schmersal bp408 User manual

Installation Manual
"bp408" System
General Instructions
Safety Instructions
Commissioning
EC-Type Examination
www.boehnkepartner.de

BÖHNKE + PARTNER GmbH
Steuerungssysteme
Bergisch Gladbach 2016
2nd Intermediate Version of 1st Edition
for 2015
Installation Manual for "bp408" System,
March 2016
Author: Development Division
Proofreading: Development
Division Formatting: Development
Division
Formatted using OpenOffice 4.1.1
This installation manual and all its parts are protected by copyright.
All rights reserved, particularly the right of translation, discourse, reproduction, duplication
by photomechanical or other ways as well as storage using electronic media.
This manual is not considered exhaustive as regards our full supply capabilities.
Regardless of the care taken during the creation of texts, images and programs, we cannot
assume legal liability for possible errors as well as their consequences.
The common names, trade names, goods designations, etc. quoted in this document might
be considered trademarks even without special designation and are therefore subject to the
corresponding legal provisions.
BÖHNKE + PARTNER, BlueModus®, WinMOS®300 and CANwizard® are registered
trademarks.
www.boehnkepartner.de

Table of Contents
1 General............................................................................................................................7
1.1 Thank You..................................................................................................................7
1.2 Intended Purpose......................................................................................................8
1.3 Documentation
References...........................................................................................................................8
2 Safety Instructions.....................................................................................................….9
2.1 Qualified Personnel............................................................................................... ....9
2.2 Safety Instructions regarding Controls ...................................................................9
2.3 Requirements regarding Constructors and Operators..........................................11
3 Product Certifications...................................................................................................13
3.1 EU Type Examination..............................................................................................13
3.2 EC Declaration of Conformity.................................................................................15
4 Standards.......................................................................................................................17
4.1 EMC-Guideline..........................................................................................................17
4.2 EN 81-20....................................................................................................................18
5 The "bp408" Control System.......................................................................................20
5.1 Product and Functional Descriptions....................................................................20
5.2 Overview of bp408 Functions.................................................................................21
5.3 Decentralized Elevator
Controls.............................................................................................................................23
5.4 The Group System..................................................................................................23
5.4.1 Priority Calls..........................................................................................................................24
5.4.2 Portrayal of Group in WinMOS®300 ...................................................................................24
5.5 bp408 Modules........................................................................................................26
5.6 bp408 Variants........................................................................................................27
5.7 Short Description of bp408....................................................................................27
5.7.1 Top view...............................................................................................................................27
5.7.2 bp408 Control Panel and LCD.............................................................................................29
5.7.2.1 Default View......................................................................................................................29
5.7.2.2 Elevator Status Bar...........................................................................................................29
5.7.2.3 Safety Loop Status Bar.....................................................................................................29
5.7.2.4 Control Panel....................................................................................................................30
5.7.3 Setup Menu.........................................................................................................................30
5.7.4 Service Menu.......................................................................................................................31
5.7.5 Call Menu.............................................................................................................................31
5.7.6 lnfo Menu.............................................................................................................................32
5.7.7 Terminal Mode.....................................................................................................................32
5.7.8 LPCmon Monitoring Program..............................................................................................32
5.7.8.1 Start of Monitoring Program..............................................................................................33
5.7.9 Storage for Program and Parameters.................................................................................33

