Aybey Elektronik AE-MAESTRO User manual

AE-MAESTRO
Integrated Lift Control System
INSTALLATION MANUAL
for Electric Package of Gearless Lift Machines
Document Name : AE-MAESTRO Lift Controller Installation Manual
for Electric Package of Gearless Lift Machines
Document Code : AEM-INSEN-GL
Document Version : 1.08d
Software Version : 2.20u (Lift Control) / 2.20g (Motor Driver)
www.aybey.com

1
A.PREFACE
This document is written to guide installation of the lift controller for pre-wired system. It guides the
installation of electric system of the lift. This document should be used in together with AE-MAESTRO
Integrated Lift Controller and Hand Terminal user manuals.
Pre-Wired system has been designed to make installation easier and faster. All the cables have either plug
and play connectors if they are going to be connected to another socket or dummy terminals to avoid any
short circuit. There are labels on all free cables and cable groups with their related information written on
them. To avoid any wrong connection, check the labels before connecting any socket or terminal.
CAUTION
This document is a quick installation document and does not contain complete information.
For more detailed information refer to the user manual of the Integrated Device and Hand
Terminal.
The scope of this manual is limited only to electrical parts.
Installation must be performed only by authorized persons.
Check the labels before connecting any socket or terminal.
Do not leave the lift in normal mode before completing and testing the system properly.
APPENDIXES:
AP01-FLOOR LEVEL ADJUSTMENT
AP02-CAR OPERATING PANEL
AP03-LANDING OPERATING PANEL
AP06-PRE-TORQUE AND LOAD MEASURING DEVICE

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1. Lift Control Panel
2. Recall Command Box
3. Inspection Command Box
4. Cartop Emergency Lighting
5. Cartop Box
6. Audible and Flashing Device
7. Pit Control Unit
8. Pit Command Box
9. Pit Inspection Reset Switch
10. Machine Side Stop Button
11. Shaft Limit Switch
12. ML1-ML2 Magnetic Switches
13. Braking Resistor
THE ELECTRICAL COMPONENTS IN SHAFT

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THE COMPONENTS USED IN SHAFT AND MACHINE ROOM
Prewired Inspection Box
KDM Pit Control Box
Pit Stop, Socket and
Alarm Box
Inspection and Recall
Command Box
In cartop, controller
and pit to move the car
Controls car circuit
Controls pit circuit
Connected to Controller
Stop Button
Audible and Visual
Alarm
Braking Resistor
Pit Leaving Switch
Used to stop the lift in
machine room
Used under the car
Connected to Controller
Used at the base
landing floor
Magnetic Switches
Flex Holder
Strip and Round
Magnets
Shaft Limit Switch
Used on the cartop
Used on the car wall
Used on the rails
Used on the cartop
FIXING MRL CONTROLLER BOX TO THE WALL
MRL type lift controller box is placed next to the
door at the top floor.
Be careful to install control panels so that the
ventilation holes are not exposed.
Use screws and brackets given to fix the metal box
to the wall as shown below.

4
CONNECTING LINE SUPPLY
Connect power line cables to the terminals
L1/R, L2/S, L3/T and N.
CONNECTING MOTOR POWER
1. Connect motor power inputs to U, V, W terminals in
controller box.
2. Use the given shielded motor cable for this.
3. Connect shielding of the cable to the earth bar in the
controller.
CONNECTING BRAKING RESISTOR
1. Fix the braking resistor onto the wall or control panel
box.
2. Do not put the resistor into the control panel box.
3. Be aware that it will be hot and will emit heat to the
surroundings during lift operation. Do not touch it during
operation.
4. Connect the cables of the braking resistor to the
terminals P+, DB in XK-BRK2 group in control box.
5. Connect the shielding of the cable to the earth bar inside
the control panel.
6. Do not run the motor without connecting the
appropriate braking resistor. Otherwise the device may
be damaged.
CONNECTING RECALL COMMAND BOX
Connect recall command box to the controller on HT-KL terminal
board by plugging XK-PREV1 and XK-PREV2 sockets.

