ALP Manual

(Automatic Landing device for Power failure)

www.sigmaelevator.com
1. UNDERSTANDING OF SYSTEM......................................................................................................... 5

1.1 OVERVIEW ................................................................................................................................................5

1) TERMINOLOGY OF DI ALP ...............................................................................................................5
2) ALP SYSTEM? ...................................................................................................................................5
1.2 SYSTEM CONFIGURATION......................................................................................................................6
1.3 CONFIGURATIONS AND FUNCTIONS OF THE ALP CONTROLLER .....................................................7
1) CONFIGURATIONS AND THE ALP CONTROLLER .........................................................................7
2) MAIN FUNCTIONS OF THE ALP CONTROLLER..............................................................................7
1.4 MAIN SPECIFICATIONS AND FUNCTIONS .............................................................................................8
1) MAIN SPECIFICATIONS ....................................................................................................................8
2) MAIN FUNCTIONS.............................................................................................................................8
1.5 FUNCTIONS OF CONTACTORS AND RELAYS .......................................................................................9
1) OPERATIONS OF MODES ................................................................................................................9
2) EXPLANATION OF FUNCTIONS.......................................................................................................9

2. FUNCTIONS AND FEATURES OF PCB............................................................................................ 10

2.1 CLASSIFICATION OF THE PCB..............................................................................................................10

2.2 DAC-100 PCB...........................................................................................................................................11
1) OUTLINE DRAWING OF THE DAC-100 PCB..................................................................................11
2) EXPLANATION OF DAC-100 PCB FUNCTIONS.............................................................................12
3) LED DISPLAY FUNCTIONS OF THE DAC-100 PCB.......................................................................13
4) DEFINITIONS OF DAC-100 PCB CONNECTOR SIGNALS ............................................................13
2.3 DAR-100 PCB...........................................................................................................................................18
1) OUTLINE DRAWING OF THE DAR-100 PCB..................................................................................18
2) EXPLANATIONS OF THE PCB FUNCTIONS ..................................................................................19
3) LED DISPLAY FUNCTIONS OF THE DAR-100 PCB.......................................................................20
4) DEFINITION OF DAR-100 PCB CONNECTOR SIGNALS...............................................................20
2.4 DAP-100 PCB...........................................................................................................................................23
1) OUTLINE DRAWING OF THE DAP-100 PCB ..................................................................................23
2) EXPLANATION OF PCB FUNCTIONS.............................................................................................24
3) LED DISPLAY FUNCTIONS OF THE DAP-100 PCB.......................................................................24
4) DEFINITION OF DAP-100 PCB CONNECTOR SIGNALS ...............................................................25

3. EXPLANATION OF SYSTEM OPERATIONS .................................................................................... 27

3.1 THE ALP OPERATION CONTROL PART................................................................................................27

3.2 THE POWER CIRCUIT PART..................................................................................................................29
3.3 THE UPS CONTROL PART .....................................................................................................................29
3.4 THE CHARGE CONTROL PART .............................................................................................................30

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4. ANNOUNCIATOR .............................................................................................................................. 32

4.1 OVERVIEW ..............................................................................................................................................32

4.2 FUNCTIONS.............................................................................................................................................32
4.3 CONFIGURATION....................................................................................................................................32
4.4 KEY INPUT ALLOCATION TABLE FOR OPERATION MODES ..............................................................32
4.5 NORMAL MODE.......................................................................................................................................34
1) INITIAL SCREEN OF NORMAL MODE............................................................................................34
2) DESCRIPTIONS OF NORMAL MODE INITIAL DISPLAY................................................................34
4.6 CHARGE MODE.......................................................................................................................................34
1) INITIAL DISPLAY OF CHARGE MODE ...........................................................................................34
2) DESCRIPTIONS OF CHARGE MODE INITIAL DISPLAY................................................................34
4.7 UPS MODE...............................................................................................................................................35
4.8 RECHARGE MODE..................................................................................................................................35
4.9 ANNOUNCIATOR OPERATION...............................................................................................................35
1) ANNOUNCIATOR CHARGE OPERATION ......................................................................................35
2) COMPLETION OF ANNOUNCIATOR CHARGING..........................................................................35
3) COMPLETION OF ANNOUNCIATOR UPS......................................................................................35
4.10 MEMORY-RELATED MODE..................................................................................................................36
1) DATA READ MODE..........................................................................................................................36
2) DATA WRITE MODE ........................................................................................................................36
4.11 ERROR-RELATED MODE .....................................................................................................................37
1) TCD DISPLAY MODE.......................................................................................................................37

5. TEST OPERATION ............................................................................................................................ 39

5.1 PREPARATION OF TEST OPERATION..................................................................................................39

1) DETAILS OF TEST OPERATION.....................................................................................................39
2) TOOLS AND MEASURING EQUIPMENT ........................................................................................40
5.3 CHECKING...............................................................................................................................................40
1) ELEVATOR.......................................................................................................................................40
2) CONTROL PANEL............................................................................................................................40
3) BATTERY .........................................................................................................................................40
4) WIRING CONNECTION BETWEEN E/L CONTROL PANEL AND ALP CONROL PANEL..............42
5) CONNECTION CHECK OF PRIMARY TERMINAL OF
TRANSFORMERS 1 AND 2 IN ALP CONTROL PANEL.................................43
5.4 ELECTRIC CIRCUIT CHECK ...................................................................................................................43
1) SAFETY WHILE WORKING .............................................................................................................43
2) PREPARATION FOR MEASURING INSULATION RESISTANCE...................................................43
3) MEASURING OF INSULATION RESISTANCE................................................................................44

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 4) RATING OF FUSES .........................................................................................................................44
5) CIRCUIT CHECK..............................................................................................................................44
5.5 VOLTAGE CHECK ...................................................................................................................................45
1) PREPARATION FOR POWER APPLICATION ................................................................................45
2) INPUT VOLTAGE CHECK OF ALP CONTROL PANEL...................................................................45
3) VOLTAGE CHECK AFTER MCCB APPLICATION IN CONTROL PANEL.......................................46
4) C9A CONTACTOR CHECK..............................................................................................................47
5) LED CHECK ON THE PCB ..............................................................................................................48
5.6 ADJUSTMENT..........................................................................................................................................49
1) ADJUSTMENT FOR BATTERY VOLTAGE DETECTION ................................................................49
2) FAILURE DETECTION SETTINGS ..................................................................................................49
5.7 TEST OPERATION ..................................................................................................................................50
1) TEST OPERATION PROCEDURE...................................................................................................50
2) TEST CHARGE OPERATION ..........................................................................................................51
3) RESCUE OPERATION WHEN STOPPING WITHIN DOOR OPENING ZONE ...............................52
4) RESCUE OPERATION WHEN STOPPING WITHOUT DOOR OPENING ZONE ...........................53
5.8 CHECKLIST FOR THE RESCUE OPERATION.......................................................................................54
1) CHECKLIST FOR CONTROL FUNCTIONS
(E/L OPERATION SWITCHES TO RESCUE OPERATION MODE)...........................54
2) CHECKLIST FOR OPERATION FUNCTIONS .................................................................................55
5.9 ACTIONS TO TAKE AFTER COMPLETING TEST OPERATION............................................................56

6. REGULAR INSPECTION ................................................................................................................... 56

7. ALP OPERATION TCD DESCRIPTION............................................................................................. 57

7.1 TCD DESIGN GUIDELINES .....................................................................................................................57

7.2 BIT DEFINITIONS OF TROUBLE_SUM FLAG ........................................................................................57

8. TCD LIST( TROUBLE SHOOTING ).................................................................................................. 58

9. ALP DIAGRAMS ................................................................................................................................ 88

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1. UNDERSTANDING OF SYSTEM

1.1 OVERVIEW

1) TERMINOLOGY OF DI ALP
• DI: Distributed and Inverter Control Elevator
• ALP: Automatic Landing Device during Power-failure

2) ALP SYSTEM?
The ALP or ARD (Automatic Rescue Device) is a system to rescue passengers trapped in the
car when the electric power failed during the normal operation of an elevator. The ALP system
is largely classified as three different forms. Figure 1 shows the external ALP as a conventional
mode in which the ALP performs a rescue operation by supplying the control power to the E/L
control panel for the operation of main motor, doors and brake.

Figure 1. External type ALP (Conventional mode) Figure 2. Internal type ALP

Figure 2 shows the internal type ALP in which the power supplying devices that the rescue
operation requires are equipped inside the control panel of the elevator, and its control circuit
performs all the necessary functions for the rescue operation. (The battery is installed outside.)
For the elevators of speed of 150(m/min) or higher, the ALP control panel is installed
separately, but its function is so limited that it can only have the power supplying system.

Figure 3 shows the UPS ALP that is more advanced than the internal ALP. The UPS ALP is
equipped with the UPS (Uninterruptible Power Supply) outside, and it has been applied to the
DI elevators (The DI ALP is abbreviated to ALP in the followings.). It is featured that the
interface to the elevator control panel is simple and the separate charge system is not necessary.