5.7.9.1 General............................................................................................................................33
5.7.9.2 Replacement....................................................................................................................34
5.7.9.3 Software Update..............................................................................................................34
5.7.10 bp408 Control System in Control Cabinet with Inverter.....................................................36
5.7.11 Easy Servicing due to Clear Arrangement.........................................................................38
5.7.12 Standard Equipment...........................................................................................................38
5.7.13 Optional Equipment............................................................................................................40
5.7.13.1 Uninterruptible Power Supply (UPS).............................................................................40
6 Installation and Assembly...........................................................................................43
6.1 Operating and Storage Conditions........................................................................43
6.2 Preparations....................................................................................................... .....44
6.3 Assembly of bp408 System Module......................................................................45
6.4 Assembly of Control System.................................................................................45
6.5 Assembly of Car Terminal Box..............................................................................45
6.6 Assembly of Absolute Encoder.............................................................................46
6.6.1 Absolute Encoder Mounting Sets.........................................................................................46
6.6.2 Assembly inside Shaft...........................................................................................................47
6.6.3 Assembly on Car...................................................................................................................48
6.7 Assembly of Magnetic Switches............................................................................49
7 Electrical Connection...................................................................................................51
7.1 Preparations............................................................................................................51
7.2 Interference Suppression Measures and Instructions.........................................52
7.3 Connections for Cable Shielding...........................................................................56
7.4 Designations in Circuit Diagrams..........................................................................56
7.5 Safety Loop..............................................................................................................63
7.6 Connection Example of Cable Controls................................................................64
7.7 Connection Example of Hydraulic Control System..............................................65
7.8 Electrical Installation..............................................................................................66
7.9 Bus Connections.....................................................................................................66
7.9.1 Electrical Bus Medium..........................................................................................................66
7.9.2 Cable Colors.........................................................................................................................67
7.9.3 Network Topology.................................................................................................................67
7.9.4 Examples for a Correct Topology.........................................................................................68
7.9.4.1 Individual Control System..................................................................................................68
7.9.4.2 Groups of Two with One Cord...........................................................................................69
7.9.4.3 Groups of Two with Two Cords..........................................................................................70
7.9.4.4 Groups of Two with Three Cords.......................................................................................71
7.9.5 Pin Assignments...................................................................................................................72
7.9.5.1 Pin Assignment of 9-Pin D-Sub-Connector........................................................................72
7.9.5.2 Pin Assignment of RJ45-Socket.........................................................................................72
7.9.5.3 Pin-Assignment of Open Style Connector..........................................................................73
7.9.6 Node Numbers of CAN Components....................................................................................73
7.9.6.1 Node Numbers of CAN Components..................................................................................73
7.10 Flat Line to Car Terminal Box..................................................................................74
7.10.1 Actuation of Inverter...............................................................................................................74

7.10.2 Actuation via CAN-Bus..........................................................................................................74
7.10.3 DCP Connection to Inverter .................................................................................................74
7.10.3.1 Pin Assignment of DCP Connector...................................................................................75
7.10.4 Parallel Wiring with RVM-01..................................................................................................75
7.11 Connection of Absolute Encoder............................................................................77
7.12 Group Connection....................................................................................................77
7.13 Data Lines for Remote Diagnostics........................................................................78
7.13.1 Analog Telephone Line..........................................................................................................78
7.13.2 Ethernet..................................................................................................................................78
7.13.3 LON........................................................................................................................................78
7.14 Connection of Emergency Call System..................................................................79
8 Commissioning.............................................................................................................81
8.1 Preparations.............................................................................................................82
8.2 Voltage Testing Module STM·02.............................................................................82
8.2.1 Prior to First Activation ..........................................................................................................82
8.2.2 Functional Description of STM-02.........................................................................................83
8.3 Technical Instructions for Control System............................................................83
8.4 Checklist prior to Activation of Control System....................................................91
8.5 Connection of Mains Voltage..................................................................................92
8.6 Examination of Control System and Drive Unit Parameters.................................93
8.6.1 Examination of Bus Lines.......................................................................................................93
8.6.2 Examination of CAN Parameters...........................................................................................94
8.6.3 Examination of DCP Connection............................................................................................95
8.7 First Movement with Releveling Controls...............................................................95
8.8 First Movement with Inspection..............................................................................96
8.9 Controlled Movement Sequence at Two Speeds (Overview)................................99
8.9.1 Shut-Off Points at High Speeds............................................................................................100
8.10 Direct Movement Sequence with DCP (Overview)...............................................101
8.11 Configuration of Floor Selector ..........................................................................101
8.11.1 Assembly of Delay Switches...............................................................................................102
8.11.2 Basic Settings.......................................................................................................................103
8.11.3 Calibration Movement with Absolute Encoder.....................................................................104
8.11.4 Travel Speeds.......................................................................................................................105
8.11.5 Deceleration by S81/S82 at the Terminal Stations during Normal Operation.....................107
8.12 First Movement in Normal Operation....................................................................109
8.13 Configuration of Emergency Call Device..............................................................111
8.14 Configuration of Group Connection......................................................................111
8.15 Configuration of Remote Diagnostics...................................................................111
8.16 Configuration of a Modem.....................................................................................112
8.17 Configuration of a Network Connection...............................................................112
8.18 Completion of Commissioning..............................................................................112
9 Troubleshooting.........................................................................................................115
9.1 Monitoring Routines.............................................................................................115
9.2 Fault Information...................................................................................................117
9.3 Fault Reporting......................................................................................................117

