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DESIGNED BY:

CHECKED BY:
APPROVED BY:

PERFACE
This manual of D10C604 contains series of diagrams, wirings diagrams and safety control circuit etc. and details how to
install, operate, maintain or inspect our products. Read this manual before attempting to install, operate, inspect our products
and keep it correctly. Make sure understand all precautions and safety information before attempting to operate. If not, the
wrong operations could result in relative serious or minor injury, damage to the products.
ATTENTION:
Specifications are subject to changes without notice.

CONTENTS:
Chatper 1

Electrical Principle, Wiring and Installation Diagrams

Chatper 2

Brief Introduction on Control System

Chatper 3

Operation Instruction

Chatper 4

Commissioning Instruction

Chatper 5

Maintenance Instruction

Chatper 6

List of Control System Elements

Chatper 7

List of Fault Codes

Chatper 8

Electrical Sets

Chatper 9

Built-in Features of Control Cabinet

ATTENTION:
While escalator is starting to change speed from lower to higher, we can feel slight trembling on the steps, for the inverter
function does not match motor output.

We may change the function of the inverter to improve it.

1. Adjust Main Speed Frequency between 50HZ and 60HZ.


2. Adjust Any Arrival Frequency between 50HZ and 60HZ.

Chatper 1

Electrical Principle, Wiring and Installation Diagrams

Chatper 2

Brief Introduction on Control System

1. OVERVIEW:
Control system contains uper cabinet, lower carbiner, lighting system, safety switches, control buttons and wiring cables.
1) PLC programe is adopted to undertake conrol and is the heart of this system. The main controls are placed in upper

cabinet. For specific combination see List of Control System Elements.


2) Input voltage:
a. Driving circuit: four wire three phase
Phase Voltage: 380V(+7%~-7%)
b. Illumination circuit: two wire single phase
Voltage: AC200~AC250V
c. Grounded resistance 4
d. Isolating resistance in driving circuit:

0.5M

Isolating resistance in Illumination circuit: 0.25M


2. MAIN FUNCTIONS
1Start in varying frequency( starting )
2Normal running
3Inspection running

4Intelligent runningaccording to users need


5Phaseless, wrong phase and motor over heating protection devices.
3. ACCESSORIAL FUNCTIONS
1) Safety brake device
2) Lubricating system
3) Escalator speed (overspeed and underspeed) monitor and non-operational reverse monitor
4) Fault display function.
5) Handrail speed (overspeed and underspeed) monitor.according to users need
6) Travel direction light. according to users need
7) Auxiliary brake deviceOptional
4. SAFETY LOOP
1) The terminal codes including A34, B10, A35, A36, A37, B11 and B13 form a basic safety circuit. Don`t jump out.
2) From B05 to A34 through A16, A17, A18, A19, A20, A21, A22, A23, A24, A25, A26, A27, A28, A29, A30, A31, A32, A33,

they form a normal safety circuit. While the escalator is working in inspection mode, you may jump out them provisionally.
But don`t jump out while normally running.
3) The terminal codes of B13 and B12 are used for diagnosis and will not affect whenever in normal or inspection state.
4)After the normal circuit and the basic circuit switch on, the main contact KC pulls in, then the escalator start running.
5. MONITOR
1) Non-operational reverse monitor
2) Escalator speed monitor
3) Handrail speed monitor
6. ESCALATOR PROTECTION DEVICES
1) Phase failure protection device.
As the phaseless or wrong phase, the phase contactor actuates to stop the escalator.
2) Overload protection device of the motor
When the motor is overloaded and the temperation of the motor coil is too high, the guard actuates to stop the escalator.

3) Step chain breakage or extension protection


While the step chain is broken or it is elongated, the guard actuates to stop the escalator.
4) Comb plate protection
While the step is running to the comb, if there is something intercalated, the guard actuates to stop the escalator.
5) Handrail inlet protection
While the handrail is running to the inlet, if a finger is intercalated, the guard actuates to stop the escalator.
6) Step sinking protection
Check the clearance between the step and the comb in the inlet or the outlet. If the step is sinking, the switch will cut the
safety circuit to stop the escalator, then the fault display board shows the fault code.
7) Skirt board clearance protection
If something is interca
lated between skirt board and step edge, the fault display board shows the fault code
8) Motor speed monitor
If the speed is less than 80% of the rated or more than 120% of the rated, or in case of non-operational reverse, the guard

actuates to stop the escalator.


