4B W4005V46-SYS/B Series Original Instructions Manual
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4B W4005V46-SYS/B Series Original Instructions Manual

Elevator monitoring system
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ORIGINAL INSTRUCTIONS
R9.6 – 22 May 2020
W4005V46-SYSx /B (BÜHLER)
Elevator Monitoring System
OPERATION MANUAL
INSTALLATION INSTRUCTIONS
MODELS: W4005V46-SYS1 /B
W4005V46-SYS2 /B
Hardware Version: R4
Software - Main Processor: 4.2.x; Ethernet Processor: 3.1.x
www.go4b.com

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Summary of Contents for 4B W4005V46-SYS/B Series

  • Page 1 ORIGINAL INSTRUCTIONS R9.6 – 22 May 2020 W4005V46-SYSx /B (BÜHLER) Elevator Monitoring System OPERATION MANUAL INSTALLATION INSTRUCTIONS MODELS: W4005V46-SYS1 /B W4005V46-SYS2 /B Hardware Version: R4 Software - Main Processor: 4.2.x; Ethernet Processor: 3.1.x www.go4b.com...

  • Page 2: Table Of Contents

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM IMPORTANT: THE LATEST VERSION OF THIS MANUAL AS WELL AS ALL THE AVAILABLE TRANSLATIONS CAN BE FOUND AT: http://www.go4b.co.uk/buhler TABLE OF CONTENTS ABBREVIATIONS AND NOTATIONS USED ........................... 4 WARNINGS ..................................
  • Page 3 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 12.19 ............................... 34 THERNET LLOCATION TROUBLESHOOTING GUIDE .............................. 40 MAINTENANCE PROCEDURE ............................. 41 COMMISSIONING ................................42 SYSTEM BREAKDOWN PROCEDURE ..........................42 MANUFACTURER INFORMATION ............................. 42 17.20 ..........................42...

  • Page 4: Abbreviations And Notations Used

    No PLC or other control intervention is needed to provide the safety of operation. 4. System Approvals and Compliance Approvals information may change due to the standards changing from time to time and due to 4B constantly expanding the portfolio of international certifications that the system components are approved to. The information given below is correct at the time of release of this manual it may become out of date from time to time though.
  • Page 5 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM Part Number ATEX IECEx NEPSI (China) EAC Ex W4005NV46AI DE/COSC/101214 Not Approved NEPSI Ex ° Ex tc IIIC T125 Ex II 3D Ex tc IIIC T125°C GYJ16.1486X Dc X Dc IP66 Tamb -20°C to...

  • Page 6: W4005V46-Sys1 /B Declaration Of Conformity

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 4.1 W4005V46-SYS1 /B Declaration of Conformity DECLARATION OF CONFORMITY Note: This is an example of the declaration of conformity. The correct and signed version is included as an insert within the printed manual together with the delivered product.

  • Page 7: W4005V46-Sys2 /B Declaration Of Conformity

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM Kirk Lane, Yeadon LS19 7LX, United Kingdom 4.2 W4005V46-SYS2 /B Declaration of Conformity DECLARATION OF CONFORMITY Note: This is an example of the declaration of conformity. The correct and signed version is included as an insert within the printed manual together with the delivered product.

  • Page 8: Transportation

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM Westfield Industrial Estate Kirk Lane, Yeadon LS19 7LX, United Kingdom 5. Transportation The system is securely packaged in a specially designed carton box with custom inserts. Nevertheless, care must be taken during the transportation of the system as the carton contains sensitive electronic components.

  • Page 9: Specifications

    M12 tapped hole or is connected magnetically using 4B’s patented Mag-Con™ adaptor (*not included in the System kit). Shaft or machine vibration does not affect the performance of the sensor, as the whole assembly moves with the shaft. With the Whirligig, installation of speed sensors is simple, safe and reliable.

  • Page 10: W4005Nv46Ai /B - W400 Series Elevator Controller

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 7.3 W4005NV46AI /B – W400 Series Elevator Controller Controller Specifications Supply Voltage: OR 100-240V ±10% 50/60Hz Power Dissipation: 25W Max Alarm Relay Contacts: 1 Pole normally open 8A@ 250VAC AC1...

  • Page 11: P300V34Ai /B - Proximity Speed Sensor

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 7.5 P300V34AI /B – Proximity Speed Sensor P300 Specifications Supply Voltage: 10-30V Sensor Output Type: Opto-Isolated Transistor (NPN or PNP use) Sensor Output Ratings: 100mA @ 30V Maximum Detectable...

