GAL GALaxy eHydro User manual

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GALaxy eHydro
Elevator Controller Manual
GAL Manufacturing Corporation LLC
50 East 153rd Street
Bronx, NY 10451
Technical Support: 1‐877‐425‐7778

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Foreword
GAL Manufacturing has developed this manual with usability and safety in mind. General and specific
safety notices and precautions are defined in the manual. However, GAL Manufacturing cannot be
responsible for any injury to persons or damage to property (including the elevator equipment) resulting
from negligence, misuse of the equipment, misinterpretation of instructions included in this manual, or
due to any other cause beyond the control of GAL Manufacturing.
All drawings, illustrations, and information herein are the property of GAL Manufacturing and must not
be made public or reproduced by any individual or entity other than the purchaser hereof without the
express written permission of GAL Manufacturing.
Revision 7.1
GAL Part Number: DOC-0119N

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GALaxy eHydro Controller Manual………………………………………………………………………………i
Foreword...…………………………………………………………………………………………………………...ii
Table of Contents………..…………………………………………………………………………………………iii
Section 1 - Product Description...........................................................................................................1-1
1.1 Product Code Compliance .........................................................................................................1-1
1.2 Specifications .............................................................................................................................1-1
1.3 Physical Layout of the Controller ...............................................................................................1-2
1.4 Selector System .........................................................................................................................1-3
1.4.1 Absolute Position System (APS) Selector..........................................................................1-3
1.4.2 Primary and Secondary Position Feedback.......................................................................1-4
1.5 Sequence of Operation ..............................................................................................................1-5
1.6 Modes of Operation....................................................................................................................1-6
1.6.1 Reset Mode........................................................................................................................1-6
1.6.2 Safety String Open Mode...................................................................................................1-6
1.6.3 Controller Inspection Mode ................................................................................................1-6
1.6.4 Car Top Inspection Mode...................................................................................................1-6
1.6.5 Access Mode......................................................................................................................1-7
1.6.6 Independent Service Mode ................................................................................................1-7
1.6.7 Load Weighing Bypass Mode ............................................................................................1-7
1.6.8 Attendant Service Mode.....................................................................................................1-8
1.6.9 Code Blue Hospital Service Mode .....................................................................................1-8
1.6.10 Fire Service Phase I Mode.................................................................................................1-8
1.6.11 Fire Service Phase I Alternate Return Mode......................................................................1-9
1.6.12 Fire Service Phase II Mode................................................................................................1-9
1.6.13 Emergency Power Sequencing..........................................................................................1-9
1.6.14 Emergency Power Battery Lowering................................................................................1-10
1.6.15 Earthquake Mode.............................................................................................................1-10
1.6.16 Stalled (Low Oil) Mode.....................................................................................................1-10
1.6.17 Automatic Mode ...............................................................................................................1-10
Section 2 - Installation ..........................................................................................................................2-1
2.1 General Information....................................................................................................................2-1
2.2 Site Selection .............................................................................................................................2-1
2.3 Environmental Considerations ...................................................................................................2-1
2.4 Wiring Guidelines and Instructions.............................................................................................2-1
2.4.1 Wiring Schematics..............................................................................................................2-2
2.4.2 Proper Field Wiring.............................................................................................................2-2
2.4.3 Ground Wiring ....................................................................................................................2-2
2.4.4 Hoistway Wiring..................................................................................................................2-2
2.4.5 Elevator Car Wiring ............................................................................................................2-3
2.4.6 Machine Room Wiring........................................................................................................2-3
2.5 Normal and Top Terminal Slowdown Limits ..............................................................................2-3
2.6 Top Terminal Limit Switches......................................................................................................2-4
2.7 Selector Installation....................................................................................................................2-4
2.7.1 APS (Absolute Position System) Selector Installation .......................................................2-4
2.7.1.1 Installation of the Encoded Tape and APS Camera ......................................................2-4
2.7.2 APS Selector Floor Position Setup (Hoistway Learn)......................................................2-14
2.7.2.1 Verify that the APS Selector Camera is Installed Correctly and Communicating........2-14
2.7.2.2 Set the Adjustable Variables –“NTS Proc Adj Vars” in the Controller.........................2-15
2.7.2.3 Zero the Hoistway ........................................................................................................2-15
2.7.2.4 Setting Hoistway Floor Levels with APS Selector........................................................2-16
Section 3 - GALaxy Startup and Adjustment......................................................................................3-1
3.1 Procedure for Initial Power-up of Controller...............................................................................3-1
3.1.1 Checking Main Line Voltage...............................................................................................3-1
Table of Contents