9) Emergency stop button
There are emergency stop buttons on the skirt board inlet and outlet.
10) Drive chain breakage protecion
While the drive chain is broken suddenly, the brake actuates to stop the escalator.
11) Auxiliary brake device
When drive chain is broken (after about 5m), the auxiliary brake actuates. If rise height is more than 6m, auxiliary brake must
be installed.
12)Step interstice light
The green light may remind passengers of being care of the interstice between the steps.
13)Step yellow demacration line
Remind the passengers of keeping far away from the skirt board
14)Handrail speed protection

If the handrail speed is less than the step speed,escalator stops. (option)
7. Intelligent escalators advantages
We find that the efficiency of the escalator without intelligent control is 50%, when it is in usual running. Because that it is
working all the time, even if no man take it. Lets compare non-intelligent escalator with the intelligent one. Hereinafter:
Non-intelligent escalator
On the assumption that Electricity fare: 0.7 dollar per degree,
Expenses per year :

motor power: 10KWworking time: 10 hours per day

360 days10 hours10 KW0.7 dollars=25200 dollars

Maitenance expense per year :

3000 dollars

Working total time :

10 years

Intelligent escalator :
Expenses per year :
Maitenance expense per year :
Working total time :

2520050%=12600 dollars
300050%=1500 dollars
1050%=20 years

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Chapter 3

Operation Instruction

1. ESCALATOR START
Start in varying frequency( starting )
1)Inspection running mode:
(1) Pull out the accessorial plug in the uper or the lower cabinet, and put on the inspection plug, take the inspection box in
hand.
(2) Switch on QS1 FU1, FU2, FU3, FU4, and FU5
(3)When the safety circuit is working well the fault display board show running state, and PC supplies stable power
make sure it displays RUN. Pull out the switch

of ST in the inspection box press SU or SD button. The process

order is like thisKC1KMBKMCKMU(KMD).

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2Normal running mode


(1 ) Make sure that both accessorial plugs are inserted.
(2) Switch on QS1,

FU1, FU2, FU3, FU4, and FU5.

(3) When the safety circuit is working wellthe fault display board shows running state and PC supplies stable power
mke sure it displays RUN insert start key. The process is like this KC1KMBKMCKMU(KMD).
3).Intelligent running mode
This kind of escalator has all the functions of the normal escalator.
(1)Simple running mode
It is a mode of normal escalators without photoelectric sensor. Insert the key and turn it to the direction of the excalator s
tendency ONCE and the escalator starts.
(2)Economic running mode
With photoelectric switches in it. Insert the key and rotate it to the direction of the excalators tendency TWICE, then the
escalator is going in the economic mode. When no man take it, after40ss full-speed running it changes into low-speed

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runing until stop button is pressed.


(3)Single direction running mode
With photoelectric switches in it. Insert the key and turn it to the excalators tendency THREE TIMES, then the escalator is
starting from low speed to high speed.

When no man take it, it will work for 40s and then automatically stop. When

people take the right direction, the escalator will start in low speed and then run in high; if people take the opposite direction,
the escalator will run in low speed for 12 seconds and then automatically stop and inform passengers the wrong direction.
(4)Double directions auto running mode
With photoelectric switches in it. Put the key into the keyhole and turn it to the direction of the excalator working FOUR
TIMES, then the escalator is starting up from low speed to high speed. When no man take it, it will work for 40s and then
automatically stop.
3) Travel direction light
There are direction indication lights on both sides: the red cautions the passenger not to take it; the green one indicates
passengers can take it.

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4). Intelligent state light (the comb lighting)


If there are the direction indication lights on both sides, the inside state light keeps lighting and it directs the passengers to
take the escalator.
5). Brake mode
When stop button is pressed, safety loop contactor actuates, or handrail speed monitor, step monitor and escalator speed
monitor actuate, the brake will stop escalator.

Chatper 4

Commissioning Instruction

I PLC PROGRAMMABLE CONTROLLER


CAUTION:

Check the specification of the PLC nameplate OR refer to other information.