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 Figure 3. UPS ALP

1.2 SYSTEM CONFIGURATION

Figure 4. Configuration of the ALP control system

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 1.3 CONFIGURATIONS AND FUNCTIONS OF THE ALP CONTROLLER

1) CONFIGURATIONS AND THE ALP CONTROLLER

ALP functions

E/L control ALP

panel (DI E/L) control panel

DOC-200 DOR-200 DPC-100 DAC-100

Operation Speed DSP

control control (32bit)

Serial

ALP operation control program

communication
UPS voltage control program
E/L speed control program

program for the charging

(RS-422)

Voltage/Current control
E/L operation control

Parallel
ALP operation speed
control program

communication
ALP operation

control program
program

2) MAIN FUNCTIONS OF THE ALP CONTROLLER

PROCESSOR PROCESSING OPERATING

MAIN FUNCTIONS
NAMES SPEED FREQUENCY
E/L operation control, Position control,
E/L i960 32 bit 20 MHz
ALP operation control
MOTOR control, Speed control, ALP speed
E/L DSP 32 bit 33 MHz
control
UPS control, Charge control, ALP operation
ALP DSP 32 bit 33 MHz
control
ALP ASIC 8 bit 5 MHz Serial communication with E/L control panel

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1.4 MAIN SPECIFICATIONS AND FUNCTIONS

1) MAIN SPECIFICATIONS

ITEMS SPECIFICATIONS REMARKS

E/L to apply DI 60 ~ 150 m/min
Number of operating systems One for E/L control panel
Maximum loading capacity 1600kg (for 24 persons)
Maximum distance of operation 40 m Without recharging
Speed of operation 10 m/min
Frequency of operation Twice Without recharging

2) MAIN FUNCTIONS
• ELEVATOR CONTROL PANEL

CATEGORIES FUNCTIONS
Rescue operation possible when safety devices are normal
Rescue operation not possible in the on-cage operation
Open doors after stopping automatically at the door opening zone in case
Operating of the power failure
functions Open only doors in case of the power failure at the door opening zone
Return automatically to the normal operation mode when the power is
restored normally
Only use for power failure
Not serving for cage-call
Clear cage-call
Not serving for hall-call
Controlling
Clear hall-call
functions
Turn off up and down lanterns
Turn on the cage direction indicator
Delete load compensation function

• ALP CONTROL PANEL (Not possible: r, Possible: ■)

Battery
Modes of Initial Power Charge Rescue E/L, ALP
under
operation power-on failure operation operation MCCB off
voltage
Rest
operation g r r r r r
Charge
operation r g r g r r
Rescue
operation r g g g g r

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1.5 FUNCTIONS OF CONTACTORS AND RELAYS

1) OPERATIONS OF MODES

ALP XC9A XC9B XC9D XR9CHR XR9B XR3AH XR9S

Rest operation O O O

Charge operation O O O O O O

Rescue operation O O O O ⊙

⊙ The setting in case that the power is restored during the rescue operation

2) EXPLANATION OF FUNCTIONS

CATEGORIES ABBREVIATIONS FUNCTIONS Use voltage

To block against turning the power on

XC9A AC 100 V
during the rescue operation
Contactors
XC9B To connect to the battery source DC 48 V

XC9D To limit the rush current DC 48 V

XR9B To check the safety circuit DC 24 V

XR9CHR To check the charge operation DC 24 V

Relays
To block against turning the power on
XR3AH DC 24 V
during the rescue operation

XR9S To detect the power failures AC 100 V

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2. FUNCTIONS AND FEATURES OF PCB

2.1 CLASSIFICATION OF THE PCB

① Classification by the name

A B C D E F

Model Location Function Speed Classification Operation

By the operation
If classification by the
operation is necessary
within the same PCB
group, the markings of
0 to 9 are used.

By the PCB

In case that the PCB of

the same function has a
By the PCB speed different form.
1: 60-150 m/min
2: 180-240 m/min
If the PCB is not related to
the speed, the type-names
developed and applied earlier
are used.

By the PCB function

C: Control
By the PCB location P: Power
R: I/O control
P: Power electronics
By the operation
O: Operation
If classification by the A: ALP
operation is necessary
within the same PCB
group, the markings of
0 to 9 are used.

② STANDARDS OF PCB APPLICATIONS

APPLICATIONS 60 ~ 150 m/min 180 ~ 240 m/min

ALP MAIN CPU PCB DAC-100 ·
ALP I/O DRIVE PCB DAR-100 ·
ALP IGBT DRIVE PCB DAP-100 ·
ANNOUNCIATOR PCB DOA-100 ·
IGBT CONNECTOR PCB DAP-200 ·

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2.2 DAC-100 PCB
1) OUTLINE DRAWING OF THE DAC-100 PCB

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2) EXPLANATION OF DAC-100 PCB FUNCTIONS

No.

1 APA connector (26P) The signal output connector to the D/A converter for monitoring

2 APB connector (4P) The power source connector receiving P15, N15, P5, and GND
from the DAR-100 PCB

3 APC connector (6P) The serial signal I/O connector to communicate with DI-E/L

4 APA connector (18P) The connector receiving the current and voltage from H.CT and
PT

5 APE connector (16P) The signal I/O connector to take the data out of the DAA-100 PCB

6 APF connector (14P) The signal I/O connector

output : PWM signal and P4.5V
input : Battery Voltage and fault signal

7 APG connector (26P) The signal I/O connector

output : relay driving signal
input : relay contact signal

8 APH connector (8P) The signal I/O connector for communication with P.C.

9 CPU The main processor to control the charging device and the UPS.
(TMS320C31PQL)

10 ASIC(CF5900PCM) The ASIC containing the PWM generator, the PWM protector, the
speed detector, the 16 bit timer, and the I/O decoder

11 Detection circuit of The circuit to detect the magnitude and phase of the 3-phase input
input voltage voltage

12 Detection circuit of The circuit to detect the magnitude of the 3-phase input current
input current

13 A/D converting circuit The circuit to convert analog signals into digital signals

14 LCD interface circuit The ancillary circuit to input and output signals to the
announciator

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3) LED DISPLAY FUNCTIONS OF THE DAC-100 PCB

LED NAMES PURPOSES COLORS LED STATUS

LED 1 UPS LIVE SIGNAL GREEN NORMAL: TOGGLE(ON-OFF)

ERROR: OFF

LED 2 DETECTION OF BATTERY GREEN NORMAL: OFF

OVER-CURRENT (OC) ERROR: ON

LED 3 DETECTION OF BATTERY GREEN NORMAL: OFF

OVER-VOLTAGE (OV) ERROR: ON

LED 4 ABNORMAL INPUT PHASE GREEN NORMAL: OFF

(PHA) ERROR: ON

LED 5 CHARGE LIVE SIGNAL GREEN NORMAL: TOGGLE(ON-OFF)

ERROR: OFF

LED 6 FAILURE OF CONTROLLER RED NORMAL: OFF

(ALARM) ERROR: ON

* While the ALP control panel stands by, LED1 and LED5 are flickering simultaneously.

4) DEFINITIONS OF DAC-100 PCB CONNECTOR SIGNALS

○ APA connector: The connector for output the data to the D/A card

PIN No. SIGNALS FUNCTIONS PIN No. SIGNALS FUNCTIONS

1 ADA0 ADDRESS #0 14 ADD5 DATA #5

2 ADA1 ADDRESS #1 15 ADD6 DATA #6

3 ADA2 ADDRESS #2 16 ADD7 DATA #7

4 ADA3 ADDRESS #3 17 AD_RD READ SIGNAL

5 ADA4 ADDRESS #4 18 GND

6 ADA5 ADDRESS #5 19 AD_WR WRITE SIGNAL

7 ADA6 ADDRESS #6 20 AD_DA CHIP SELECT SIGNAL

8 ADA7 ADDRESS #7 21 GND Ground

9 ADD0 DATA #0 22 GND Ground

10 ADD1 DATA #1 23 P5 +5V

11 ADD2 DATA #2 24 N15 -15V

12 ADD3 DATA #3 25 GND Ground

13 ADD4 DATA #4 26 P15 +15V

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○ APB connector: A power input connector for DAC-100 PCB

PIN No. SIGNALS DIRECTIONS FUNCTIONS

1 P15 DAR DAC +15V

2 P5 DAR DAC +5V

3 N15 DAR DAC -15V

4 GND DAR DAC Ground

○ APC connector: This is for serial communication with DI E/L

PIN No. SIGNALS DIRECTIONS FUNCTIONS

1 RX+ APC (MK/1) +RECEIVE

2 RX- APC (MK/2) -RECEIVE

3 GND

4 TX+ APC (MK/4) +TRANSEIVE

5 TX- APC (MK/5) -TRANSEIVE

6 GND

○ APD connector: To be connected to H.CT

PIN No. SIGNALS FUNCTIONS PIN No. SIGNALS FUNCTIONS

1 P15 +15V 10 CTCHK Connector check

2 N15 -15V 11 P15 +15V

3 IAS R-phase current input 12 N15 -15V

4 GND Ground 13 IBAT Battery current input

5 P15 +15V 14 GND Ground

6 N15 -15V 15 VCS C-phase voltage

7 IBS S-phase current input 16 VBS B-phase voltage

8 GND Ground 17 VAS A-phase voltage

9 GND Ground 18

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○ APE connector: To be connected to the announciator.

