
TR5,Time Delay
FUSE-ELITE-2
F5
200mA
TR5,Time Delay
FUSE-ELITE-200
Table 6 –W4005NV46AI /B Fuse Ratings
7.4 TS1V4AI /B –TouchSwitch™Alignment Sensor
TouchSwitch Specifications
Supply Voltage:
24VDC (TS1V4AI)
Power Consumption:
50mA
Indication:
Red LED indicates when powered up and relay is energized
Adjustment:
Force Sensitivity is factory set to 3.6 kg (8 lb)
Output:
Voltage free changeover relay contact rated at 5A 250vac;
Non-inductive
Body Construction:
Pressed seamless steel, powder coated
Face Construction:
Hardened stainless steel
Cable Length:
3 meters (9ft)
Conductors:
6 cores; 22AWG
Weight:
1.36 kg (3 lb.)
Protection:
IP 66
Dimensions:
86mm (3.5”) Diameter x 44mm (1.75”) Deep
(AutoCAD Drawing Available)
Table 7 - TS1V4AI /B Specifications

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7.5 P300V34AI /B –Proximity Speed Sensor
P300 Specifications
Supply Voltage:
10-30VDC
Sensor Output Type:
Opto-Isolated Transistor (NPN or PNP use)
Sensor Output Ratings:
100mA @ 30VDC MAX
Maximum Detectable
Speed:
200Hz (1500 RPM MAX shaft speed when used with WG4A-BR mount)
Cable Length:
3metres (9 feet)
Conductors:
4 cores; 22AWG
Detection Range:
12mm
Protection:
IP65
Dimensions:
30mm Diameter x 92mm Long (AutoCAD Drawing Available)
Weight:
0.2kg
Table 8 - P300V34AI /B Specifications
7.6 WG4A-BR /B –Whirligig® Speed Sensor Mounting
Whirligig Specifications
Shaft Material:
Stainless Steel
Body Material:
Polypropylene
Bearing Type:
Sealed Stainless Steel
Mounting Thread Size:
M12
Maximum Speed:
1500 RPM
Number of Targets:
4
Protection:
IP40
Dimensions:
AutoCAD drawing available
Weight:
0.25kg
Table 9 - WG4A-BR /B Specifications
7.7 ADB910V3AI /B - Adjustable Depth Bearing Temperature Sensor
ADB910 Specifications
Thermistor Type:
NTC
Response Curve:
Exponential
(Please contact 4B for more details)
Cable Length:
3metres (9 feet)
Conductors:
2 Core; 22AWG; Polarity Independent
Probe length:
100mm
Body Mounting Thread:
1/8” Rc (BSPT)
Dimensions:
AutoCAD drawing available
Protection:
IP65
Weight:
0.25kg
Table 10 - ADB910V3AI /B Specifications

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8. Mechanical Installation
DANGER: EXPOSED BUCKETS AND MOVING PARTS WILL CAUSE SERIOUS INJURY OR
DEATH. THE OPERATOR MUST ALWAYS LOCKOUT POWER BEFORE REMOVING COVER OF
THE INSPECTION DOOR OF THE ELEVATOR OR PERFORMING ANY INSTALLATION OR
MAINTENANCE WORK.
8.1 TS1V4AI /B –TouchSwitch™Alignment Sensor
The TouchSwitch™ hole should be cut into the housing with a 55mm diameter hole saw (Figure 2), centered
on the edge of the belt. The hole should be cleaned and de-burred to avoid the TouchSwitch™ puck binding
and giving false misalignment alarms. You can mount the TouchSwitch™ with 2 of the 4 flange holes,
provided they are diagonal from one another (Figure 1). The enclosed flange shims can be used as a template
to properly place the flange holes. The TouchSwitch™ needs to be mounted on a flat surface, preferably with
the cable entrance between the 3 to 9 o’clock.
Figure 2 –TouchSwitch Mounting Hole Drill
The TouchSwitch™ can be mounted using one of the following three methods:
a) Drill and tap the machine casing for M6 threaded bolts supplied with the system. Make sure that the
bolts used to secure the TouchSwitch™ are short enough that they do not interfere with the operation
of the machine
b) Use threaded rivet nuts for M6 threads. The length of the rivet nut will depend on the thickness of
the machine’s casing. Make sure that the bolts used to secure the TouchSwitch™ are short enough
that they do not interfere with the operation of the machine
c) CD weld M6 x 30mm threaded welding studs to the machine casing
When placing flange shims on TouchSwitch™ make certain belt and or pulley contacts the TouchSwitch™
face before it can contact any internal surface of leg or conveyor housing. It is best not to be any further
away from the pulley than 30mm to 40mm to the face of the TouchSwitch™.
Figure 1 –TouchSwitch Mounting Hole