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CONNECTING BRAKE, THERMISTOR AND MACHINE SIDE STOP
1. Motor brakes, thermistor and stop are placed in XK-
BRK2 terminal group in controller box.
2. Connect motor thermistor to T1 and T2 terminals in
controller box.
3. If there is no thermistor in motor then bridge T1 and
T2 terminals in controller.
4. Connect brake coils and brake contacts as shown in
the figure to the related controller terminals.
5. Note that the brake monitoring contacts are
normally closed (NC).
6. Connect machine stop to 110 and 110A terminals
(EN81-20).
CONTROLLER OUTPUT TERMINALS AND SOCKETS
The system is prewired. Therefore, there are very few direct cable connections to the controller. The
connections are mostly done by plugging sockets or connecting external devices to the labelled dummy
terminal. The drawing below shows the output terminals of the controller. The sockets have been
arranged in groups for specific tasks.

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In order to start with autotuning operation safety line must be closed.
If safety line has been already bridged on HT-KL board with first installation cables in control
panel, then these cables must be removed after termination of the installation process!
If the safety line bridging cables are not avaible for HT-KL board and the car circuit is not wired
yet, you can connect inspection box and flex cable next to the controller box.
So, the safety circuit will be closed and autotuning operation can be started.
CONNECTING FLEX CABLE TO CONTROL PANEL
The terminals for the flex cable are on HT-KL board.
There are two pieces flex cables between car and
controller, one 12 the other 24 wires.
In installation, if the car is not been already installed then
you can connect the inspection box in machine room. This
is necessary to have the safety contacts closed in order to
run motor for autotuning.
1- Take 24 wire flex cable and connect its terminals
labelled with…
XK-FLX1-1
XK-FLX1-2
XK-FLX1-3
to their corresponding sockets on HT-KL board in
the controller box.
2- Take 12 wire flex cable and connect its terminals
labelled with XK-FLX2 to its corresponding socket on
HT-KL board in the controller box.
CAR ELECTRIC INSTALLATION
1. Place inspection box onto the cartop.
2. Flexible cable is already equipped with plug in
connectors on both ends.
3. There are two boards inside the inspection board
PWL and PWH.
4. Connect flex cable to the related terminals in PWL
and PWH boards inside the inspection box as shown
on the connection diagram on page C01-FLEXIBLE
CABLE CONNECTIONS presented in project schemas.
5. PWH is the lower board and carries safety line and
220V / 230V signals.
6. PWL is the upper board and it serves as the car
controller.

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7. Take other end of 24 wire flex cable and connect its
terminals labelled with…
XH-HV3
XL-LV2
XH-HV1
XH-HV2
to their corresponding sockets on PWL and PWH boards in
cartop inspection box.
8. Take other end of 12 wire flex cable and connect its
terminals labelled with XL-LV1 to its corresponding
socket on PWL board in cartop inspection box.
CONNECTION OF CAR PANELS
1. For ALYA Series COP
a) Connect cable labelled CON(A) between CON(A)
socket in PWL board and CONA socket of ALYA
car panel.
b) If you have two COPs inside the cabin, then
connect CON(B) between PWL board and CON
socket of the second ALYA car panel in the cabin.
Set door type to B from ALYA car panel dip
switch.
2. For other COP Series
a) Connect cable labelled CON(A) between CON(A)
socket in PWL board and CON socket of PWS
board in car panel.
b) If you have two COPs inside the cabin, then
connect CON(B) between PWL board and CON
socket of PWS board inside the second car panel
in the cabin. Set door type to B from PWS dip
switch.
See AP02-CAR OPERATING PANEL section in Appendix for
mechanical and electrical installation of car panels.
CONNECTIONS OF CAR CIRCUIT
Connect the remaining car devices to the inspection box as shown in the following circuit diagrams
presented in schemas of the project on pages:
C02-CAR TOP CONNECTIONS PWH and C03-CAR TOP CONNECTIONS PWL

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CONNECTING LANDING PANELS
1. Read the manual of landing panels (LOP) in Appendix-3, AP-03.
2. Landing panels are serially connected and must have a unique floor
number id to communicate.
3. All LOPs are delivered as their floor numbers already saved.
4. So, read their floor numbers on their pockets to find their floor.
5. You can set the floor number of any LOP at any time by following
the instructions in LOP manual AP03-LANDING OPERATING PANEL
in Appendix.
6. Fix LOPs to the walls at the landings regarding to the instructions in
AP-03.
7. Connect XK-CB socket to the controller.
8. Connect all landing panels to the cable of XK-CB.
9. If the pit board (SPT) is not used in system, a termination resistor
must be installed at the end of the line.
CONNECTING LANDING DOORS
1. Connect XK-KK socket to the controller terminals to connect door
contacts.
2. At each floor disconnect the dummy white terminal shown below
and connect these cables to the door contacts. LKK/A-B is the name
of this cable.
3. Connect green-yellow cable to the metal chassis of the door.