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3.1.3 Verify the Main CPU is Operating ......................................................................................3-1
3.2 Start-Up Procedures...................................................................................................................3-2
3.2.1 Requirements for a running platform during initial startup .................................................3-2
3.2.2 Complete the Installation of Equipment .............................................................................3-4
3.3 Adjustment Procedures..............................................................................................................3-5
3.3.1 Set Toggle Switches...........................................................................................................3-5
3.3.2 Ready the Car to Run on Inspection..................................................................................3-5
3.3.3 Prepare for the Car for Hoistway Learn .............................................................................3-6
3.3.4 Verify the Hoistway.............................................................................................................3-7
3.4 Adjust the Elevator .....................................................................................................................3-7
3.4.1 Automatic Run....................................................................................................................3-7
3.4.2 Adjust the Slowdown Distances.........................................................................................3-8
3.4.3 Adjust the Stop...................................................................................................................3-9
3.4.4 Verify Proper Operation of All Safety Circuits and Signal Devices ..................................3-10
3.4.5 Perform Required Tests ...................................................................................................3-10
Section 4 Troubleshooting...................................................................................................................4-1
4.1 General Information....................................................................................................................4-1
4.2 Microprocessor CPU ..................................................................................................................4-1
4.3 Input/Output Boards ...................................................................................................................4-1
4.4 Run Sequence............................................................................................................................4-2
4.5 The Safety PAL Functions .........................................................................................................4-3
4.6 Safety PAL .................................................................................................................................4-5
4.7 System Faults.............................................................................................................................4-6
4.8 Main CPU Inputs and outputs ....................................................................................................4-6
4.9 NTS Processor Inputs and Outputs .........................................................................................4-11
4.10 Relocate I/Os............................................................................................................................4-12
4.10.1 Relocate I/Os –Add IO Relocation ..................................................................................4-13
4.10.2 Relocate I/Os –Remove Relocation IO ...........................................................................4-14
4.10.3 Car Trace Screen.............................................................................................................4-15
Section 5 LCD Interface........................................................................................................................5-1
5.1 Operating the LDC Interface ......................................................................................................5-1
5.2 LCD Menus ................................................................................................................................5-2
5.2.1 Elevator Status...................................................................................................................5-2
5.2.2 Main Menu........................................................................................................................5-12
5.2.3 Date and Time..................................................................................................................5-13
5.2.4 Set Calls and Lockouts.....................................................................................................5-14
5.2.5 Inputs and Outputs...........................................................................................................5-17
5.2.6 Job Statistics ....................................................................................................................5-20
5.2.7 Adjustable Variables.........................................................................................................5-21
5.2.8 Diagnostics.......................................................................................................................5-22
5.2.9 Software Utilities...............................................................................................................5-29
5.2.10 Hoistway Tables...............................................................................................................5-33
5.2.11 Fault Log...........................................................................................................................5-39
Section 6 - Main CPU Faults & Detailed Faults ................................................................................6-40
6.1 Main CPU Faults ......................................................................................................................6-40
6.2 Device Fault in Fault Log .........................................................................................................6-84
6.3 Detailed Faults Data and Description.......................................................................................6-99
6.3.1 Detailed Fault I/O Data Example....................................................................................6-112
6.3.2 Detailed Fault I/O Data Form .........................................................................................6-115
Section 7 - Main CPU Adjustable Variables........................................................................................7-1
Section 8 - Appendix A .........................................................................................................................8-1
8.1 Testing Stall Mode & Low Oil Operation....................................................................................8-1
8.2 Reset Low Oil, Hot Oil, or MC/SPD Fault...................................................................................8-2
8.3 Performing a Stop Ring Test......................................................................................................8-2