Exsample of the PLC nameplate:


MODEL : CPM1A 30CDR

SUPPLY VOLTAGE : AC 100~240V

TERMINAL OUTPUT : DC 5~36V

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Input

Signal definition

State

Output

Signal definition

1000

State
on

0000

Speed check

flash

0001

Speed check

flash

1001

Auxiliary brake

on

0002

Up start

on

1002

Ring

ring on

Down start

on

0004

Inspection

off

1004

VF up running

on

0005

Safety loop input

off

1005

VF down running

on

0006

Inspection signal

off

1006

VF low speed running

on

0007

Brake feedback

on

1007

VF auxiliary output

on

0008

Handrail speed

flash

1100

Upper intelligent greenlight

Intelligent downwards

0009

Handrail speed

flash

1101

Upper intelligent redlight

Intelligent upwards

1102

Under intelligent greenlight

Intelligent upwards

1103

Under intelligent redlight

Intelligent downwards

0003

0010

0011

Clasp

1003

Lower throat intelligent


photoelectric
blocked on

on
Oil pump

Upper throat intelligent


photoelectric
blocked on

15

II.Escalator Speed Meter


Speed meter sensor connects 0000 with 0001 in PC; 0000 and 0001 light on when step wheel faces the sensor.
In normal running, the step wheel blocks the sensor every 0.55s.
In underspeed running, block intervals become longer. In case the interval is more than 120% of escalator speed, PC cuts
off output. Bell rings simultaneously to remind workers.
In overspeed running, block intervals become shorter. In case the interval is less than 80% of escalator speed, PC cuts off
output. Bell rings simultaneously to remind workers.
Realization of non-operational reverse prevention: When the escalator moves upward normally, 0000 of pc lights first and
0001 follows; When the escalator moves downward normally, 0001lights first and 0000 follows. If 0001 lights first when
moving upward, system will judge reverse and cut off output. When escalator stops, the bell rings 3 times.
Overspeed, underspeed and anti-reverse functions are still of effect during inspection running.
When overspeed, underspeed or anti-reverse actuate, system cuts off output and keeps. Manual reposition is required. For
reposition method see Chapter 11.1.

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IIIMethods of Overspeed and Underspeed Sensors Inspection:


(1)Underspeed: do photoelectric autotune first, remove wires of terminal A02 or A03. When escalator runs in full speed,
PLC system will cut off output in underspeed state and then stop.
(2)Overspeed: do photoelectric autotune first, and short connect terminal A01 and A02, otherwise A01 and A03. When
escalator runs in full speed, PLC system will cut off output in overspeed state and then stop.
(3)During anti-reverse running, in case 0000 lights first and 0001 follows, exchange the two time orders. Then output is cut
off and escalator is stopped.
(4)Signal shaking or non-signal are caused by sensor malfunction. In this case, after three times continuous stops, system
automatically cuts off sensor input--sensor now is of no effectand alarms for 1s after each star-triangle start. The alarm
reminds inspectors that photoelectric speed meter has broken down and overspeed, underspeed, anti-reverse functions are of
no effect. After replacement, do autotune once and system will matically generate protection function.
Note: When inspecting on various switches and functions, inspectors should take care of safety.
IV Fault Display Screen (XS-B)

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a) Fault displays rated voltage is AC8V or AC110V.


b) When safety loop gets through,

is displayed, the inside relays GKC and GKC1 pull in to connect terminal B11

with terminal B12.


c) When the switch in the safety loop actuate, corresponding fault codes are displayed on screen. (see diagram)
V After leaving factory escalators are affected by these factors: transportation, shipping, construction, etc. So before
installation, these components shall be readjusted: skirt clearance, skirting switch, comb teeth, comb switch, etc.
VI Alarm function
VII In normal running, insert the key and rotate it, bell rings and escalator stops. Pull out the key, the bell stops and
escalator continues running.
VIII In inspection running: Press the button for first time, the bell rings and escalator stops. Press the button for second time,
bell stops and escalator continues. Interval between first time and second shall not be longer than 3seconds, or memory will
be cancelled.
IX In intelligent running: Insert the key and rotate it in required direction. Bell rings and escalator stops. Pull out the key,