PIN No. SIGNALS FUNCTIONS PIN No. SIGNALS FUNCTIONS

1 LD0 Data #0 9 SCAN_KEY KED-PAD output

signal

2 LD1 Data #1 10 RS RESET output signal

3 LD2 Data #2 11 574_CLK CLOCK output signal

4 LD3 Data #3 12 LCD_E LCD Chip selector signal

5 LD4 Data #4 13 P5 +5V

6 LD5 Data #5 14 P5 +5V

7 LD6 Data #6 15 GND Ground

8 LD7 Data #7 16 GND Ground

○ APF connector: To be connected to the DAP-100 PCB.

PIN No. SIGNALS FUNCTIONS PIN No. SIGNALS FUNCTIONS

1 U+ U+phase PWM 8 SCN U-,V-,W- phase fault

signal signals

2 SCA U+phase fault signal 9 W+ W+phase PWM

signal

3 U- U-phase PWM signal 10 BATTV Battery voltage

4 SCB V+phase fault signal 11 W- W- phase PWM signal

5 V+ V+phase PWM 12 GND Ground

signal

6 SCC W+phase fault signal 13 P4.5 +5V

7 V- V-phase PWM signal 14 GND Ground

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○ APG connector: To be connected to the DAR-100 PCB.

PIN No. SIGNALS FUNCTIONS

1 XR9CHR The relay to check the charging device operation

2 ZR9B The command of the ALP safety relay

3 XR9S The relay to check the normal power source

4 ZR3AH The relay to check the UPS operation

5 XR9B The ALP safety relay

6 ALP_LIVE The ALP LIVE signal output

7 XC9B The contactor for the battery

8 ZR9CHR The relay command to check the battery charging

9 XC9A The contactor for E/L main power input

10 ZC9B The contactor command for the battery

11 XC9X The contactor for the UPS

12 ZC9X The contactor command for the UPS operation

13 XC9D The contactor to limit the initial rush current

14 ZC9D The contactor command to limit the initial rush current

15 XR3AH The relay to check the UPS operation

16 ZFAN The operation command for the radiation-plate fan

17 RY_OUT I48A Chip select

18

19 SEQ_CON

20

21

22

23

24

25 GND Ground

26 GND Ground

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○ APH connector: To be connected to the PC

PIN No. SIGNALS FUNCTIONS PIN No. SIGNALS FUNCTIONS

1 DR0 Data input 5 DX0 Data output

2 CLKRX0 Clock input signal 6 GND Ground

3 FSRX0 Synchronous input signal 7 GND Ground

4 LAT-CLK Data latch input signal 8 P5 +5V

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2.3 DAR-100 PCB
1) OUTLINE DRAWING OF THE DAR-100 PCB

- 18 -
2) EXPLANATIONS OF THE PCB FUNCTIONS

No.

1 APK connector (26P) The signal I/O connector connected to DAC-100PCB

2 APR connector (20P) The connector for contactor-drive and contact signal I/O

3 APP connectors (6P) The power supply connector linked to the battery
The connector for the power supplied to DAP-100 PCB

4 APM connector (4P) The connector receiving output voltage from input transformer
(TR2)

5 APS connector (8P) The connector for power supplied to DAC-100 PCB

6 Fuse 1 The fuse for power received from the battery

7 Fuse 3 The fuse for 100V power received from the input transformer
(TR2)

8 Fuse 2 The fuse for 45V power received from the input transformer
(TR2)

9 Power circuit of P5, The circuit to generate 5V, 15V, and –15V from the input direct
P15 and N15 voltage (DC60V)
5V, 15V, -15V: Power for the DRC-100 PCB circuit

10 Power circuit of P24 The circuit to generate 24V, and 12V from DC 60V
and P12 24V: Power for the relay drive
12V: Power for the FET driving signal

11 Power supply circuit When power fails: DC 60V of the battery is supplied to the power
When operation is normal: DC 60V of the power supply is
supplied by rectification of AC45V
When power is loaded: The initial rush current is limited by NTC

12 Contactor drive circuit The circuit to drive the contactors (97SB, 97SBX, 97SD, FAN)
FET: 97SB, 97SBX, 97SD
SSR: Drive the FAN

13 Relay drive circuit The circuit to drive the relays (97B, 35AH, 97CHR) by relay
driving signals from the DAC-100 PCB

14 Surge arrester circuit The circuit to absorb the surge voltage when switching on and off
for the contactor the contactor(97SA), the relay(97SC, 97S), and FAN

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3) LED DISPLAY FUNCTIONS OF THE DAR-100 PCB

NAMES PURPOSES COLORS STATUS

LED1 5V power check Green Normal: ON
Error: OFF
LED2 15V power check Green Normal: ON
Error: OFF
LED3 -15V power check Green Normal: ON
Error: OFF
LED4 24V power check Green Normal: ON
Error: OFF
LED5 Power failure check (97S) Red Normal: ON
Power failure: OFF
LED6 Charger operation check (97CHR) Red Operation: ON
Normal: OFF
LED7 ALP failure display (97B) Red Normal: ON
Error: OFF

4) DEFINITION OF DAR-100 PCB CONNECTOR SIGNALS

○ APK connector: To be connected to the DAC-100 PCB

CONNEC- OPERATING
PIN SIGNALS DIRECTIONS REMARKS
TORS CONDITIONS
1 XR9CHR DAR DAC High Relay signals of charger
operation
2 ZR9B DAC DAR High Driving signal of ALP
safety relay
3 XR9S DAR DAC High Relay for detection signal
of power failure
4 ZR3AH DAC DAR High Driving signal for the relay
to block the 97SA
5 XR9B DAR DAC High Detecting signal of the ALP
safety relay
6 ALP-LIVE
7 XC9B DAR DAC High Detection signal of the
contactor operation to the
A battery
P 8 ZR9CHR DAC DAR High Relay-driving signal of the
K charging device operation
9 XC9A DAR DAC High Detection signal of the main
contactor operation of the E/L
10 ZC9B DAC DAR High Driving signal of the
contactor to the battery
11 XC9X DAR DAC High Detection signal of operation
for the charging device and
the contactor
12 ZC9X DAC DAR High Contactor-driving signal of
the charger operation
13 XC9D DAR DAC High Contactor detection signal for
limiting the rush current
14 ZC9D DAC DAR High Contactor driving signal for
limiting the rush current

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CONNEC- OPERATING
PIN SIGNALS DIRECTIONS REMARKS
TORS CONDITIONS
15 XR3AH DAR DAC High Detection signal for the relay
to block the 97SA
16 ZFAN DAC DAR High FAN operation signal
17 RY_OUT DAC DAR High I48A Chip select
A 18 NC
P 19 SEQ-CON DAR DAC Low Connection status check of
the connector
K
20 NC
~
24
25 GND
26 GND
NC means NO CONNECTION.

○ APR connector: To be connected to the contactor

CONNEC- OPERATING REMARKS (Contact spec.

PIN SIGNALS DIRECTIONS
TORS CONDITIONS other party of connector)
1 NC
2 97SB_a 97SB DAR High Aux. contact (a type contact)
(MCA/2)
3 97SA_a 97SA DAR High Aux. contact (a type contact)
(MCA/3)
4 97SBX_a 97SBX DAR High Aux. contact (a type contact)
(MCA/4)
5 97SD_a 97SD DAR High Aux. contact (a type contact)
(MCA/5)
6 ALP_LIVE DAR E/L High High: ALP normal (MK/1)
7 ALP_LIVE DAR E/L High Low: ALP failure (MK/2)
8 NC
9 P24 (MCA/8)
A 10 FR_FFB FFB DAR High Operating contact (a type
contact) (MK/7)
P
R 11 97SBX_b 97SBX DAR High Aux. contact (b type contact)
(MCA/11)
12 97SD_a 97SD DAR High Aux. contact (a type contact)
(MCA/12)
13 97CHR_a 97CHR High Aux. contact (a type contact)
DAR (MCA/13)
14 97SA_c 97SA DAR High Contactor coil (MCA/14)
15 97SA_b 97SA DAR High Aux. contact (b type contact)
(MCA/15)
16 FAN_U FAN DAR High FAN power (U phase)
17 97SB_c 97SB DAR High Contactor coil (MCA/17)
18 97SBX_c 97SBX DAR High Contactor coil (MCA/18)
19 97SD_c 97SD DAR High Contactor coil (MCA/19)
20 97SB_b 97SB DAR High Aux. contact (b type contact)
(MCA/20)

