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

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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.

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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.