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When mounting on the head section of an elevator try to catch the belt and the pulley. On an elevator,
mount the TouchSwitch™ above the center line of the head shaft on the discharge side of the pulley when
possible. Sometimes this is not possible due to an inspection door or other obstruction. In this case, the
TouchSwitch™ can be mounted on the top or up side of the head pulley. Try to mount TouchSwitches so they
are accessible from the head section walkway. Be sure to mount TouchSwitches straight across from one
another. For typical mounting positions on a bucket elevator, see Figure 4 and Figure 5.
On an elevator boot, mount the TouchSwitch™ on the up side of the tail pulley if there are no obstructions.
If obstructions are encountered, use the down side of the pulley, but be sure to have the TouchSwitches
mounted directly across from one another. Mount the TouchSwitch™ above the center line of the boot shaft
at the shaft’s highest possible position (Figure 5).
8.1.1.TouchSwitch Dimensions
Figure 3 –TouchSwitch Mechanical Dimensions

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8.1.2.TouchSwitch Mounting Diagrams
8.1.2.1. Typical Mounting Positions on a Bucket Elevator
Touchswitch™ must be installed above the
head shaft between the 9 o’clock and 3
o’clock position and as close to the 3
o’clock as possible.
Note: mount pair of TouchSwitches directly
across from each other on right and left
side of bucket elevator.
Mount Touchswitch™ on upside of leg
(if possible) at the highest point that the
bootshaft can be adjusted to.
Figure 4 –Touchswitch Mounting Positions –Elevator Leg

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8.1.2.2. Typical Mounting Positions On Tail/Boot Section Of Bucket Elevator
8.2 WG4A-BR /B and P300V34AI /B –Proximity Speed Sensor and Bracket
Installation
a) Install the sensor to the base plate; leave a 2 mm (approximate) gap between the sensor face and
the target guard cover. Use the supplied universal bracket and screws to mount the P300 sensor
b) There are two options to attach the Whirligig® to the machine’s shaft:
Option 1 - Drill and tap the center of the machine shaft for M12 x 15mm deep thread. Thread the
Whirligig® onto the machine shaft with a M16 open ended spanner using suitable thread locking
adhesive (Loctite or similar)
Option 2 - Use Mag-Con™ magnetic connector. Thread the Mag-Con™ onto the Whirligig® using a
suitable thread locking adhesive (Loctite or similar) and attach the unit onto the machine shaft
c) Wire the sensor in accordance with the manufacturer’s instructions while observing all relevant
electrical regulations and according to IEC 60079-14, IEC 60079-10
d) Fix the white flexible strap to a solid structure
e) Please refer to Figure 6 for an Illustration of the installation process
Mount touchswitch™ on upside of
leg (if possible) at the highest point
that the bootshaft can be adjusted
to.
Mount touchswitches directly
across from each other and in line
with the pulley and belt to detect
misalignment of either the pulley
or the belt.
BOOTSHAFT
BELT
PULLEY
Figure 5 –Touchswitch Mounting Position –Bottom Pulley

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IMPORTANT: DO NOT REMOVE THE WHIRLIGIG® TARGET GUARD COVER. THE ROTATING COMPONENTS
UNDER THE COVER COULD CAUSE SERIOUS INJURY.
8.3 ADB910V3AI /B - Adjustable Depth Bearing Temperature Sensor
a) Remove the existing grease nipple from the bearing sensor
b) Drill out and tap to 1/8” Rp (BSPT) x 6mm deep if needed
c) Slacken the olive nut and remove the sensor probe
d) Screw the sensor body into the new tapped hole in the bearing housing
e) Re-insert the temperature probe in to the olive nut adjusting the depth to suit the bearing depth
f) Tighten the olive nut using an appropriate spanner
g) The maximum recommended torque for the olive nut is 2N-m (18 lb-in). Please do not exceed.
Figure 6 –P300 and Whirligig Mounting Bracket Mechanical Installation