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 ○ APP connector: To be connected to the DAP-100 PCB and battery

CONNEC- OPERATING
PIN SIGNALS DIRECTIONS REMARKS
TORS CONDITIONS
1 Batt_48V Batt DAR DC48V Input of battery 48V
2 DRV_DCN DAR DAP DCN Supply DCN to the DAP
PCB
A 3 DRV_60V DAR DAP DC60V Supply DC 60V to the DAP
P PCB
P 4 Batt_60V Batt DAR DC60V Input of battery 60V
5 Batt_60V DAR DAP DC60V Supply battery 60V to the
DAP PCB
6 DRV_DCN Batt DAR DCN Input of DCN

○ APM connector: To be connected to the transformer for detecting power failure

CONNEC- OPERATING
PIN SIGNALS DIRECTIONS REMARKS
TORS CONDITIONS
1 AC110_U TR2 DAR AC110V 97SA drive and power-failure
detection

A 2 AC51_U TR2 DAR AC51V For driving the power

supplying system
P
3 AC110_V TR2 DAR AC110V 97SA drive and power-failure
M detection
4 AC51_V TR2 DAR AC51V For driving the power
supplying system

CONNEC- OPERATING
PIN SIGNALS DIRECTIONS REMARKS
TORS CONDITIONS

1 GND DAR EARTH GND

2 GND GND

3 GND GND
A
4 GND DAR DAC GND
P
5 P24 DAR (MCA/8) 24V
S
6 N15 DAR DAC -15V

7 P15 DAR DAC 15V

8 P5 DAR DAC 5V

- 22 -
2.4 DAP-100 PCB
1) OUTLINE DRAWING OF THE DAP-100 PCB

- 23 -
2) EXPLANATION OF PCB FUNCTIONS

No.

1 ADA connector (20P) The signal I/O connector linked to the DAP-200 PCB

2 APF connector (14P) The signal I/O connector linked to the DAC-100 PCB

3 ADB connector (8P) The connector for the power supplied by DAR-100 PCB

4 P15 power circuit The circuit to generate the phases of (U,V,W,U-,V-,W-) IPM
power 15V from the DAR-100 PCB and AD210AN power
15V to detect the battery power

5 IPM drive circuit The circuit to drive IPM through the photo coupler by using
the PWM signals supplied by the DAC-100 PCB.

The circuit to supply the DAC-100 PCB with errors generated

by IPM

6 Battery detection circuit The circuit to detect the battery voltage supplied by DAR-100

3) LED DISPLAY FUNCTIONS OF THE DAP-100 PCB

NAMES PURPOSES COLORS STATUS

LED1 15V power check Red Normal: ON

Error: OFF

LED2 15V power check Red Normal: ON

Error: OFF

LED3 15V power check Red Normal: ON

Error: OFF

LED4 15V power check Red Normal: ON

Error: OFF

LED5 15V power check Red Normal: ON

Error: OFF

- 24 -
4) DEFINITION OF DAP-100 PCB CONNECTOR SIGNALS
○ APF connector: To be connected to the DAC-100 PCB.

PIN No. SIGNALS FUNCTIONS PIN No. SIGNALS FUNCTIONS

1 U+ U+phase PWM 8 SCN U-,V-,W-phase fault

signal signals
2 SCA U+phase fault signal 9 W+ W+phase PWM
signal
3 U- U-phase PWM signal 10 BATTV Battery voltage
4 SCB V+phase fault signal 11 W- W-phase PWM signal
5 V+ V+phase PWM 12 GND Ground
signal
6 SCC W+phase fault 13 P4.5 +4.5V
signal
7 V- V-phase PWM signal 14 GND Ground

○ ADA connector: To be connected to the DAP-200 PCB.

PIN No. SIGNALS FUNCTIONS PIN No. SIGNALS FUNCTIONS

1 IPM_UP U+phase PWM 11 IPM_WN W-phase PWM

signal signals
2 E_UP U+phase fault 12 NC
signal
3 IPM_VP V+phase PWM 13 P15_UP U phase power
signal
4 E_VP V+phase fault 14 GND-UP U phase ground
signal
5 IPM_WP W+phase PWM 15 P15_VP V phase power
signal
6 E_WP W+phase fault 16 GND-VP V phase ground
signal
7 IPM_UN U-phase PWM 17 P15_WP W phase power
signal
8 E_UVWN U-V-W-phase fault 18 GND-WP W phase ground
signal
9 IPM_VN V-phase PWM 19 P15_UVWN U-V-W-phase
signal power
10 NC 20 GND-VWN U-V-W-phase
ground

• NC means NO CONNECTION.
- 25 -
○ ADB connector: To be connected to the DAR-100 PCB.

OPERATING
PIN SIGNALS REMARKS
CONDITIONS

1 NC

2 NC

3 NC

4 NC

5 Batt_60V DC60V To receive battery 60V from the DAR PCB (APP5)

6 DRV_DCN DCN To receive DCN from the DAP PCB (APP2)

7 DRV_60V DC60V To receive DC 60V from the DAP PCB (APP3)

8 NC

• NC means NO CONNECTION.

- 26 -
3. EXPLANATION OF SYSTEM OPERATIONS
The ALP control panel is composed of the ALP operation control part, the UPS control part, the
charge control part, and the power circuit part.

3.1 THE ALP OPERATION CONTROL PART

In the ALP control part, the I960 processor of the DOC-100 PCB serves for the control S/W that
relates to operation of the elevator, and the DSP (320C31) of the DPC-100 PCB serves for the
control S/W that relates to the speed control of the inverter. Also, the DSP (320C31) of the
DAC-100 PCB in the ALP control panel serves for UPS voltage control, charge control, and
operation control of the ALP itself. Figure 5 shows a flow chart of the rescue operation.

Outbreak of E/L
power failure panel

ALP
panel
Detection of
power failure

NO
Is it 3 seconds
or longer?
Completion of
YES rescue operation

Activate the ALP

panel UPS
Stop the UPS at
the ALP panel
Activate the E/L
control panel

Display of the
Normal safety rescue operation
circuit

Is power NO
YES Is it at the door restored?
opening zone?

NO YES

Door open Rescue operation Return to the

normal operation

Figure 5. Flow chart of rescue operation

- 27 -
If power fails during the normal operation of the elevator, the relay (R9S) of power failure detection in
the DAR-100 PCB is activated. Once the DSP judges that power failure is 3 seconds or longer with
recognition of the signal, it activates the ALP control to be ready for rescue operation. The DSP of the
DAC-100 PCB generates constant AC voltage of constant frequency that is supplied to the elevator
control panel. The E/L control panel activated by the ALP control checks whether or not the safety status
of the elevator is normal. When position of the car is at the door opening zone, passengers can be rescued
by opening the doors. Otherwise, the DSP compares weight of the car with that of the counter weighter
for commanding the DPC-100 PCB to control the speed patterns for rescue operation, in that the elevator
moves downward if the car weighs more, but upward if it weighs same or less. Once the DPC-100 PCB
receives speed patterns, it controls the inverter to drive the motor in rescue operation speed, making the
car stop at the door opening zone to rescue passengers in the car. Once rescue operation is completed, the
E/L control panel sends a signal informing completion of rescue operation to the ALP control panel. The
ALP control panel that received the completion signal ceases the UPS operation, and it displays status of
the ALP control panel and lasts rescue operation until the power is restored. Then, the E/L control panel
returns to the normal status.

Detection of Detection of
battery voltage power failure

NO Is the charging NO
necessary? Is it 3 seconds
or longer?
YES YES

UPS operation
Operation of the
charge device

Completion of
rescue operation
Completion of
charge operation

Did it last for 5

minutes? NO
YES

Rest of the
ALP operation

Figure 6. Operation flow chart of ALP control operation

- 28 -
 Figure 6 shows flow chart of the ALP operation. If the ALP operation lasts for 5 minutes after
power is restored, it activates the charge operation to charge the battery. If power fails again
during the charge operation, it ceases the charge operation and performs the rescue operation
again. Once the charge operation is completed, the ALP control panel returns to standby status
until the next event occurs.

3.2 THE POWER CIRCUIT PART

This is composed of a battery (as emergency power), an inverter to convert DCV of the battery
into ACV, a transformer to convert the output PWM voltage of the inverter into the sinusoidal
wave voltage of the same magnitude as commercial voltage, and a filter. Here the inverter
serves for two different roles, one is as an inverter in case of power failure, the other is as a
charger in normal operation, depending on remained capacity of the battery.

3.3 THE UPS CONTROL PART

The elevator operates in a rescue mode, in case of power failure. In this case, the ALP controller
operates as an UPS.