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CONNECTING SHAFT PIT (Only for EN81-20 Standard)
Connect XK-KDM-SF1 and XK-KDM-PWR sockets
to the controller to implement shaft pit.
Connect SPT board, which is in shaft pit box
KDM, to the socket of the LOP in ground floor.
Connect other shaft pit devices to the terminals
of the KDM box as shown on the diagram in the
project schemas.
Place KRR switch at the landing onto door frame
or onto a wall near it. It must be located outside
of the shaft.
KRR switch must change its state after an exit
from pit inspection. Otherwise the system will not
switch to the normal mode.
CONNECTING SHAFT PIT (Only for EN81-1 Standard)
Connect XK-KDM-SF1 socket to the controller to
implement shaft pit.

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ENCODER CONNECTIONS FOR GEARLESS MACHINES
1. Open the front cover of the device. ICA board should be placed on the right side.
2. Check the supply voltage information of the encoder.
3. Read the product code written on the encoder and check if it matches to one of encoders given
below. Otherwise connect encoder to ICA board regarding the colours given in the data sheet of the
encoder used.
4. Encoder cables should be connected to ICA board as shown the diagrams below.
5. Please check data sheet of the encoder before connecting it to ICA board to verify cable colours of
the encoder. The cable colours of the encoders may change depending on the manufacturer of the
traction machine.
6. You should specify the type of the absolute encoder you are using in parameter M16.

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1. The controller must be started in inspection mode due to
the position of the switch in recall command box.
2. Switch on power to energize the controller.
FRONT LED PANEL
There is a led panel in front cover of the device.
It gives information about the status of some important
variables.
LED panel is used by default to show current floor number.
However, it can be used to monitor a number of variables, too.
This can be done by adjusting parameter E03-LED DISPLAY.
There is a bar between two LED columns, which shows the
state of the system.
Green means normal mode, yellow inspection mode and red
error case.
In case of any motion the bar flashes
The safety line 120…140 can be monitored here.
HAND TERMINAL
Hand Terminal should be used to adjust parameters and carry
on the services implemented in the device software.
It must not be present during operation of the lift.
Hand terminal can be used as plugged onto the device as well
as via CAN-Bus in the shaft and cabin.
The software of the device can be updated by using hand
terminal. Program file is transferred from an SD card.
Read AE-MAESTRO Hand Terminal manual before going
further. You will need it to monitor the lift, edit parameters
and performing operations.
However, as an example how to change the number of floors
will be explained below.
To work with software (Control-2.20u and Motor Driver 2.20g)
you need a terminal software 2.20t or higher. Please check.
The main screen shows the following values about the lift:
Real time travel of the car.
Safety line.
Car position
Car speed
Door state
Current calls
A message line about the state of the lift.
Some of the important inputs and outputs.

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Press ENT button to go to the menu.
In this screen you can move by using cursor keys (arrows).
In order to enter into an application or sub-menu come to the
related icon by using cursor keys on the screen and press ENT
when its icon is highlighted.
For example, select Parameters and press ENT while
parameter icon is being highlighted.
So, you will go into parameter menu.
In Parameters menu select Group A by using up and down arrows
and press ENT when Group A is highlighted.
You can select other parameter groups similarly.
Then select A01-NUMBER OF FLOORS in order to change number
of floors with arrow keys in the list of the Group A parameters as
explained above and press ENT.
In the following screen Number of floors will be displayed on
the screen.
Select the number you want to set as number of floors of the
lift by using up and down arrow keys.
Then press ENT key to save your selection.
So parameter A01 is saved as 2.
You can use this method to see and change other parameters.