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8.4 W4005NV46AI /B –W400 Series Elevator Controller
8.4.1.W4005NV46AI /B Enclosure Installation
a. The IP66 rating of the enclosure must be maintained. You must use the correct cable, glands and sealing
arrangement and in accordance with the installation codes detailed in EN 60079. Please order the W400-
CG-KIT /B gland kit if not able to source the adequate components.
b. Where other certified components are used as part of the assembly or installation procedure, the user
must take in to account any limitations which might be listed on the relevant certificates.
c. All unused entry apertures must be sealed using component certified stopping plugs as specified in EN
60079-14. The end user must install component or apparatus certified stopping plugs and cable glands
in strict accordance with the manufacturer’s instructions. Please order the W400-CG-KIT /B gland kit if
not able to source the adequate components.
d. All wiring must be carried out in accordance with relevant codes of practice and/or instructions (IEC
60079-14, IEC 60079-10).
e. The electronics inside the enclosure should not be modified. No new components can be added. The
W4005NV46AI /B is approved only with the electronics supplied by the manufacturer. Any modifications
will void the approvals and warranty.
f. Bare wires must not extend beyond 1mm of the metal face of the terminals.
g. All wires must be insulated and rated for the appropriate voltage.
h. Not more than one cable with a maximum cross section as detailed in Table 5 –W4005NV46AI /B
Controller Specifications is to be connected to any terminal unless multiple conductors have previously
been joined in a suitable manner (e.g. boot lace ferrule) such that they present a single connection point
to the terminal.
i. A parallel shaft screwdriver of the correct size should always be used when tightening terminals.
Maximum torque is 0.51 N-m.
9. Electrical Installation and Wiring
DANGER: ALL ELECTRICAL POWER TO THE SYSTEM AND WIRING MUST BE ISOLATED PRIOR
TO STARTING ANY INSTALLATION OR MAINTENANCE WORK. WORKING ON OPEN LIVE
CIRCUITS IN ATEX ZONES IS PROHIBITED AND CAN LEAD TO AN EXPLOSION.

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9.5 Warnings
•Analogue signals must be shielded if cables are longer than 10m
•Digital signals can be shielded
•Keep sensor wiring separate from high voltage cables
•Never run sensor cables in the same conduit as 3-phase motor cables
•Never weld near or around the supplied system components
•Track belts and commission plant prior to installing TouchSwitches
9.6 TS1V4AI /B –TouchSwitch™Alignment Sensor
Mount a suitable junction box within 3m of the sensor and make the necessary wiring connections inside
this junction box. A 3m long PVC coated cable connected to the sensor contains the following 22 AWG wires:
Wire Color
Function
Red
+24VDC
Black
0VDC
Green
PE (Power Earth)
White
Relay Common Connection
Blue
Relay Contact, N.O. (Sensor Output to Controller or PLC)
Orange
Relay Contact, N.C. (DO NOT USE!) –Make sure this conductor is isolated
Table 11- TouchSwitchTM Electrical Sensor Wiring
All Wiring Must Be in Accordance With Local and National Electrical Codes and Should Be Undertaken
By an Experienced and Professional, Qualified Electrician. In order to comply with the ATEX regulations,
the installation design and process must also comply with the latest IEC 60079 range of standards.
Test Knob
TouchSwitch Sensor
+24VDC / RED
0VDC / BLACK
Relay Common / WHITE
Relay N.O. / BLUE (Sensor Output)
Relay N.C. / ORANGE (DO NOT USE!)
PE (Power Earth) / GREEN
Figure 7 –TouchSwitchTM Electrical Connection

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9.6.1.Sensor Operation
This is an electronic limit switch. The sensor reacts to pressure applied to the sensor face. If the pressure is
higher than 3.6kg, then the sensor switches the relay to an alarm condition (see Figure 9). If the sensor is
correctly powered, working and no pressure is applied to the sensor face then the sensor will energize the
relay and indicate the OK state by a lit-up LED (see Figure 8).
NOTE: TouchSwitchTM is delivered factory pre-calibrated and no sensitivity adjustment is possible. The sensor
is calibrated to switch to the alarm state when pressure exceeds 3.6kg. Should you require adjusting this
value, please contact your 4B Representative for more information.
Blue
White
Orange
RED LED ON
Sensor Powered and No Pressure is Applied
No
Pressure
Applied
Sensor
Face
Blue
White
Orange
RED LED OFF
Pressure is applied or No Power or Sensor Faulty
Sensor
Face
Pressure
Applied
Figure 8 - TouchSwitch in OK Condition
Figure 9 - TouchSwitch in Alarm Condition

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9.6.2.Testing and Commissioning
TouchSwitchTM has a unique self-test feature which allows verifying that the system wiring is correct without
the need of removing the sensor. The system has an active self-checking mechanism between the sensors
and the controller; however, 4B would still recommend checking if the Stop signal from the W4005NV46AI
/B controller shuts down the elevator and that the alarm/fault relay signal is visible to the operators at least
annually. The test procedure is given below.
1) Observe that the red output LED on the sensor housing (see Figure 8) is ON and the belt or pulley are
not touching the sensor
2) Slowly turn the test knob (see Figure 7) clockwise by hand, until the LED goes OFF
3) Check that the alarms and shutdowns of the overall system work as expected (see Figure 9)
4) Once completely satisfied that the system can be stopped and that the alarm is processed correctly
turn the test knob back to its original position (about 1 turn) and make sure that it is loose
5) Observe that the LED is now ON
9.6.3.TouchSwitch Electrical Wiring
Figure 10- TouchSwitch Wiring Diagram