Figure 7. Operation in an UPS mode

- 29 -
 If DC 60V of battery is converted into PWM voltage supplied to the main transformer (TR1) by
the inverter, the output voltage (AC380Vrms) of the main transformer flattens to the sinusoidal
wave voltage of the same magnitude as commercial voltage by the filter to be supplied to the
E/L control panel. Features of the UPS control are as follows.
a. It controls the voltage and frequency of the power which is supplied to the E/L control panel.
b. It detects the voltage using the voltage sensor to the adjust the voltage supplied to the E/L
control panel to the commercial voltage, generating voltage command accordingly.
c. It generates the output of the constant voltage and frequency by switching the inverter in a
high speed PWM mode, and also maintains the voltage supplied to the E/L control panel as
the sinusoidal wave voltage to avoid the distortion of voltage for the operation.

3.4 THE CHARGE CONTROL PART

During normal operation, the ALP control switches to the charge mode when remained capacity
of the battery is below a certain level, and maintain its level above a certain level by operating
the inverter as the charge device.

Figure 8. Operation in a charge mode

- 30 -
Figure 9 shows the charging pattern. The charge control is governed by the same control algorithm as the
PWM voltage typed converter. It has following advantages.
Battery lifetime extends by setting the charge pattern of the battery according to the battery type.
Battery lifetime extends by reducing ripples of the charge current during the battery charging.
The harmonic distortion is reduced by controlling the input current to be a sinusoidal wave through
the high speed PWM switching.
Energy loss is minimized by controlling the input power factor to be “1” while charging.

Figure 9. The charge operation pattern

If the battery voltage is 60V or less, the charging begins by operating the charge device. In case that the
battery voltage is DC 72V or less while charging, the operation is proceeded for three hours in a constant
current mode, otherwise it is proceeded in a constant voltage mode. If the battery voltage is DC 54V or
less, the battery under voltage is displayed 80V or more, it displays a failure by detecting the battery
over-voltage.

- 31 -
4. ANNOUNCIATOR

4.1 OVERVIEW
By arranging a maintenance controller on the board in the form of separated PCB, the necessary
functions for installation and repair, for example, data search, data set, and failure detection, are
provided.

4.2 FUNCTIONS
Display the ALP status
Data set for test & commissioning
Controlling charge operation, UPS operation, rescue operation, etc.
Data read

4.3 CONFIGURATION
Following is a configuration of the DOA-100 PCB.

4.4 KEY INPUT ALLOCATION TABLE FOR OPERATION MODES

OPERATION MODE AND DATA READ

MAIN MODE RESETTING

MODES KEY I/O
MODE DESCRIPTIONS
INPUT TYPES
Operation ANN charge operation C00E DIGI FFFF
related mode ROM SPEC delete C04E DIGI
ANN charge completion C07E DIGI
ANN UPS completion C08E DIGI
Memory BATT -VOLTAGE B00E DIGI FFFF
related mode BATT-CURRENT B01E DIGI
(DATA READ)
INPUT RELAY B02E HEX
OUTPUT RELAY B03E HEX
B04E
mode_selector B05E DIGI

- 32 -
 MAIN MODE RESETTING
MODES KEY I/O
MODE DESCRIPTIONS
INPUT TYPES

Memory trouble_sum B06E HEX FFFF

related mode TROUBLE_10 B07E HEX
(DATA READ)
TROUBLE_20 B08E HEX
TROUBLE_30 B09E HEX
TROUBLE_40 B0AE HEX
TROUBLE_50 B0BE HEX
TROUBLE_60 B0CE HEX

Charge_op_mode B16E HEX

Ups_op_mode B17E HEX

ERROR CHECK MODE

MODES MODE DESCRIPTIONS KEY INPUT RESETTING

Error related mode TCD DISPLAY A FFFF

(DATA READ)
Re-output of TCD DISPLAY FFFF

ERROR CLEAR DDDD

- 33 -
4.5 NORMAL MODE

1) INITIAL SCREEN OF NORMAL MODE

Column
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Row

1 – R E S T M O D E –

2 E R R – N O :
3 M O D – N O :
4 V A L U E :

2) DESCRIPTIONS OF NORMAL MODE INITIAL DISPLAY

① 1st row: displays a normal operation mode
② 2nd row: displays ERROR when there is an error
③ 3rd row: displays the current key input by key-pad
10th to 13th column: displays the status of current key input by key-pad
④ 4th row: displays the various status by key-pad input

4.6 CHARGE MODE

1) INITIAL DISPLAY OF CHARGE MODE

Column
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Row

1 – C H A R G E M O D E –

2 E R R – N O :
3 M O D – N O :
4 T I M E : 0 : 0 0

2) DESCRIPTIONS OF CHARGE MODE INITIAL DISPLAY

① 1st row: displays a charge operation mode
② 2nd row: displays ERROR when there is an error
③ 3rd row: input “FFFF” to display the various status
Once “FFFF” is input, the display mode is released, and the display on 4th row changes to
the following

4 V A L U E :
- 34 -
 Once the display on the 4th row changes, it is possible to output the status description that
needs to be displayed
④ 4th row: displays the charging time
Once “FFFF” is input on the 3rd row, the display of the charging time changes to the “VALUE:”

4.7 UPS MODE

INITIAL SCREEN OF UPS MODE
The 1st row on the initial screen of the normal mode changes to the following.

1 – U P S M O D E –

The 2nd, 3rd, and 4th rows are same as the initial screen of the normal mode.

4.8 RECHARGE MODE

INITIAL SCREEN OF RECHARGE MODE

1 – R E S T M O D E –

4 R E C H A R G E : 0 0 0 0

Numbers on the 11th to 14th columns of the 4th row increase from 0 to 7500, followed to
be changed to the charge mode.
The 2nd and 3rd rows are same as the initial screen of the normal mode.

4.9 ANNOUNCIATOR OPERATION

1) ANNOUNCIATOR CHARGE OPERATION

INITIAL SCREEN OF NORMAL OPERATION MODE

3 M O D – N O : C 0 0 E –

Input “C00E” in the normal mode.

Once “C00E” is input, the normal mode is switched to the charge mode and the charging
begins.

2) COMPLETION OF ANNOUNCIATOR CHARGING

SCREEN OF CHARGE OPERATION MODE

3 M O D – N O : C 0 7 E –

Input “C07E” in the charge mode.

Once “C07E” is input, the charge mode is switched to the normal mode and the charging
is completed.

3) COMPLETION OF ANNOUNCIATOR UPS

SCREEN OF UPS OPERATION MODE

3 M O D – N O : C 0 8 E –

Input “C08E” in the UPS mode.

Once “C08E” is input, the UPS mode is switched to the normal mode and the UPS
operation is completed.
- 35 -
4.10 MEMORY-RELATED MODE
1) DATA READ MODE

SCREEN OF DATA READ MODE

4 V A L U E :
Check if “VALUE” is displayed on the 1st to 7th columns of the 4th row.

CHANGE THE SCREEN FROM THE CHARGE MODE TO THE DATA READ MODE
In case that the 4th row in the charge mode is displayed as the following, input “FFFF”
on the 3rd row.

4 T I M E : 0 : 0 0
Once “FFFF” is input, the 4th row changes to the data read mode, and the data is
displayed on it.

KEY INPUT SCREEN

3 M O D – N O : B 0 0 E
Input “E” followed by the related key numbers to be initial B.

DATA OUTPUT SCREEN

4 V A L U E : 0 7 2
Once the key input is completed, the data are displayed on the 12th to 14th columns of
the 4th row.

DATA READ MODE RELEASE SCREEN

3 M O D – N O : F F F F
To release the data read mode, input “FFFF” on the 3rd row.
Once the data read mode is released, the data of the 4th row are not displayed, but the 4th
row screen of the previous mode is displayed.

2) DATA WRITE MODE

SCREEN OF DATA WRITE MODE

3 M O D – N O : C 0 1 E
Input “E”, followed by the related key numbers to be initial C on the 3rd row in normal
operation.
Once “E” is input, the screen does not display the code which was entered on the 3rd row,
but wait for the data to be input.

DATA INPUT SCREEN

3 M O D – N O : 0 1 E
Input “E” if the data input is completed by inputting the data of two digits.
Once “E” is input, the screen does not display the code which was entered on the 3rd row,
but wait for the key input.

- 36 -
 RELEASE SCREEN OF DATA WRITE MODE

3 M O D – N O : F F F F

To release the data write mode, input “FFFF” on the 3rd row.
Once the data write mode is released, the data of the 3rd row is not displayed.
To check if the data was input correctly, switch to the data read mode and input the
related code.

4.11 ERROR-RELATED MODE

1) TCD DISPLAY MODE

INITIAL SCREEN OF TCD DISPLAY MODE

2 E R R – N O :
Unless there is an error, no data are displayed on the 2nd row.

TCD DISPLAY MODE SCREEN

2 E R R – N O : E R R O R

If there is an error, the “ERROR” message is displayed on the 10th to 14th columns of the
2nd row.