  • Page 12: Mechanical Installation

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 8. Mechanical Installation DANGER: EXPOSED BUCKETS AND MOVING PARTS WILL CAUSE SERIOUS INJURY OR DEATH. THE OPERATOR MUST ALWAYS LOCKOUT POWER BEFORE REMOVING COVER OF THE INSPECTION DOOR OF THE ELEVATOR OR PERFORMING ANY INSTALLATION OR MAINTENANCE WORK.
  • Page 13 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM When mounting on the head section of an elevator try to catch the belt and the pulley. On an elevator, mount the TouchSwitch™ above the center line of the head shaft on the discharge side of the pulley when possible.
  • Page 14 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 8.1.2. TouchSwitch Mounting Diagrams 8.1.2.1. Typical Mounting Positions on a Bucket Elevator Touchswitch™ must be installed above the head shaft between the 9 o’clock and 3 o’clock position and as close to the 3 o’clock as possible.

  • Page 15: Wg4A-Br /Band P300V34Ai /B - Proximity Speed Sensor And Bracket Installation

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 8.1.2.2. Typical Mounting Positions On Tail/Boot Section Of Bucket Elevator Mount touchswitch™ on upside of leg (if possible) at the highest point that the bootshaft can be adjusted...

  • Page 16: Adb910V3Ai /B - Adjustable Depth Bearing Temperature Sensor

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM Figure 6 – P300 and Whirligig Mounting Bracket Mechanical Installation IMPORTANT: DO NOT REMOVE THE WHIRLIGIG® TARGET GUARD COVER. THE ROTATING COMPONENTS UNDER THE COVER COULD CAUSE SERIOUS INJURY.

  • Page 17: W4005Nv46Ai /B - W400 Series Elevator Controller

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 8.4 W4005NV46AI /B – W400 Series Elevator Controller 8.4.1. W4005NV46AI /B Enclosure Installation a. The IP66 rating of the enclosure must be maintained. You must use the correct cable, glands and sealing arrangement and in accordance with the installation codes detailed in EN 60079.

  • Page 18: Warnings

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 9.5 Warnings • Analogue signals must be shielded if cables are longer than 10m • Digital signals can be shielded • Keep sensor wiring separate from high voltage cables •...
  • Page 19 The sensor is calibrated to switch to the alarm state when pressure exceeds 3.6kg. Should you require adjusting this value, please contact your 4B Representative for more information. Page 19 of 48...
  • Page 20 The system has an active self-checking mechanism between the sensors and the controller; however, 4B would still recommend checking if the Stop signal from the W4005NV46AI /B controller shuts down the elevator and that the alarm/fault relay signal is visible to the operators at least annually.

  • Page 21: P300V34Ai /B - Proximity Speed Sensor

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 9.7 P300V34AI /B – Proximity Speed Sensor Figure 11 - Speed Sensor Wiring Diagram 9.8 ADB910V3AI /B - Adjustable Depth Bearing Temperature Sensor Figure 12 - HBS Wiring Diagram...

  • Page 22: W4005Nv46Ai /B - W400 Elevator Controller

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 9.9 W4005NV46AI /B – W400 Elevator Controller 9.9.1. Overall System Wiring Schematics Figure 13 – Overall System Wiring Diagram Page 22 of 48...
  • Page 23 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 9.9.2. Motor Start / Stop Circuit Wiring Diagram (+24VDC Power) Figure 14 - Motor Start / Stop circuit wiring (+24VDC Power) Page 23 of 48...
  • Page 24 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 9.9.3. Motor Start / Stop Circuit Wiring Diagram (100-240VAC Power) Figure 15 - Motor Start / Stop circuit wiring (100-240VAC Power) Page 24 of 48...
  • Page 25 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM Warning: Contactor feedback voltage applied across pins 17 and 18 must be 24Vdc only! Voltage higher than this will damage this circuit and should not be used! Note: Please see section 7.3 - W4005NV46AI /B – W400 Series Elevator Controller for information on the relays Voltage and Current ratings.

  • Page 26: W4005Nv46Ai /B Controller Operation Description

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 10. W4005NV46AI /B Controller Operation Description 10.10 Overall Operation Description The W4005NV46AI /B controller provides a fully automated elevator dust explosion hazard prevention system. All the major elevator explosion hazard conditions are constantly monitored and the elevator is stopped when it is unsafe to carry on the operation.

  • Page 27: W4005Nv46Ai /B Controller Buttons

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 10.12 W4005NV46AI /B Controller Buttons MUTE Button TEST Button Long Press (5s) – Controller Short Press – Simple Alarm/Fault Reset after an Controller Test alarm shutdown All LEDs blink once It is not possible to re-start the Two Short Presses –...

