A400E

MANUAL

Rev. 21-12-1999
 CONTENTS

INTRODUCTION

1 SPECIFICATIONS

1.1 CONTROL UNIT

1.2 ELEVATOR ALIGNMENT SENSOR

2 INSTALLATION INSTRUCTIONS

2.1 CONTROL UNIT

2.2 ELEVATOR ALIGNMENT SENSOR

3 ELECTRICAL WIRING

4 OPERATING INSTRUCTIONS

4.1 ADJUSTMENT OF ALIGNMENT SENSORS

4.2 ADJUSTMENT OF SWITCHES
4.3 THE TEST FUNCTION
4.4 STARTING AND ACCELERATING
4.5 NORMAL RUNNING
4.6 NORMAL STOPPING
4.7 MISALIGNMENT ALARM
4.8 MISALIGNMENT STOP (SHUT DOWN)
4.9 RESTARTING
4.10 TWO SEPARATE ELEVATORS
4.11 ONE ELEVATOR WITH FOUR SENSORS

5 FAULT FINDING

DRAWINGS

A ALIGNMENT SENSING POSITIONS ON UP LEG

B SENSOR POSITIONS FOR BELT ALIGNMENT ON STEEL BUCKETS
C SENSOR POSITIONS – SIDE VIEW
D SENSOR POSITIONS FOR BELT ALIGNMENT SENSING ON BOLTS
E SETTING UP SENSOR FOR BELT ALIGNMENT SENSING ON BOLTS
F BLOCK DIAGRAM AND SENSOR WIRING
G SUPPLY AND RELAY WIRING

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 A400 ELITE ALIGNMENT MONITOR

INTRODUCTION

The A400 ELITE is a microprocessor controlled unit which is able to accept signals of
alignment from one or two bucket elevators and is able to cause alarm and shutdown of
the elevator and or feeders, when hazardous conditions are detected. The control unit is
housed in a self contained wall-mounting enclosure, and the alignment sensors are
separate items for mounting on the elevators. The A400 ELITE will operate from 115v
to 230v AC or from 12v to 24v DC.

The alignment sensors operate in pairs to detect the correct alignment of elevator buckets.
The control unit can accept signals from the pairs of sensors which may be on one or on
two separate elevators. When both pairs of sensors are mounted on one elevator, they are
intended to monitor the bottom and the top of the elevator. When both pairs of sensors
are mounted on two different elevators, they are each intended to monitor the elevators
independently.

1. SPECIFICATIONS

1.1 The Control Unit

A plastic enclosure houses the electronics and terminal connectors. The unit contains a
printed circuit board to accommodate power supply circuitry, output relays,
microprocessor and terminals. A short ribbon cable is connected to the lid of the
enclosure where the indicator lamps are mounted. Adjustments are provided on the
printed circuit board for setting up. A magnetic ‘push button’ is mounted in the lid to
allow the unit to be tested during operation.

Electrical Supply – 115 to 230VAC +/- 10% 50/60Hz

- 12 to 24VDC +/- 10%
Power Consumption - 10VA/10 WATTS
Alarm Relay Contacts - 1 Pole normally open 8A@ 250VAC
Stop Relay 1 Contacts - 1 Pole normally open 8A@ 250VAC
Stop Relay 2 Contacts - 1 Pole normally open 8A@ 250VAC
Sensor Inputs - 12V DC Approx, Pulses. 20-4000 per min
Sensor Supply - 12V DC Current 150 ma available
Terminals - Power 4mm² 14 AWG max
- Signals 2.5mm² 16 AWG max Plug In
Protection - NEMA12,IP55,Class II DIVI,E,F,G
Height - 9.7”, 246mm
Width - 7.4”, 188mm
Depth - 4”, 102mm
Fixing Centres - 8.75” high x 4” wide, 222mm x 102mm
Cable Entry - 2 Holes 11/8” DIA, 28mm, ¾” CONDUIT
Weight - 3lbs, 1.3Kg

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Status Indicator Lamps - Viewed through front panel
- POWER
- SENSOR 1A
- SENSOR 2A
- MISALIGNMENT A
- SENSOR 1B
- SENSOR 2B
- MISALIGNMENT B
- ALARM
- STOP A
- STOP B
Magnetic Switch - TEST

Internal adjustments
- Misalignment Tolerance A Low/High
- Misalignment Tolerance B Low/High
- Alarm Delay Low/High
- Stop Delay Low/High
- Alignment Sensor Sensitivity Control 1A
- Alignment Sensor Sensitivity Control 2A
- Alignment Sensor Sensitivity Control 1B
- Alignment Sensor Sensitivity Control 2B

1.2 The Elevator Alignment Sensors

The sensor is designed to detect moving ferrous material which passes within its sensing
range. It will not detect plastics, rubber, stainless steel, aluminium etc, and it will not
detect a stationary or slow moving target. It is designed to detect steel elevator buckets,
either from the side of the elevator leg or through the elevator belt. It can also detect steel
bolts used to attach non-magnetic buckets to the elevator belt, by sensing from the back
of the belt. With two sensors correctly mounted, misalignment of the belt/buckets/bolts
can be detected.