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9.4 Fault Stack............................................................................................................118
9.5 Fault List...............................................................................................................118
9.6 Messages............................................................................................................. .119
9.7 Repairs............................................................................................................. .....120
10 Maintenance................................................................................................................121
Annex..........................................................................................................................................122
A bp408 Menu Navigation ..............................................................................................122
B Quick Overview of Service Menu................................................................................124
C Quick Overview of Setup Menu...................................................................................143

7
1 General
1.1 Thank You
Dear Customer!
Thank you for showing your trust in Böhnke + Partner by purchasing the
"bp408". Please take your time to read carefully this Installation Manual
and the documentation pertaining to the individual components.
Improper handling can present a high risk of injury. Please observe all
the provided information and thereby save on time and the need for
questions during commissioning.
The term "manual" refers to the entire documentation that we use to inform
our customers about our company and its products in a comprehensive
manner. To provide a better overview, this manual has been divided into
multiple parts. The "Installation Manual" covers the dangers and risks that
may lead to severe injuries and economic damage in case of improper
behavior. It also provides the information required to commission the control
system.
The Installation Manual is supplied with every control system and is therefore
a component of the overall control system documentation.
Should you still have any questions, you can contact us via:
Böhnke + Partner GmbH
Steuerungssysteme
- Member of the Schmersal Group -
Heinz-Fröling-Straße 12
51429 Bergisch Gladbach
Germany
Tel.: [phone]
Fax: [phone]
Hotline: [phone]
www.bp408.de
www.boehnkepartner.de
[e-mail]

8
1.2 Intended Purpose
The "bp408" control system is a piece of equipment used for
elevator systems.
1.3 Documentation References
This manual is not considered exhaustive as regards our full supply
capabilities. All the supplied information merely serves the purpose of
product description and are not considered assured capabilities in a
legal sense. Any claims for damages against us, no matter for which
legal reason, are excluded, unless intent or gross negligence can be
asserted. No warranty is assumed that the specified circuits or
procedures are free of third party property rights. A reprint, even in part,
is only allowed with the express permission of Böhnke + Partner and
with an exact indication of sources.
The Böhnke + Partner logo and the company designation are
protected trademarks
The information in this manual is regularly checked. Required
corrections are contained in subsequent editions.
Hazard warnings and other pieces of special information are highlighted
in this technical manual in the following manner and provided with a
corresponding symbol.
C AUTION !
This indication is used, if an imprecise performance or non-
compliance with instructions or procedures can lead to the device
being damaged, injuries or even death being incurred.
W ARNING !
This indication is used, if an imprecise performance or non-
compliance with instructions or procedures can lead to injuries or
lethal accidents due to electric current.
N OTE !
This indication is used, if the attention is to be drawn to a special
feature or characteristic.
Installation Manual "bp408" System –General

9
2 Safety Instructions
Prior to installation and commissioning of this device, please read the
safety and warning instructions carefully and observe all the warning signs
fitted to the device. Make sure that the warning signs on the device are in
a legible condition and replace missing or damaged signs at once.
2.1 Qualified Personnel
In accordance with this documentation and/or the warning instructions on
the product itself, qualified personnel refers to such persons that are
entrusted with installation, assembly, commissioning, operation and
maintenance of the product and that possess the corresponding
qualifications, for example:
Training and instructions and/or permission to turn circuits and
devices on and off, as well as to ground and label them in
accordance with the applicable standards of safety engineering.
Training and instructions in accordance with the standards of safety
engineering regarding maintenance and use of proper safety
equipment.
First-aid training.
2.2 Safety Instructions regarding
Controls
C AUTION !
Excerpt from German "Data sheet on safety measures for the assembly
and maintenance of elevator systems" (ZH 1/312; Issue: 10/1983)
German Federation of Institutions for Statutory Accident Insurance and
Prevention:
3.1) Notification
If a technician is supposed to perform work on an elevator system
by himself, he must notify the custodian or other person (for
example caretaker, tenant) of his presence.
3.2) Locking of elevator systems
Prior to the beginning of the work on the elevator system, the facility's
normal operation must be suspended. Attach the following sign to every
shaft access door> "Elevator out of order". Block off open access doors
in such a manner that unauthorized persons are not allowed to access the
facility.
3.3) External controls
The external controls must be rendered ineffective prior to beginning
the work.