  • Page 28: Settings Switches

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 10.13 Settings Switches The W4005NV46AI /B has all the adjustable settings available via the two switches on the PCB – SW1 is a rotary switch and SW2 is a DIP switch. Please see Figure 18 for the location of the two switches.
  • Page 29 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 10.13.2. DIP Switches (SW2) These switches are used to set the following settings: Switch Number Description Left Position Right Position Speed Detection Mode Single Speed Mode Differential Speed Mode...

  • Page 30: W4005Nv46Ai /B Calibration

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 10.13.2.4. PLC Protocol Selection The W4005NV46AI /B supports two of the industry’s major Industrial Ethernet protocols: ProfiNet and Ethernet/IP. 10.13.3. Fixed Settings There are a number of settings that are fixed within the unit and cannot be changed. It is very important that the user is familiar with these settings when operating the product.
  • Page 31 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM Underspeed Alarm – Belt Slipping 10.15.1. This condition is detected by constantly measuring the speed of the bottom shaft (single speed mode) or by comparing the speeds of top and bottom shafts (differential speed mode). The behaviour is different depending on the speed mode selected.

  • Page 32: Test Functionality

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM a) Open Circuit b) Short Circuit c) High Temperature Alarm The temperature value above which the alarm will be detected is configured as described in paragraph 10.13.1. The high temperature condition will not allow the elevator to start if detected when elevator is stopped.

  • Page 33: Alarm Shutdown Restart

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM The operator should stop the Elevator by pressing the Stop button on the control panel. This should remove the run signal from terminal 16 of the W4005NV46AI /B controller.

  • Page 34: Ethernet Data Allocation

    FTP server to store any files as it may become problematic to perform future firmware updates if not enough free space is left on the device. Please contact 4B sales support to obtain the firmware update guide.
  • Page 35 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM Special Commands Command ACK Table 19 – Ethernet Data Allocation (Output) Ethernet Data Allocation Table - Input Section Name Length (Bytes) Byte Offset Special Commands Special Command Number...
  • Page 36 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM When in Calibrating state (System State == CALIBRATING) this field represents the % of calibration process complete in 10% units. The value must be multiplied by 10 to display the % complete units.
  • Page 37 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 12.19.6. Muted This field is currently not implemented and has been reserved for future use. Please ignore the value of this field. 12.19.7. Speed Status Value State Name...
  • Page 38 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 12.19.13. Belt Alignment Status (same for the Head and Tail) Value State Name Description 0 OK No misalignment is detected 3 MISALIGNMENT ALARM Misalignment is detected 1,2 and INVALID STATE Invalid State - System Error Occurred.
  • Page 39 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM Settings – SW2 12.19.18. This is a BYTE length bit field. Below is the bit decoding information. See Table 13 – SW2 W4005NV46AI /B Settings for more information on settings controlled by SW2.

  • Page 40: Troubleshooting Guide

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 13. Troubleshooting Guide Condition Solution • Check that power is applied to the unit on terminals 25-28 Power LED is OFF • Check that the main input fuse F6 is not damaged •...

  • Page 41: Maintenance Procedure

    CIRCUITS IN ATEX ZONES IS PROHIBITED AND CAN LEAD TO AN EXPLOSION. Even though this system conforms to ISO13849 Cat 2 PLd, 4B recommends that the system and all of its components are inspected at least once every 6 months. Below is the procedure that the end user must adhere to in order to maintain the system in a safe state.

  • Page 42: Commissioning

    R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM 15. Commissioning DANGER: EXPOSED BUCKETS AND MOVING PARTS WILL CAUSE SERIOUS INJURY OR DEATH. THE OPERATOR MUST ALWAYS LOCKOUT POWER BEFORE REMOVING COVER OF THE INSPECTION DOOR OF THE ELEVATOR OR PERFORMING ANY INSTALLATION OR MAINTENANCE WORK.

  • Page 43: Revision History

    ORIGINAL INSTRUCTIONS 18. Revision History Revision Date Modifications 25 October 2013 Initial Document Release 27 January 2014 1) Added ProfiNet Support Section 2) Updated Warranty and Legal information 3) Minor change to +24V terminal numbers in the sensor wiring section 4) Minor changes to the TS commissioning and testing section 18 February 2014 1) ProfiNet section temporarily removed...
  • Page 44 1) Updated the Interlock wiring diagram – used the correct N/C contact symbol 15 June 2015 1) Added a note before the table of contents with a link to 4B website that has all the translations that are currently available 19 March 2016...
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  • Page 48 R9.6 – 22 May 2020 4B - W4005 BÜHLER ELEVATOR MONITORING SYSTEM With subsidiaries in North America, Europe, Asia, Africa and Australia along with a worldwide network of distributors, 4B can provide practical solutions for all your applications no matter the location.

This manual is also suitable for:

W4005v46-sys1/bW4005v46-sys2/bW400 seriesW4005nv46ai

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