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LOADING AND SAVING PARAMETERS
The parameter set of the device can be saved into the SD
card and reloaded from it again.
So, the parameters can be back-up, transferred to another
device or restored from the file in SD card.
Use IMPORT utility in hand terminal to save parameters
into a file in SD card.
Use EXPORT utility in hand terminal to restore parameters
from a file in SD card.
EXPORT and IMPORT utilities work only on the device not
via CAN-Bus.
SOFTWARE UPDATE
Software of the device can be updated by using the hand
terminal.
Copy the program file you want to load to the device into
the SD card.
Insert SD card into the slot in the hand terminal.
Place hand terminal onto the device.
Update operation cannot be performed via CAN-Bus.
Select Data-Software icon.
There are two processors inside the device. Therefore,
you should select ICM or ICS Upload icon to upload.
To update the hand terminal software, hold F1 during
energizing the hand terminal.
You can start the update with the ENT button on the
selected file from the screen that appears.
Press STOP button to inhibit any motion.
Before starting any update procedure switch the
controller to the inspection mode
You should select the file you want to upload on the
screen by using UP and DOWN arrow keys.
Then press ENT to select the program file and start
uploading.
Do not switch off the system during operation.
You must switch off and restart the system after software
update.

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INITIAL PARAMETER SETUP
AE-MAESTRO has an interactive installation menu which
can be used to set most of the general parameters.
Using this menu facilitates setting up the system.
You will be asked to set requested parameters one by one
depending on the previous selections.
Firstly, switch to the INSPECTION mode.
Then click on the SETUP icon to start with the installation.
Installation menu starts with A15 INSTALLATION MODE
parameter.
In order to go to the application, you must select A5=1 to
activate installation and initiate setup.
Installation mode bypasses some errors since the system
has not been installed properly in the shaft yet.
You will need this facility to place shaft switches, magnets,
etc.
Installation Mode is only in inspection mode active. Its value
will be switched to 0 as soon as the system is switched to the
normal mode.
Once setup application has been started, you will be asked
for entering a number of parameters related to your system
and motor specifications.
You can leave this menu by using ESC button.
When you click on the CONFIRM button the next screen for
the next parameter will come.
When A03 Motor Type is asked, select 2-Syncronous for
gearless traction machine.
Select appropriate parameters on each screen.
So, the required parameters to start installation work with
the controller and to run the motor will be adjusted.
Of course, you will need to do some more modifications on
parameter related to comfort, timing and special requested
functions.
You can also change these parameters at any time after
completing the setup program, when needed.

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The last screen in setup menu is M18 Tuning Mode.
If you confirm this parameter, setup operation will be
terminated and you will be directed to the tuning
operation.
If you want, you can leave the setup program now and
execute tuning later.
Tuning procedure is explained below.
If you want to continue with the tuning operation follow
the instructions of tuning as explained below.
AUTOTUNING
1. Autotuning operation should be carried out to get
encoder offset position and motor characteristics
2. Switch recall switch to position 1 on recall command
box.
M18 TUNING MODE
0- Stationary Tuning
In this method, tuning process is carried out without any
rotation of motor.
This method should be selected if the ropes have already
been hanged onto the pulley. Otherwise rotating tuning is
preferred.
Any motion of the motor must be prevented.
Be sure that the brakes are closed and are holding the
motor fixed.
Select 0-STATIONARY TUNING in M18 TUNING MODE
parameter M18=0.
M18 TUNING MODE
1- Rotating Tuning
Rotating tuning is always preferred and gives better
result, use this method if possible.
Be sure that the ropes are disconnected out of the pulley
and the rotation of the motor will not move the car.
The motor will rotate less than one quarter tour during
the operation.
This rotation will be smoothly.
Select 1-ROTATING TUNING in M18 TUNING MODE
parameter M18=1.

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TUNING IN OPERATION
Turn on INSPECTION switch on recall command box
to INSP position.
The system must stay in inspection mode and safety
line must be closed along the operation to execute
tuning process.
To start tuning operation, select R04-TUNING under
SERVICES icon.
The car must not be staying at bottom or at top
floor. Move it anywhere not close to the ends of the
shaft.
Operation Stage 1
Press the blue RUN button on the recall command
box and hold it pressed until the end of the tuning
process.
Press UP arrow button on the hand terminal to start
the operation.
Operation Stage 2
So, tuning operation has been started.
Continue pressing onto RUN button on recall
command box.
IN OPERATION
In rotating tuning…
1. If the motor rotates more than one tour, then
terminate operation by releasing RUN button.
2. In rotating tuning the motor rotates smoothly until
the nearest pole position.
3. If it is currently staying just in its pole position, then
it firstly rotates for some degrees to get away from
this position and rotates again to find the pole
position.
4. If there is no rotation the system will terminate the
operation by giving an error message.
5. Increase the value of the parameter C20-TUNING
CURRENT and repeat the tuning operation once
more.
6. If the operation fails again, then increase C20 step
by step until the tuning operation will complete
successfully.