Contained within the probe body is a powerful magnet and an electronic detector circuit.
The body itself is manufactured from tough plastic and all of the components are rigidly
potted in epoxy resin. None of the materials used in the sensing end of the sensor are
capable of producing a friction spark from accidental collision within the elevator. A
four core cable is permanently attached to the outer end of the sensor. A small LED is
moulded into the outer end of the sensor and this is arranged to flash each time that a
target is detected. A clamp block is provided to attach the sensor to the elevator panels
and to allow easy adjustment of sensing distance.

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Electrical Supply - 12V DC Approx from Control Unit
Supply Current - 35ma
Output Signal - 12V DC Approx – Pulsed
Min target size - 1” (25mm) dia
Max target distance - 2” (50mm) approx
Min target speed - 20 Ft/min (6 metres/min)
Max rate - 2000 per min
Sensitivity Control - from control unit

2 INSTALLATION INSTRUCTIONS

2.1 The Control Unit

The Control Unit box should be installed in a suitable control or starter switch room and
mounted at an eye level position so that the warning lights can be readily seen. The box
should have sufficient space to open the lid for wiring and adjustment. An audible alarm,
hooter or visual indicator lamp can be installed in or outside of the control room.

The Control Unit is susceptible to static voltage. Connection of a clean ground to

terminal 29 is essential for optimum performance. Prior to this connection, static
handling precautions should be taken.

2.2 The Alignment Sensors

. Two alignment sensors are required to be mounted on each elevator.

. Install the 2 sensors in the ‘up’ leg trunking or tight belt side, immediately above
the boot, as shown in drawing A or in a similar position immediately below the
head.
. For side mounting for steel buckets, a sensor should be installed at each side of
the trunking, either in line with the centre of wide spaced buckets at a distance of
no more than 2” from the buckets, or with the outer edge of the sensor in line
with the tips of the bottomless or very closely spaced steel buckets at a distance of
no more than 1½” from the steel buckets, and by backing the probe out, obtain the
best position for the minimum sensitivity requirement of the sensor. Set the
sensor so that it does not have to work at maximum sensitivity, as shown in
drawings B and C. Always ensure that in the worst case of elevator
misalignment, the sensors will not be damaged within the elevator.

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. For rear mounting for plastic buckets with steel bolt heads, a sensor should be
installed on either side of the rear of the trunking, each about ½” to the outside of
the end bucket bolthead, as on drawing D. Each sensor should be flush or
protrude slightly through the trunking and be a maximum of 1” from the bucket
bolt head as shown in drawing E.

3 ELECTRICAL WIRING

Refer to Drawings F & G

Mount a conduit junction box within 6ft (2 metres) of each sensor – generally one
junction box can be used for a pair of sensors. Connect the sensor cable to the junction
box using sealing glands and protect the cable from damage. If flexible conduit is to be
used, a conduit adaptor is available to attach to the sensor. Connect the junction box back
to the control unit. We strongly recommend the use of shielded wires when wiring the
alignment sensors to the control unit. When terminating conduits at the control unit,
ensure ground continuity by using a suitable bushing such as Allen Bradley 1490-N19.

When installing the equipment in an area which is likely to be hazardous from Ignitable
Dusts, use liquid tight conduit and fittings and follow all local codes.

4 OPERATING INSTRUCTIONS

4.1 Adjustment of Alignment Sensors

Note : If the control unit is mounted in a hazardous area, switch the electrical supply OFF
before opening the lid of the control unit to make the following adjustments. Close the
lid before switching the electrical supply ON. Repeat this each time an adjustment is
required inside the control unit.