TCD RETRIEVAL SCREEN

2 E R R – N O : E R R 1 0

3 M O D – N O : A

If “A” is input on the 10th column of the 3rd row, the most significant TCD number of
the errors made on the 2nd row is displayed.
If “A” is input again on the same column, the TCD number of the next significant error is
displayed .

RELEASE SCREEN OF TCD DISPLAY MODE

2 E R R – N O : E R R 6 0

3 M O D – N O : A A A A

If “A” is displayed on both 10th and 11th columns of the 3rd row, it means that the error
TCD number on the 2nd row has been displayed to the least significant rank.
Once the error TCD number is displayed, input “AAAA” on the 10th to 13th columns of
the 3rd row.

- 37 -
 TCD DISPLAY RE-OUTPUT SCREEN

3 M O D – N O : F F F F

Input “FFFF” on the 3rd row to re-output the error TCD number, and the TCD retrieval
screen is displayed on the 3rd row.

ERROR RELEASE SCREEN

3 M O D – N O : D D D D

Input “DDDD” on the 3rd row to release the error TCD number, and the screen is switched
to the normal mode.

- 38 -
5. TEST OPERATION

5.1 PREPARATION OF TEST OPERATION

1) DETAILS OF TEST OPERATION

① Once the elevator has been operated normally, the test operation of the ALP operation
should be proceeded. This is because there are many unnecessary operations of the ALP
which causes an electric shock by frequent turning on and off an electric power during
installation and Testing of an elevator.
② The speed of rescue operation is 10m/min.
③ The MCCB of the ALP control panel must be turned off ahead of the main power MCCB of
building.

Commercial
power EMI Filter
MCCB
E/L

Power Stack I.M

E/L
control panel

ALP BKM
control panel
MCCB

Battery
ALP

Power Stack
detection
Power
failure

C9A

If it is necessary to work for the elevator after installing the ALP, make sure to turn off the MCCB
in the E/L control panel. Turning the MCCB of the distribution panel of the building off, the ALP
control panel recognizes this to be a power failure and applies voltage same as a commercial
power (AC380V) to the E/L control panel. This increases a possibility of electric shock.
▷ When turning the E/L MCCB off, power of the ALP control panel is turned off.
▷ Although the MCCB of the ALP control panel is turned off, it does not affect operation
of the elevator.
▷ Although the MCCB of the ALP control panel is turned off, be careful against an electric
shock, since AC380V is applied to the failure detection circuit in the ALP control panel.
▷ In case that the ALP control panel requires a partial repair during normal operation of the
elevator, do not turn off the BKM switch on the input terminal of the transformer (TR2)
which serves for supplying power to the failure detection circuit in the ALP control
panel, because the elevator stops in an emergency mode.

- 39 -
 ▷ In case that the ALP control panel requires a whole repair and therefore the BKM switch
needs to be off, conduct the repair work while the elevator is not in use after turning off
the MCCB of the E/L control panel.
▷ Although a trouble occurred on the ALP control panel, it does not affect normal
operation of the elevator at all.
▷ In case that rescue operation lasts for 5 minutes, the ALP control panel stops UPS and
displays excess of the rescue operation time (TCD42).
▷ Once the rescue operation is completed, the elevator returns to a rest mode after stopping
the UPS. Following the rest state, the charge operation is automatically performed at 10
minutes after the power returns.

2) TOOLS AND MEASURING EQUIPMENT

(1) THE REQUIRED TOOLS
① Spanner set
② Driver set
③ Cutting pliers, cutting nippers, pressing tools (2-14SQ, 22-38SQ)
* Tools must be inspected before using.

(2) THE MEASURING EQUIPMENT

① Digital multimeter (Input impedance: 1Mohm or more, minimum measurable voltage:
10mV)
② Hook meter (Current measurement)
③ Megger Tester
④ Speed meter
⑤ Analog tester
* Equipment must be inspected and calibrated before using.

5.3 CHECKING

1) ELEVATOR
① Check if the elevator doors of all the stories are closed and the locking devices are safe and
firm.
② Is there any interference by equipment installed in the hoistway?
③ Is there any problem in the safety system of the elevator?
④ Is the elevator operated normally?

2) CONTROL PANEL
① Is the control panel arranged clearly?
② Are the power lead-in, Wiring & Bolting between the E/L and ALP control panels good?

3) BATTERY
① Check if the case is broken or if anything appears wrong.

- 40 -
 ② Check clean of terminals after tightening and applying them with grease or Vaseline.
③ Then check if it is covered with a rubber cover.
④ Check if a battery charge indicator is in normal.
⑤ Take a careful look around the battery against fire, static electricity, and electric short
between the terminals.

※ Status of a battery change indicator

Green White Red

(Normal) (Insufficient charge) (To be Changed)

⑩ Inspect battery capacity

Guidelines of battery application

Speed (m/min)
45 60 90 105 120 150
5.5 ~ 7.5 ㎾
Motor capacity

40Ah
11 ㎾
applicable

13 ~ 15 ㎾
50Ah
Not

18 ~ 22 ㎾ 60Ah
30 ㎾ Not applicable
Battery capacity Number of uses Drawings
40Ah, 12V 5EA (60V) 3×04866A
50Ah, 12V 5EA (60V) 3×04866B
60Ah, 12V 5EA (60V) 3×04866C

▷ Battery type: Check if it is for car-application

▷ Check if color of a remnant capacity indicator of the battery is normal
▷ Proceed rescue operation using the announciator once a month
(Refer to a users manual of the announciator when in use)
▷ Make sure that negative (-) terminal of battery and ground of control panel frame are not
connected together.

- 41 -
4) WIRING CONNECTION BETWEEN E/L CONTROL PANEL AND ALP CONROL
PANEL

▷ Check if the shieled cable is used for the communication line

(3X04871: Refer to drawing for the circuit connection of the machine room)

MCCB
(Auxiliary
contacts)

Serial
communication

- 42 -
 5) CONNECTION CHECK OF PRIMARY TERMINAL OF TRANSFORMERS 1 AND 2
IN ALP CONTROL PANEL

Change position
E/L control panel
3-phase power E/L control panel Connection to the TRANS-1
MCCB
of building Power trans of ALP control panel
Secondary voltage
Primary terminal Primary terminal
of TR1 of TR2
200-240V Available 380V U380,V380,W380 380V, 0V
460-480V
380V None
400V None 400V U400,V400,W400 400V, 0V
440V None 440V U440,V440,W440 440V, 0V

5.4 ELECTRIC CIRCUIT CHECK

1) SAFETY WHILE WORKING

※ Insulation is defined as property of the electrical resistance of insulator. Goals of this
section is to prevent the electric shock by measuring the insulating properties, to protect
equipment against poor insulation, and furthermore to prevent the incident due to trouble
during operation of the elevator and the ALP.

(1) Prevention of electric shock

Voltage of DC 70V is applied to each ends of battery, likewise DC 50V to the each ends of the
condenser, and AC 100V to the DAR-100 PCB. According to a function of the ALP control
panel, operation of the elevator is not affected by turn-off of the MCCB in it. Thus, voltage of
AC 110V is applied to the ALP control panel, although its MCCB is turned off. Therefore, the
ALP control panel is completely powered off by turning the MCCB of both the elevator and
ALP control panels off. Make sure that you can touch them only after confirming voltages of
various points to be 0V, using the multi meter or tester.

(2) Prevention of PCB damage

① Low voltage megger: Megger-test all the connectors and terminals inside the control panel
using a constant voltage megger (generated voltage: 15V) or a digital multi meter.
② High voltage megger: Megger-test terminal boxes and contactor points inside the control panel.

2) PREPARATION FOR MEASURING INSULATION RESISTANCE

① Close hoistway doors and car doors by stopping the elevator between the stories.
② Turn off the MCCBs for power lead-in to building, for the E/L control panel, for lighting,
and for the ALP control panel.
③ Disconnect power wires lines of connectors and terminal boxes connected between the E/L
control panel and the ALP control panel.

- 43 -
 ④ Disconnect the power wires connecting the ALP control panel contactors from the battery
terminal boxes.
⑤ Disconnect all the connectors led to the PCB.
⑥ Remove all the fuses out of the fuse holder
⑦ Common both ends of DCN and DCP of the DC link using clips.
⑧ Common input terminals of the power MCCB and I/O terminals of reactors using clips.
⑨ Disconnect the primary and secondary ends of the main transformer (TR1), and common
transformer terminal boxes (U1,V1,W1,U2,V2,W2) using clips.

3) MEASURING OF INSULATION RESISTANCE

① Use a jack to hold the earth plate of the control panel
② Record the results after measuring following items in the table below.