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bell stops and escalator runs in simple mode; rotate again, it is in economic mode; the third time in single direction mode;
the fourth time in double direction mode. (The last three-time rotating directions comply with simple mode direction.)
X Instructions on autotune:
All leaving factory escalators have passed autotune. Following is autotune method: In 5s after start rotate the key in one
direction until bell stops. Escalator begins to automatically distinguish the step and handrail sensor. If sensor breaks down
during autotune, system will abandon this sensor. If one sensor breaks down, escalator will only run in single direction
mode; if both sensors break down, escalator intelligence will stop in 40s and then run in simple mode. Non-passenger
running time is 40s. It can be changed. Do autotune. When bell stops ring, release the key. Block once the sensors at inlet
and outlet respectively and imediately press emergency stop button. The interval between the two blocks is a new time set.
In order to get back to default 40s, do autotune and press the emergency button without blocking sensors.
XI Other instruction:
1. If escalator stops for sensor reason, press emergency stop button and rotate the key in down direction until bell stops.
2. If escalator abandon sensors, press emergency stop button and rotate the key upward until bell stops.

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3. If escalator runs without but need sensor, do once autotune or press emergency stop button, insert inspection plug and at
the same time press up-and-down button on inspection box. Bells ring means OK.
4. If escalator slides more than 1.5m or overspeed is up to 140% of rated after stop, auxiliary brake will actuate and
escalator cannot restart. Rotate the key downward until bell stops, auxiliary brake will release. Thus escalator can move
upward at first and move downward in 15s.

Chapter5 Maintenance Instruction


I Everyday Maintenance:
Periodically inspect and adjust safety switches;
(2) Periodically dedust and maintain control screen and its interior electric contactors;
(3) Periodically inspect static brush and grounding terminals;
(4) If auto-greaser is installed, PC bases on running time and calculates working time. Auto-greaser fuels once for 10s every
24hs. If required, manual petrol can be undertook through pressing buttons. Users can lubricate according to requirements.

20

(Lubrication time and period can be set)


II Simple Maintenance Methods:
a) Unable to start
Electricity is normal and operation is right but the escalator still cannot start. In this case, please open front edge cover and
check if there are fault codes displayed on fault screen.
If there are fault cods, check PL input and output.
If trouble still exists, please contact supplier.
b) Stop during running
Confirm the electricity first. If the key switch cannot restart escalator, check if it is overloaded. If not, open front edge cover
and check if there are fault codes displayed on fault screen.
If there are fault cods, check PL input and output.
If trouble still exists, please contact supplier.
Note: Prohibit untrained person from undertaking maintenance;

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Prohibit non-electricity or inexperienced electrician from undertaking adjustment.

Chatper 6

No.

Name

List of Control System Elements

Model/Specification

Quant
ity

Installation position

KMU

Up contactor

AC110V

LC1/ D0901

Up control panel

KMD

Down contactor

AC110V

LC1/D0901

Up control panel

KC1

Control contactor

AC110V

LC1/D3201

Up control panel

KMC

VF output contactor

AC110V

LC1/D3201

Up control panel

KC

Safety loop contactor

AC110V

LC1/D0901

Up control panel

KMB

Brake contactor

AC110V

LC1/D0901

Up control panel

VVVF

Converter

VFD-A

KPH

Phase order relay

FD-BJ

Up control panel

FRT

Motor thermal relay

3UA59

Up control panel

Remarks
D5601 when in two-speed
drive and high power
D5601 when in two-speed
drive and high power
D5601 when in two-speed
drive and high power
D5601 when in two-speed
drive and high power
D5601 when in two-speed
drive and high power

Non when in VF

22

QF1-QF6

Fuse

DZ47-C6C3

Up control panel

XSI-U

Two-hole flat socket

220V

Up control panel

XSZ-U

Two-hole flat socket

220V

Up control panel

XSI-D

Two-hole flat socket

220V

Down control panel

XSZ-D

Two-hole flat socket

220V

Down control panel

XS-B

Fault display screen

Up control panel

PC

Programmable control

Omron CPM1A-30/20

Up control panel

QS1

Main power switch

1S3-32

Up control panel

QK2

Illumination power switch

DZ47/C6

Up control panel

TC1

Working transformer

Up control panel

TC2

Working transformer

Up control panel

MT

Alternating motor

AC380 triphase

Up machine room

MB

Brake motor

AC380 triphase

Up machine room

ZPQ

Imported brake coil

DC100V

Up machine room

KZD

Auxiliary brake

AC220V

Up machine room

XPI

Inspection addional plug

P20JHQ

Inspection socket

(30A)