Ensure that the Alignment Sensors have been correctly mounted as described in para. 2.2.
At this point it will be necessary to start the elevator. Note that until the A400 Elite is
correctly set up and adjusted, the elevator may not run continuously subject to the method
of wiring to the motor starter. With the elevator running and correctly aligned, adjust the
Sensitivity Control potentiometers in the control unit as follows. Turn the potentiometer
for the relevant alignment sensor fully anti clockwise; at this position, the relevant sensor
indicator lamp on the lid of the control unit will probably not be flashing. Increase the
potentiometer in a clockwise direction until the indicator lamp flashes steadily then
increase a little more for allowable misalignment. Repeat for all other sensors. When all
sensor adjustments are complete, test the complete assembly as follows. With the
elevator running correctly and aligned correctly, slacken the clamp screw on each
alignment sensor in turn, slowly pull out the sensor, measuring how far the sensor is
withdrawn until the LED on the sensor (and the lamp on the control unit) no longer
flashes steadily. This is the amount of tolerable misalignment. If this amount is too
great, reduce the control potentiometer setting by turning slightly anti clockwise. If this
amount is too small, increase the control potentiometer setting by turning slightly
clockwise. When the adjustment is completed, clamp the sensor back in its original
position. Repeat for all sensors.

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4.2 Adjustment of Switches

Ensure that the electrical supply to the control unit is OFF.

Open the lid of the control unit and locate four small slide switches, near the left hand
row of terminals. Initially all four switches should be in the left (LOW) position.
SWITCH 1 (Top) Sets the allowable misalignment tolerance for sensor
1Aand 2A. Set to the right (HIGH) position only if
nuisance alarms are generated because of bucket/belt
problems
SWITCH 2 As for SWITCH 1 but for sensors 1B and 2B.
SWITCH 3 Sets the delay between detecting a misalignment condition
and energising the ALARM RELAY.
Low = 10secs, High = 20secs
SWITCH 4 (Bottom) Sets the delay between energising the ALARM RELAY
And de-energising the relevant STOP RELAY.
Low = 10secs, High = 20secs.

4.3 The TEST function

4.3.1 Normal Test

The A400 ELITE is equipped with a self test function, initiated by the magnetic
‘pushbutton’ on the lid of the control unit. When the Test Magnet is touched on the
TEST target, the Alarm lamp flashes and then the following automatic test is initiated as
the Test Magnet is removed.
1. All lamps illuminate – the ALARM lamp continues to flash
2. After 5 seconds all lamps return to their normal conditions

This test can be performed when the elevator is running or stopped and tests the correct
function of the microprocessor and of all lamps.

4.3.2 Extended Test

If the Normal Test is initiated as in 4.3.1 and if the Test Magnet is touched on the TEST
target again, while the ALARM lamp is flashing, the extended test operates as follows:
1. All lamps illuminate – the ALARM lamp continues to flash
2. The Test Magnet is applied again
3. The ALARM and STOP A lamps flash for a further 5 seconds (8 seconds total
time)
4. The ALARM RELAY and STOP RELAYS are inverted and the ALARM,
STOP A and STOP B lamps flash
5. After 3 seconds all lamps and relays return to their normal conditions
If this test is performed when the elevator is not running, the Alarm will sound but the
STOP RELAYS will have no effect on the elevator. If this test is performed when the
elevator is running, the Alarm will sound and the STOP RELAYS will stop the elevator!
This test should be performed on a regular basis to check the safety of the installation.

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4.4 Starting and Accelerating

The A400 ELITE automatically detects that the elevator is running by testing the signals
from the Alignment Sensors. If two pulses are received from either of the ‘A’ sensors
within the allowed start up time (preset to approx 10seconds), the elevator is considered
to be running and the STOP A relay will energise to maintain the motor starter circuit.
Similarly the ‘B’ sensors will energise the STOP B relay.

4.5 Normal Running

As long as the relevant sensors both receive the correct number of pulses, the elevator is
considered to be running normally and the relevant STOP relay will remain energised and
the STOP inidicator lamps will remain off.

4.6 Normal Stopping

When the elevator is stopped by means of the motor starter, when the pulses cease from
both sensors, and after a further 10seconds the relevant STOP relay will de-energise,
ready for the next starting operation. If the elevator is re-started within this 10 second
delay, as the STOP relay is still energised, starting is still enabled.

4.7 Misalignment Alarm

If the ratio of the pulses from a pair of alignment sensors falls to a value which is less
than that set by SWITCH 1 or SWITCH 2 as appropriate, the elevator is in misalignment
and the MISALIGNMENT A or MISALIGNMENT B lamp will be energised. If the
lamp remains energised for a time which is longer than that set on SWITCH 3, the
ALARM RELAY will energise. If the misalignment condition subsequently corrects
itself, the MISALIGNMENT A (or B) lamp and ALARM RELAY will de-energise.