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8.4 Testing NTSD.............................................................................................................................8-2
8.5 Testing Terminal Speed Reducing Device.................................................................................8-3
8.6 Testing the Load Weighing Device ............................................................................................8-3
8.7 Testing Phase 2 Operation With a Ground or Short Circuit.......................................................8-3
8.8 Testing Phase 1 & 2 Operation After Power Interruption and Restoration ................................8-3
8.9 Testing Recycling Operation......................................................................................................8-4
8.10 Testing Plunger Gripper Operation............................................................................................8-4
8.11 Testing Phase 1 Operation Under Special Conditions...............................................................8-4
8.12 Testing Phase 2 Operation Under Special Conditions...............................................................8-5
8.13 Testing Plunger Following Guide Protection..............................................................................8-6
8.14 Testing the Auxiliary Power Supply With the Disconnect Switch Open.....................................8-6
8.15 Testing Low Pressure Switch.....................................................................................................8-6
8.16 Testing Low Pressure Switch.....................................................................................................8-6

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SYMBOLS USED IN THIS MANUAL
CAUTION
This manual uses the CAUTION symbol to identify procedures and practices that may result
in personal injury and/or equipment damage, if not followed correctly.
DANGER
This manual uses the DANGER symbol as an alert to a danger of electrocution or an acute
electrical shock. The DANGER symbol provides elevator personnel with a warning of
severe personal injury or potential fatality that can result if safety precautions are not
observed.
NOTE / INFORMATION
In this manual, this symbol identifies information helpful to elevator personnel when carrying
out a specific procedure or task.
NOT APPLICABLE / DOES NOT EXIST
When this symbol appears inside a table, it indicates that a value or property is not defined,
or is nonexistent, for the item listed.

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WARNINGS AND CAUTIONARY NOTES
Installation and wiring must be in accordance with the national electrical code, all local
codes, and all elevator safety codes and standards. The 3‐phase AC power supply to
the equipment must originate from a properly fused disconnect or circuit breaker that is
properly designed and sized for the specific controller requirements and the “Short
Circuit Current Rating” listed on the controller. Improper motor branch circuit
protection will void warranty and may create a hazardous condition.
Wiring to the controller terminals must be installed in a careful, neat manner. Stranded
wire conductors must not have strands left out of the terminals. Leaving strands of wire
out of the terminals can create a potential short circuit. All terminals and cable
connectors must be seated properly. (See the IMPORTANT notice on the next page.)
Elevator control products must be installed by elevator personnel who have been
trained in the construction, maintenance, repair, inspection, and testing of elevator
equipment. The elevator personnel must comply with all applicable safety codes and
standards. This equipment is an O. E. M. product designed and manufactured to
comply with ASME A17.1-2016/CSA B44-16 Safety Code for Elevators and Escalators.
It is the responsibility of the installer to ensure that the installation is performed safely
and that the installation complies with all applicable codes.
Proper grounding is vitally important to the safe and successful operation of this
system, and proper grounding should be installed to comply with all applicable codes.
A separate ground wire should be installed from the building earth ground to the earth
ground terminal in each controller. Proper conductor size must be utilized for
grounding. In order to minimize resistance to ground, the shortest possible length
should be used for the ground conductor.
Do not install the controller in a hazardous area where excessive vapors and chemical
fumes are present. Do not install the controller in a dusty area. Do not install the
controller in a carpeted area. The space in which the controller equipment is installed
should be temperature controlled, moisture free, and should be maintained within a
temperature range of 32° F and 110°F.The space in which the controller equipment is
installed should be kept clean. The controller should be kept dry and should not be
exposed to moisture or water condensation. Make sure the power supply voltage
feeding the controller equipment does not fluctuate by more than +/- 10%.
Every safety precaution, whether or not specifically stated in this document, must be
implemented when installing, adjusting, or servicing elevator equipment. All safety
precautions must be followed to ensure the safety of elevator personnel and the general
public.
Use only the correct rated fusing for controller protection. Use of improperly rated
fusing will void the warranty.