10
3.4) Auxiliary personnel
If a technician conducts working operations that require the presence
of a second person, the elevator's custodian or any other instructed
person can be enlisted for this purpose.
3.5) Short-circuiting of control lines and switches
When conducting maintenance operations and inspections, the short-
circuiting of control lines and switches is prohibited. If the need to
short-circuit control lines and switches cannot be avoided during
maintenance operations, they may be short-circuited with greatest
possible care. Any bypasses must be removed immediately after
completion of maintenance operations.
3.6) Switching agreements
Switching agreements based on time and direct calls are not
permissible.
3.7) Working on live components
If work has to be performed on live parts in special cases,
isolated tools and documents as well as suitable personal safety
equipment must be used. Observe the applicable regulations of
DIN EN 50110 Parts 1 and 2, I DIN VDE 0105 Part 100
"Operation of electrical installations".
3.8) Elevator operation
Until the working operations have been completed, the elevator
system may not be operated by the technician, unless this is required
for the performance of this work.
3.9) Presence of the car roof
When driving the car from a top the car roof, turn on the command
switch (inspection switch) on the car roof (if available). Only then the
shaft door can be closed. If this command switch is not available, a
suitable assistant (auxiliary personnel) must be used.
A command and/or switching impulse to move the elevator may only
be issued by persons atop the car roof, if all persons there have
stepped back into the bounds of the car. Working while the car is
moving is prohibited.
No more people than are required to perform the necessary work are
permitted atop the car roof.
Installation Manual "bp408" System –Safety Instructions

11
2.3 Requirements regarding Constructors and Operators
C AUTION !
The "bp408" control system has been developed in accordance with the
current state of engineering and is safe to operate. The only occasions
when hazards can arise are presented if personnel that was improperly
instructed (or not at all) uses the devices in an improper fashion or for an
unintended purpose.
The proper and safe operation of the devices requires proper
transportation and storage, installation and assembly as well as careful
operation and maintenance.
Any mode of operation that adversely affects the safety of the
devices has to be refrained from.
Arbitrary modifications and changes, which affect the safety of the
devices, are not allowed.
During operation, the drive units exhibit dangerous and live
moving or rotating parts. For this reason, they can cause severe
injuries or material damage, for example in case of
unauthorized removal of necessary covers or improper
maintenance.
Only qualified personnel may be tasked with working on the devices. The
personnel must keep the supplied operating instructions and all
documents pertaining to the product documentation available during
working operations at all times and always observe these. Unqualified
personnel may not work on the devices or in their vicinity.
The operator is responsible for ensuring that the drive unit is placed in a
safe condition after device failure, as otherwise personal injuries or
property damage may be incurred.
C AUTION !
Disconnect the devices from the power supply and check that no voltage
is present prior to any intervention.

12
3 Product Certifications
3.1 EU Type Examination
The bp408 system module contains an electronic retrieval unit for the safety
loop and a pilot control system for the driving contactors. The circuit board
also contains a safety circuit (SMZ). The safety circuit can be used in the
cases specified in the following and derived from EN 81-1/2 and EN 81-
20/50:
Preparatory measures with opened car and shaft doors
Approaches with opened car and shaft doors
Fine adjustment with opened car and shaft doors
Detection of an unintended car movement with open doors (UCM).

13
Figure 2
bp408 System Module
Section with SPL-01 circuit board
Requirements of
95/16/EC
EN81-20:2014
Directive
EN 81-50:2014
EN 81-1:1998+A3:2009
EN 81-2:1998+A3:2009
Reg. No. 01/208/5A/6020.00/15
of 2016-02-03

14
Installation Manual "bp408" System –Product Certifications

15
3.2 EC Declaration of
Conformity
Figure 3
Declaration of Conformity

16

17
4 Standards
REFERENCE TO OTHER REGULATIONS
AND RISKS
• The procedural instructions and circuit excerpts portrayed in the
documentation have to be interpreted correspondingly. Adaptability
to the respective application must be verified. Böhnke + Partner does
not guarantee suitability.
• To ensure proper functioning of the complete control system, the
supplied documentation pertaining to other manufacturers (for
example the instruction manual for the inverter) must be observed.
• The bp408 control system may only be used for information
processing in elevator control systems.
• Control systems, assemblies, modules or other devices that were
damaged in transit may not be installed or commissioned.
• The assemblies contain electrostatically sensitive components.
Discharge your own body prior to touching an electronic component.
This can be achieved by touching a conductive and grounded item
(for example a bare metal component of the switchgear cabinet)
immediately prior to being in contact with the electronic component.
4.1 EMC-Guideline
All industrial and electronically controlled machines (PCs,
microprocessors, computers, PLC) can be influenced by interference
pulses, if no countermeasures are taken. These interference pulses can
be generated by both external systems, such as voltage changes from
the feed line as well as control impulses of inverter power elements.
Böhnke + Partner considers all the usual measures during manufacturing
of the control systems. The used components exhibit a low sensitivity to
ambient interference pulses.
C AUTION !
• Observe the EMC instructions of the manufacturer of the inverter at
all times!
•If there are any questions regarding the EMC-Directive, our service
team will gladly be at your disposal.
•Also observe the instructions regarding interference suppression
measures contained in this manual.