4.8 Misalignment Stop (Shutdown)

If the alarm relay remains energised for a time which is longer than that set on SWITCH
A, the relevant STOP RELAY will de-energise and the relevant STOP lamp will
energise. When the elevator has stopped and the pulses have ceased on the relevant
sensors, the relevant STOP lamp and MISALIGNMENT lamp will flash to indicate the
reason for the stop condition.

4.9 Restarting

If the elevator has stopped because of a misalignment condition as in 4.8 the lamps
described above will remain flashing indefinitely. When the elevator is re-started, as
soon as the normal starting conditions described in 4.4 are met, the flashing lamps will be
cancelled.

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4.10 Two Separate Elevators

If the A and B sensors are fitted to two separate elevators, the above descriptions 4.1 to
4.9 apply separately to each elevator except that the ALARM relay and lamp are common
to both elevators.

4.11 One Elevator with Four Sensors

If the A and B sensors are mounted on the same elevator, (for example A at the top and B
at the bottom) the control unit will differentiate between misalignment faults at the two
sensor locations. Normally, the two STOP relays would be connected so that both can
stop the elevator.

BRAIME ELEVATOR COMPONENTS LIMITED

HUNSLET ROAD ♦ LEEDS LS10 1JZ ♦ ENGLAND
Web: http://www.braime.com ♦ Email: elevators@braime.co.uk
Tel. +44 (0) 113 246 1800 ♦ Fax. +44 (0) 113 243 5021

4B COMPONENTS LTD
729 SABRINA DRIVE ♦ EAST PEORIA, IL 61611-3578 ♦USA
Web: http://www.go4b.com ♦ Email: go4b@aol.com
Tel. 309 698 5611 ♦ Fax. 309 698 5615

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 CHECKLIST
For problems after initial start-up

1. Are all the buckets magnetic (steel) or non-magnetic (plastic, rubber or stainless
steel )? If magnetic, ie steel, the Alignment Sensor should be directed at the
bucket as in drawings B and C. If non-magnetic, the Alignment Sensor should be
directed at the steel bolt heads as drawings D and E.
2. Are all the buckets present on the belt (none missing) and equally spaced?
3. Is there excessive interference on the electrical power supply? Power
conditioners and surge (spike) suppressor may have to be fitted.
4. Has the wiring for the Sensors been routed away from power cables? See
paragraph 2.2.
5. Are the Sensors mounted away from plastic abrasion liners (which could cause
static interference), electric motors and other magnetic fields?
6. Is the A400 Elite circuit properly grounded?
7. Is the elevator leg grounded to prevent static build-up?
8. Is the belt running true?

9. Does the belt stay in alignment when material is fed into the elevator leg?
10. Is the elevator leg belt tightened up sufficiently to prevent belt slip and
misalignment?
11. Check that there is no tramp metal in the intake, no loose head pulley lagging, and
no loose abrasion liners.
12. Have the Sensors been mounted rigidly and free from vibration?
13. Check that the Sensors do not foul the buckets or the bolts.
14. If sensing on the bolt heads, are the Sensors positioned on the outside of the bolt
heads as drawing E?
15. Is the Micro-processor control unit overheating, if so mount in temperature-
controlled environment of maximum temperature 104°F (40°C).
16. If the elevator bucket bolts are non magnetic (stainless steel), insert mild steel
fender washers under the bolt heads as targets.
17. Check that high powered ‘Walkie Talkie’ radios are not operated immediately
near the A400 Elite control unit or Sensors as this will affect the performance.
18. If your bucket elevator has a weighted take up please ensure that there is
sufficient weight on it to prevent belt slip .

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5 FAULT FINDING CHART

SYMPTOM CAUSE REMEDIAL ACTION

LED on Alignment Sensor Sensor too far away from Move Sensor closer to
does not flash buckets bucket if possible
Sensor adjustment incorrect Turn Sensitivity Control
Wiring connection faulty clockwise
Check wiring

LED on Alignment Sensor Sensor too close to buckets Move Sensor away from
flashes excessively Sensor adjustment incorrect buckets
Interference in wiring Turn Sensitivity Control
anti clockwise
Use shielded cable and rigid
conduit

Sensor LED on Control unit Elevator is not running See section 1 above
does not flash Sensor not operating Check wiring
Wiring Fault
Sensor connected to wrong
terminals

Wrong Sensor LED on unit Sensor connected to wrong See drawing F

flashes input

Alarm LED on Belt misaligned Check belt

Stop LED on Stop condition occurred Check motor starter

Belt misaligned Check belt

Elevator fails to start Check wiring

Wiring fault

Elevator starts but fails to Belt slipping Check belt

keep running Start signal too short Wait for minimum of two
pulses before releasing start
button
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