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IMPORTANT NOTICE
Most of the field connections to GALaxy controls are made using stranded wire. When inserting this stranded
wire into the terminals –especially those for EPD’s (Electrical Protective Devices) – care must be taken to
ensure that all the strands are properly inserted into the terminals. Improper stripping and insertion may leave
strands outside of the terminals. Strands not properly inserted into the terminals may make contact with wires
from an adjacent terminal.
The danger associated with an occurrence as described above has led GAL Manufacturing to recommend that,
for all connections to the Electrical Protective Devices listed in ASME A17.1-2016/CSA B44-16, Requirements
2.26.2.1 through 2.26.2.39, elevator personnel must follow the guidelines listed below:
•Inspect all terminals used to connect Electrical Protective Devices. Ensure that the cage clamp is fully
open before inserting a wire into the terminal block.
•Perform corrective action for wires with stray strands by one of the following methods:
oReconnect the wire with all wire strands correctly installed into the terminal. Visually verify that
no wire strands are outside of the terminal. The conductor should be stripped and inserted
completely into the terminal in such a manner that no more than two millimeters of bare wire is
visible; or
oAttach a ferrule to the end of field wire for safety devices (as pictured below in Figures 0-1 and
0-2) and insert the ferrule into the terminal; or
oUse an acceptable method such as tinning.
•After removal and replacement of any of these field wires, the actual Electrical Protective Device
should be checked for proper operation.
Figure 0-1
Crimp Tool for Ferrule
Figure 0-2
Stranded Wire with Ferrule
Attached

GALaxy eHydro Elevator Controller Section 1 –Product Description
1-1
Section 1 - Product Description
The GALaxy traction elevator controller is a computer-based system that offers superior performance,
flexibility and reliability. It has been designed to save time in installation and troubleshooting, but it is still
very important that the field personnel familiarize themselves with this manual before attempting to
install the equipment.
1.1 Product Code Compliance
•CSA B44.1-14/ASME A17.5-2014
•ASME A17.1-2016/CSA B44-16
1.2 Specifications
Standard Features:
•Inspection Operation (car top and controller)
•Access Operation
•Independent Service
•Fire Service Phase I
•Fire Service Phase I Alternate Return
•Fire Service Phase II
•Emergency Power
•Earthquake Service
•On Board Diagnostics LEDs
•On Board LCD Interface
•Motor Protection Timers
•Door Motor Protection Timer
•Field Adjustable Parameters
•Elevator Duty Rated NEMA Motor
Environment:
•32° F to 110° F ambient
•12,000 feet altitude
•95% humidity
Optional Features:
•Selective Rear Doors
•Attendant Service
•Code Blue Hospital Service
•Security
•Remote Diagnostics
•Emergency Power

GALaxy eHydro Elevator Controller Section 1 –Product Description
1-2
1.3 Physical Layout of the Controller
Figure 1-0 shows the general layout of the GALaxy eHydro Controller cabinet. The components in the
cabinet include the following items.
1) Main I/O Board:
The 1121 main control board contains input and output
devices, controller switches, fuses and field wiring
terminal connections. This board also includes the, the
Safety PAL and the NTS Processor.
2) Main CPU:
The 1132 CPU board is a dual core 32-bit CPU. It
executes the main control system programs. The main
core runs the car operation and the secondary core runs
the group operation. The LCD Interface mounted on the
Main CPU provides a user interface to all controller
adjustment and setup parameters. It also shows
diagnostic information.
3) PI Driver Board:
Driver for CE or E-Motive Position Indicator Displays.
4) Car I/O Panel:
Provides space for additional car I/O.
5) Terminal Block and Options:
Space for additional terminal blocks, optional contactors
and circuit breakers.
6) Power Supplies:
A 5 VDC power supply for the controller 5 Volt power and
a 24 VDC supply for all call button and lantern power.
7) Soft Starter:
Controls the soft start and running of the pump motor.
8) Power Distribution Board:
Contains fuses and distributes 120 VAC and 24 VDC for
the system.
9) Transformer:
Transforms the line voltage to the proper voltages for
signals and other controller functions.