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4.2 EN 81-20
Provisions of EN 81-20:
We hereby point out in a precautionary manner that Böhnke +
Partner shall not be held responsible or liable for damages that
are caused by compliance with the requirements of EN 81-20!
Example: Readjustment for hydraulically operated elevators, in spite
of tripped runtime monitoring due to failure of a phase
Installation Manual "bp408" System –Standard

19
5 The "bp408" Control System
5.1 Product and Functional Descriptions
The bp408 Control System is an electronic component used to control
elevator systems. Different variants are available, comprising safety
loop queries for different voltages as well as variants with/without
integrated safety circuits.
Basic functions of an elevator control system, such as safety loop
queries and safety circuits have been consistently integrated into the
bp408 control system.
The bp408 control system is a decentralized micro-processor
system with dispersed "intelligence". The decentralized modules are,
by default, connected through the CANopen Lift interfaces in
accordance with the CiA 417 standard (www.CANopen-Lift.org). Other
interfaces for older protocols used in elevator construction are also
available.
The bp408 control system contains the following modules:
the pilot control system,
the safety loop query system,
the safety circuit (also optional),
freely programmable inputs, outputs and relays,
electronically monitored standard inputs and outputs,
as well as interfaces for:
controlling inverters with DCP3, DCP4+ and CANopen Lift (CiA
417) interfaces,
absolute encoders of various manufacturers and using different
technologies,
remote data diagnostics using WinMOS@300 via BluetoothTM or
WiFi, Modem (USB) or Ethernet,
building automation via EIS protocol, LONworks standard, Modbus,
OPC or Profibus DP.
CANopen Lift components,
LAN for remote diagnostics and monitoring
USB device for connecting a laptop for diagnostics purposes and
software updates,
USB host for USB sticks, modems, BluetoothTM or WiFi adapter
Based on this concentration of functions and the decentralized control
concept, small control cabinets can be used. The standard control
cabinet for the bp408 control system has a size of 600 x 600 x 300
mm. This means that the bp408 system is predestined for use in
elevator systems where there is only little space.
Installation Manual "bp408" System –The "bp408" Control System

20
In combination with the remote data monitoring system WinMOS®300
(www.WinMOS.de), it is possible to significantly increase the elevator's
availability. This system also makes it possible to fully switch to a
condition-based maintenance application.
5.2 Overview of bp408 Functions
Individual controls
Group controls for up to 8 elevators without separate group controller
128 floors/stops configurable
SFS –automatic control system
SFR –automatic control system with call memory ("taxi controls")
1KS –collective single button controls
1KSab –collective single button for downward
movement
1KSauf –collective single button for upward
movement
2KS –collective dual button controls
Collection of operating data: movements, hours, faults, messages
Traction elevators: pole-changeable, single-speed, dual-speed,
frequency inverter
Hydraulic elevator: Star delta and direct startup, valve controls, soft
startup, frequency inverter
Resistor monitoring for drive motor integrated
Safety circuit monitoring integrated (230 VAC standard, 48/110
V AC optional
Main contactor controls 230 VAC integrated
Safety circuit (SMZ) integrated
Inputs and outputs for all standard requirements integrated
Positive switching logic (24 VDC)
Outputs protected against overload
Diagnosis of inputs and outputs via LCD or laptop
Diagnosis and configuration of CANopen Lift components using
CANwizard®
Operator guidance using laptop with WinMOS®300
Operator guidance with 7 buttons and illuminated, graphic LCD
On-site parameterization via LCD using mobile phone over
BluetoothTM and/or WiFi/laptop
Parameters saved in EEPROM in failsafe manner (2 complete
sets of data)
Real-time clock
integrated
Setup menu and service menu separated
Code lock separately adjustable
Menu interface in German, English, Dutch and Swedish