LG MEASUREMENT
MEASUREMENT POINTS
SPECIFICATIONS RESULTS
EP1(E/L FRAME) <--> EAP1(ALP FRAME) 1MΩ or more
Terminal box (U,V,W) <--> EAP1
Terminal box (R,S,T) <--> EAP1
Transformer terminal box (U1,V1,W1) <--> U2,V2,W2)
Transformer terminal box (U1,V1,W1) <--> EAP1
Transformer terminal box (U2,V2,W2) <--> EAP1
Reactor I/O terminal box <--> EAP1
FUSE HOLDER of DAR-100 PCB <--> EAP1 0.5MΩ or more
97SA Main contacts <--> EAP1
97SB Main contacts <--> EAP1
97SBX Main contacts <--> EAP1
97SD Main contacts <--> EAP1

※ Check the followings before applying power, followed by measurements

1 Bring the common state back to the previous state
2 Bring all the disconnected terminals back to the previous connected state.

4) RATING OF FUSES
Check if the rating of fuses 1-3 in the DAR-100 PCB is 125V and 5A.

5) CIRCUIT CHECK
① Check if all the connectors and terminal boxes which are disconnected for an insulation
resistance test are brought back to the previous state.

- 44 -
 ② Prepare a multi meter.
③ Check the wirings according to the following table.

CONNECTORS CONNECTORS REMARKS

MK CONNECTORS Serial communication, MCCB contacts
DAC-100 APG DAR-100 APK CTT, Relay I/O
APF DAP-100 APF PWM signals, error
APE DOA-100 LCD Announciator connection

APD H.CT, PT
APC Serial transfer
APB DAR-100 APS P5, P15, N15 power
DAR-100 APR MT (CTT ASY) CTT contact, driving line
APP DAP-100 ADB Battery power source
APM TR2 AC110V, AC45V
DAP-100 ADA IGBT MIG IGBT driving signal

5.5 VOLTAGE CHECK

1) PREPARATION FOR POWER APPLICATION
① Remove the connectors ADA and APF of the DAP-100 PCB
② Remove the connector APB of the DAC-100 PCB
③ Switch off MCCB and APY in the ALP control panel

2) INPUT VOLTAGE CHECK OF ALP CONTROL PANEL

(1) Check the secondary power of the elevator MCCB
① Check voltage of the secondary power of the E/L control panel MCCB before switching on
the MCCB and APY in the ALP control panel, refer to the below table 1.

Table 1. Voltage at various places on the power of the building

Change position
E/L control panel
3-phase power E/L control panel Connection to the TRANS-1
MCCB
of building Power trans of ALP control panel
Secondary voltage
Primary terminal Primary terminal
of TR1 of TR2
200-240V Available 380V U380,V380,W380 380V, 0V
460-480V
380V None
400V None 400V U400,V400,W400 400V, 0V
440V None 440V U440,V440,W440 440V, 0V

- 45 -
 ② Check if the primary voltage of C9A CTT in the ALP control panel is same as the
secondary voltage of MCCB in the E/L control panel shown in Table 1, and also the
primary voltages of TR1 and TR2 in the ALP control panel are same as those of Table 1.
Adjust them if necessary.

3) VOLTAGE CHECK AFTER MCCB APPLICATION IN CONTROL PANEL

① Switch BKM (APY) on
② Check if the C9A contactor is turned on
③ Check if the primary voltage of MCCB in the ALP control panel is same as the secondary
voltage of MCCB in the E/L control panel
④ Turn MCCB of the ALP panel on
⑤ Check if the primary voltage of the main transformer (TR1) is same as the secondary
voltage of MCCB in the E/L control panel
⑥ Check if the secondary voltage of the main transformer (TR1) is AC 30V, and also if the
secondary voltage of TR3 is AC 12V.
⑦ Check if voltage of IGBT terminal (U, V, W) is AC 30V.
⑧ Check if voltage between the each ends (DCN, DCP) of condenser is in the range of DC
36V to DC 48V.

⑨ Record the voltage of the DAR-100 PCB in the following table.

RATED MEASURED
No. MEASURING POINTS REMARKS
VOLTAGE VOLTAGE
1 APP.1⊕ – APP.2 DC 48V
2 APP.4⊕ – APP.2 DC 60V
3 APP.3⊕ – APP.2 DC 60V
4 APP.5⊕ – APP.2 DC 60V
5 APM.1 - APM.3 AC 110V
6 APM.2 - APM.4 AC 45V
7 APS.5⊕ – APS.1 DC 24V Not drawn outside
(APS # 2,3,5)
8 APS.6⊕ – APS.2 DC -15V
9 APS.7⊕ – APS.3 DC 15V
10 APS.8⊕ – APS.4 DC 5V

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 ⑩ Record the voltage of the DAR-100 PCB in the following table.

RATED MEASURED
No. MEASURING POINTS REMARKS
VOLTAGE VOLTAGE
1-1 ADB.1⊕ - ADB.2 DC 60V Before correction
2-1 ADB.3⊕ - ADB.2 DC 60V
1-2 ADB.5⊕ - ADB.6 DC 60V After correction
2-2 ADB.7⊕ - ADB.6 DC 60V
3 CH1⊕ - CH2 DC 6V
4 ADA.13⊕ - 14 each ends DC 15V
5 ADA 15⊕ - 16 each ends DC 15V
6 ADA 17⊕ - 18 each ends DC 15V
7 ADA 19⊕ - 20 each ends DC 15V
8 LED5 each ends DC 2V

※ Measure the voltage between CH1 and CH2 by adjusting the variable resistor VR1 so that
ratio of ADB1-ADB2 (before correction, 4P MOLEX) and ADB5-ADB6 (after correction,
8P MOLEX) are to be (10:1)+0.2V.

⑪ Insert the APB connector of the DAC-100 PCB

⑫ Record the voltages of the DAR-100 PCB in the following table.

RATED MEASURED
No. MEASURING POINTS
VOLTAGE VOLTAGE
1 APB.1⊕ - APB.4 DC 15V
2 APB.2⊕ - APB.4 DC 5V
3 APB.3⊕ - APB.4 DC -15V

4) C9A CONTACTOR CHECK

Check if the C9A contactor is turned on simultaneously when switching APY on. It must
operate independent of MCCB on-off in the ALP control panel (Do not turn the APY switch of
the ALP control panel off during normal operation of the elevator, because this leads to power
off the C9A contactor of the ALP control panel, resulting in a sudden stop of the elevator due
to turn-off of elevator power.).

※ Turn off the MCCB and APY switch of the ALP control panel, and insert the connectors of
APF and ADA in the DAP-100 PCB.

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5) LED CHECK ON THE PCB
Turn on the MCCB and APY switch of the ALP control panel.

① DAC-100 PCB

LED NAMES PURPOSES OPERATIONS

LED1 UPS live signal Flickering during rescue operation
LED2 Battery over-current detection (OC) ON if detected
LED3 Battery over-voltage detection (OV) ON if detected
LED4 Trouble in input phase ON if detected
LED5 CHG LIVE signal Flickering during charge operation
LED6 Controller failure (ALARM) ON when controller in trouble
※ LED 1 and LED 2 are flickering when ALP control panel is at rest.

② DAR-100 PCB

LED NAMES PURPOSES OPERATIONS

LED1 P5V power establishment ON when power is established
LED2 P15V power establishment ON when power is established
LED3 P15V power establishment ON when power is established
LED4 P24V power establishment ON when power is established
LED5 Normal power establishment ON when power is established,
OFF when power failure occurs
LED6 Check charge operation ON during charge operation
LED7 Failure of safety relay of ALP ON when normal, OFF when in
control panel trouble

③ DAP-100 PCB

LED NAMES PURPOSES OPERATIONS

LED1 P15V power establishment (N-phase) ON when power is established
LED2 P15V power establishment (U-phase) ON when power is established
LED3 P15V power establishment (V-phase) ON when power is established
LED4 P15V power establishment (W-phase) ON when power is established
LED5 P15V power establishment (ISO-AMP) ON when power is established

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5.6 ADJUSTMENT

1) ADJUSTMENT FOR BATTERY VOLTAGE DETECTION

① Make voltage between the check terminals (CH1-CH2) to be (10:1)+0.2V of voltage
between each ends of battery by adjusting the variable resistor VR1.
② Check the address B00E using the announciator, and make it the same as the voltage
between each ends of battery by adjusting the variable resistor VR1.