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IN OPERATION
In stationary tuning…
Since there will be no rotation, brakes must be held
closed along the operation.
However, if the brakes are not adjusted well to hold
the machine fixed then the motor may rotate. In this
case tuning operation fails.
Therefore, the brakes must be checked before
tuning operation.
In stationary tuning the system will apply signal to
the motor to find pole position without any rotation.
Faults in Operation related to Tuning:
ENCODER ERROR:
This error is caused mainly due to the faulty or
wrong earth connections.
Check earth connections and wires.
MOTOR CONNECTION ERROR:
The device output stage does not sense three motor
phase windings.
The wires and connections between motor and the
device output should be checked.
ENABLE ERROR
This error arises if the safety line is cut by any
reason during the operation. Releasing RUN button
may cause this error.
TUNING ERROR
Any rotation of the motor in stationary tuning may
cause tuning error.
Operation Stage 3
When the operation has been completed then you
will be informed on the screen.
Then stop pressing RUN button.
Now, you can return to the main menu by pressing
ESC button.
Continue staying in inspection mode.
MOTION TEST
1. Give a motion command by pressing RUN and UP or DOWN buttons in recall command box.
2. If you observe a very rapid rotation or no motor rotation, then reverse the value of the
parameter M17-ENCODER DIRECTION in MOTOR PARAMETERS.
3. Then try the first step once more.
4. You should observe a normal rotation in both directions. Otherwise, increase C20-TUNING
CURRENT and repeat the tuning operation once more.

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DIRECTION TEST
Give a motion command by pressing RUN and UP or DOWN buttons in recall command box.
Observe the motion of the car.
If the car travel direction is opposite to the command direction given, then reverse the value of
the parameter M19 MOTOR DIRECTION in MOTOR PARAMETERS.
After that, the motor runs at the desired direction with desired speed then tuning operation is
successfully completed.
Now you can start the processes to prepare the system for normal operation.
Continue staying in inspection mode.
CONNECTION OF DOOR OPERATOR AND SIGNALS (EN81-20)
Door Operator is connected with two cable groups:
1. XL-DS carries door control signals from PWL. The signals
are:
KA output is Door Open Command
KK output is Door Close Command.
KO is the common terminal of KA and KK.
R3 is the Slow Close Command.
C3 is common of Slow Close.
KL1: Door Close Limit for Door 1
DTP: Door Motor Temperature
K1C: Obstruction Contact for Door 1
2. XH-DR carries power supply for door operator from
PWH. These are:
DR2 is Line
DR3 is Neutral
PE is Earth
CONNECTION OF DOOR OPERATOR AND SIGNALS (EN81-1)
Door Operator is connected with two cable groups:
XL-DS carries door control signals from PWL. The signals are:
KA output is Door Open Command
KK output is Door Close Command.
KO is the common terminal of KA and KK.
XH-DR carries power supply for door operator from PWH.
These are:
DR2 is Line
DR3 is Neutral
PE is Earth

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CAR ILLUMINATION CONTROL
There is a detection system for car illumination control inside
car operating panel.
It inhibits the motion of the car if the light inside the cabin
goes off, while the car light is on (busy signal on).
Sensitivity of the light detector system can be adjusted with
the potentiometer on GN02 board inside the car panel. It is
marked by the red circle in the photo.
BYPASS SWITCH (Only for EN81-20 Standard)
Bypass switch has 4 positions and bypasses only car or
landing doors.
Position 0: No bypass. This is for NORMAL OPERATION
mode.
Position 1: 120 and 125 are bridged. This means:
In systems with two automatic doors, landing door contacts
of side B are bridged.
In systems with semiautomatic doors landing door contacts
are bridged
Position 2: 125-130 are bridged. This means:
In systems with automatic doors, landing door contacts in
side A are bridged.
In systems with semiautomatic doors landing door locks are
bridged
Position 3: 130-140 are bridged, namely car door contacts
are bridged (side A and B).
Note: In order to be able to move the car in inspection mode,
while door contact are bridged, door limit switches KL1 (for
car door side A) and KL2 (for car door side B) must have been
already installed and defined.
AUDIBLE AND FLASHING DEVICE (Only for EN81-20 Standard)
When the lift is moved in the bypass mode, it gives an
audible and light warning.
It can be mounted anywhere under the cabin.