2) FAILURE DETECTION SETTINGS

PROCESSES AND
No. ITEMS SETTINGS
CHECK POINTS
1 Battery over-current 98A Process in the PCB inspection
guideline
2 Battery over-voltage 80V Process in the PCB inspection
guideline
3 Battery under-voltage 54V Program modification
4 Trouble in UPS voltage control Commercial Program modification
voltage±10% Adjust primary tap of transformer
(TR1) according to the voltage
specification
5 IGBT over-current 158 A IGBT equipped internally
6 Protection against IGBT-short- 360A IGBT equipped internally
circuit
7 Protection against over-heating 111°C IGBT equipped internally
8 Excess of the rescue operation 5 minutes Program
time
9 Excess of the charge operation 4 hours Program
time
10 Commercial power under AC280V (75%) Program
voltage

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5.7 TEST OPERATION

1) TEST OPERATION PROCEDURE

Building MCCB ON
E/L MCCB ON
ALP PANEL BKM(APY) S/W ON

1. Check APM connector

Check if C9A connector is ON NO
2. Check Fuse 3
3. Check connection of CTT
ASY drawing (D#:3X04878)

ALP panel MCCB ON

LED5 of DAR-100 PCB

NO
(Check ON)

Check LED of DAC-100 PCB LED2 ON: Battery over-current

LED1, 5: flickering NO LED3 ON: Battery over-voltage
LED2, 3, 4, 6: OFF LED4 ON: Trouble in input phase
LED6 ON: ALP controller failure

Check LED of DAR-100 PCB

LED1, 2, 3, 4, 5, 7: ON NO LED5 OFF: When safety relay is in
LED6: OFF trouble
LED6 ON: When charge device is
in operation

Check LED of DAP-100 PCB

LED1, 2, 3, 4, 5: ON

Check LED5 of DAR-100 PCB NO LED5 OFF: When safety system of

(ON within 5 seconds after power-on) ALP control panel is in trouble

--- REST MODE ---

ANN initial screen display ERRO-NO:
MOD-NO:
VALUE:

- 50 -
2) TEST CHARGE OPERATION

Input “C00E” into ANN “C00E” is rescue operation

mode for maintenance

Check if contactor C9D is ON C9D is to limit

initial rush current

Check if contactor C9B is C9B is for battery connection

ON after C9D is ON C9X is for keeping of OFF

Check fan operation

Check if “-CHARGE MODE-” Charge operation mode

is displayed on ANN

Input the address “FFFF” Change to data read mode

into ANN

B00: Voltage of battery is normal if

Input “E” after inputting the 72V±4.
address “B00” into ANN It must be same as DCN(-)-DCN(+)
of TB3 measured by multi-tester

Input “C07E” into ANN after “C07E” is completion of

performing charge operation charge operation
longer than 10 minutes

Check if contactors of C9D and

C9B and FAN are OFF

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3) RESCUE OPERATION WHEN STOPPING WITHIN DOOR OPENING ZONE

Put status of both E/L and ALP

control panels normal

Stop the E/L car within door

opening zone between the floors

Turn off incoming MCCB

of building side

Check if C9A turns off. Check if

contactor C9B turns on after C9D.
Check if fan operates.

Check if power is applied to E/L

control panel after 3 seconds.

Check if there is the #136 error on #136 error: Communication

ANN of E/L control panel error between ALP and INV

Check if the hall and

car calls are deleted

Check if door is open

Check if UPS stops

after 15 seconds

Check if fan and contactors of

C9B and C9D turn off

- 52 -
4) RESCUE OPERATION WHEN STOPPING WITHOUT DOOR OPENING ZONE

Operate the elevator in

No load inside the cage
normal high speed

Turn off incoming MCCB of the

building when the car is at the
middle floor

Check if power is applied to E/L

control panel after 3 seconds

Check if there is the #136 error #136 error: Communication

on ANN of E/L control panel error between ALP and INV

Check if the hall and

car calls are deleted

Check if speed of the E/L is

Check if the car moves upward
10m/min using speed meter

Check if the car stops within

door opening zone

Check if door is open

Check if UPS stops

after 15 seconds

Check if contactors of C9B

and C9D turn off

- 53 -
5.8 CHECKLIST FOR THE RESCUE OPERATION

Power supplied Outbreak of

to E/L control Commercial power failure
panel power ALP power

Normal
operation
E/L speed Rescue
operation

Power failure of 3 seconds or longer

1) CHECKLIST FOR CONTROL FUNCTIONS (E/L OPERATION SWITCHES TO

RESCUE OPERATION MODE)

No. INSPECTION LIST EXPECTATION RESULT

1 Is car call deleted? Yes

2 Is car call not registered? Yes

3 Is hall call deleted? Yes

4 Is hall call not registered? Yes

5 Is direction lantern deleted? Yes

6 Is car direction indicator on? Yes

- 54 -
2) CHECKLIST FOR OPERATION FUNCTIONS

No. INSPECTION LIST EXPECTATION RESULT

1 Is the ALP control panel in the rest mode and the E/L control Yes
panel in the normal operation mode when commercial
power is applied?
2 Is normal power supplied to the E/L control panel in 3 Yes
seconds from power failure, by UPS operation of the ALP
control panel?
3 Was E/L control panel active correctly after the power was Yes
supplied, as shown above 2?
4 Was the E/L operation mode switched to the ALP operation Yes
mode (ACD=01) after it was activated, as shown in the
above 3.
5 Is the operation status of the ALP control panel in the rest Yes
mode, in case of power failure within 3 seconds?
6 Is the ALP control panel operation switched to the UPS Yes
operation although power failure occurred during the charge
operation?
7 Does the rescue operation continue although commercial Yes
power is restored during the operation?
8 In case of that commercial power is restored during the Yes
rescue operation, if it last about 3 seconds after completing the
rescue operation, is the battery power switched to the
commercial power and does the E/L control panel return to
the normal operation mode?
9 Does ALP control panel stop the UPS operation and return Yes
to the rest mode unless commercial power is stored even
after the rescue operation is completed?
10 Does the ALP control panel perform the charge operation Yes
in 5 minutes after the rescue operation has been completed
and commercial power has been restored?
11 Is it impossible to perform the rescue operation if there is a Yes
trouble in the safety system?
12 Is it impossible to perform the rescue operation during the Yes
on-cage operation?
13 In case that position of the car is within the door opening Yes
zone when power failure occurred during the normal
operation, is the door open and is the UPS power turned
off in 15 seconds?
14 If the car is without the door opening zone as shown in above Yes
13, does the elevator move as describing “3.1 THE ALP
OPERATION CONTROL PART” on pages of 27~29?
15 In above 14, does the elevator move downward if both Yes
weights are almost same?
16 After moving toward the directions of above 13 and 14, Yes
does the elevator stop within the door opening zone, the
door open, and then the UPS power turn off about 15
seconds later?

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 5.9 ACTIONS TO TAKE AFTER COMPLETING TEST OPERATION
Clear the numbers of times for charge operation and rescue operation from the announciator.
① If the address B16E is pressed, the number of charge operation is displayed on the VALUE
space of the announciator. Also, if the address B17E is pressed, the number of times for
rescue operation is displayed on the VALUE space of the announciator.
② If the address C04E is pressed, “ERASE OK” is displayed on the VALUE space of the
announciator.
③ Turn off/on the MCCB of the ALP control panel, press the address B16E to check if “000”
is displayed on the VALUE space, and also press B17E to check if “000” is displayed.

6. REGULAR INSPECTION

No. INSPECTION LIST EXPECTATION RESULT

1 Is color of the battery charge indicator normal? Green

2 Is the battery voltage good? DC 64V or more

3 ① Check the number of times for rescue operation Refer “※Note 1” below in
from the announciator? (Address: B17E) case that the number of times
for charge operation is “2”
② Check the number of times for charge operation more than that for rescue
from the announciator? (Address: B16E) operation.

4 Charge battery by operating the charge device.

(Follow section 5.7.2)

5 Check battery voltage during charge operation. DC 70V or more

6 Is color of the battery charge indicator normal? Green

7 Is the supplied voltage to the control panel during Commercial voltage±10%

rescue operation normal?

8 Is the rescue operation performed well? Items 3 and 4 in section 5.7

(Pages 52~53)

9 Change battery immediately if problem from

above three questions are found, because lifetime
of battery is 3 ~ 5 years.
※ Note 1.
① Check voltage between each ends of battery using the DC meter.
② Check the battery voltage using the announciator (Address B00E).
③ If the above result of ② is smaller than that of ① as much as 2V or higher, adjust the variable
resistor (VR1) in the DAP-100 PCB to make the results of ① and ② same.
④ If the above result of ② is same as or larger than the result of ①, change the battery.

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7. ALP OPERATION TCD DESCRIPTION

7.1 TCD DESIGN GUIDELINES

① The trouble codes mentioned in this document are equally applied to the ALP for DI
elevators (60-150 m/min).
② TCD is classified by a function using the numbering system of 10 through 67.
③ When troubles listed in the TCD numbers occurred, the ALP operation is controlled and
managed by Trouble_sum Flag.

7.2 BIT DEFINITIONS OF TROUBLE_SUM FLAG

bit LABEL NAMES RANK EXPLANATIONS REMARKS

0 TROUBLE-10 A1 Not possible for charge and rescue operations R9B off

1 TROUBLE-20 A2 Not possible for charge and rescue operations R9B off

2 TROUBLE-30 B1 Not possible for charge and rescue operations R9B off

3 TROUBLE-40 C1 Not possible for rescue operation

4 TROUBLE-50 D1 Not possible for rescue operation

5 TROUBLE-60 D2 Not possible for rescue operation

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