BK-100output
110/110/8Vinput 380V
BK-100 output36V
input220V

60A when in two-speed


drive
BK250 when in two-speed
drive

23

JUZ

Auto fuel device

VERSA AC220V

Inside metal frame

XIB

Inspection operating lever

LA-4H

Manual
device

SXI-U

Inspection socket

P20JHA

Up control panel

SXI-D

Inspection socket

P20JHA

Down control panel

IU

Up panel emergency stop button

LAY5-M

Up control panel

ID

Down panel emergency stop button LAY5-M

Down control panel

DU

Upside emergency stop button

LAY33.14

Escalators up end

DD

Downside emergency stop button

LAY33.14

Escalators down end

SRST-U

Upside key switch

LAY3-Y

Escalators up end

SRST-D

Downside key switch

LAY3-Y

Escalators down end

UL

Up step illumination

AC220 20W

Inside upside of truss

DL

Down step illumination

AC220

Inside downside of truss

KRD

Up left throat switch

TR231/TRA236

KLD

Up right throat switch

TR231/TRA236

KLV

Down right thoat switch

TR231/TRA236

20W

inspection

In the skirt board of up


left throat
In the skirt board of up
right throat
In the skirt board of
down right throat

24

KRV

Down left thoat switch

TR231/TRA236

WRU

Up right skirt switch

LXW5-110

WLU

Up left skirt switch

LXW5-110

WRD

Down right skirt safety switch

LXW5-110

WLD

Down left skirt safety switch

LXW5-110

KDD

Drive chain safety switch

ZR231/ZRA236

CR

Right step chain safety switch

ZR231/ZRA236

CL

Left step chain safety switch

ZR231/ZRA236

SLD

Up right comb teeth abnormal


ZR231/ZRA236
switch

SRD

Up left comb teeth abnormal switch ZR231/ZRA236

SRU

down right comb teeth abnormal


ZR231/ZRA236
switch

TU

Up step trap switch

ZR231/ZRA236

SLU

Down left comb teeth abnormal


ZR231/ZRA236
switch

In the skirt board of


down left throat
Inside up right skirt
board
Inside up left skirt board
Inside down right skirt
board
Inside down left skirt
board
By drive chain
On the intension device
of right step chain
On the intension device
of left step chain
Down right of up comb
teeth front board
Down left of up comb
teeth front board
Down right of down
comb teeth front board
On the up-step down
bending ledge
Down left of down comb
teeth front board

25

TD

down step trap switch

ZR231/ZRA236

KAS

Right handrail breakage switch

JLXK-111

KAX

Left handrail breakage switch

JLXK-111

TK12NC4C KFA005

Handrail photoelectric speed meter

TK12NC4C

Up/downthroat photoelectric

EQ-34

Regualar power

S35-24 AC220V/DC24V
1.5A

CS0CS1 Motor photoelectric speed meter


CS2
CS 3
CS4
CS 5

SU

Inspection box up button

SD

Inspection down button

ST

Inspection box stop button

DF

Bell

AC220V 8W

Display screen interior relay

DC12V

GKC/1

Chatper 7

On the down-step down


bending ledge
Right handrail intension
device
left handrail intension
device
Inside metal frame

NPN output
NPN output

Thoat

NPN output
option

Inside metal frame


2

UP control panel

List of Fault Codes

26

Code

Electric safety switch name

Code name

29

drive chain safety switch

KDD

28

safety switch of up comb teeth abnormality(left right)

SRD SLD

27

up throat safety switch (left right)

KRD KLD

26

up right skirt board safety switch

WLU

25

up left skirt board safety switch

WRU

24

up step trap safety switch

TU

23

down step trap safety switch

TD

22

down skirt board safety switchleft

WRD

21

down skirt board safety switchright

WLD

19

down throat safety switch (left right)

KLV KRV

18

down comb teeth abnormality safety switch (left right)

SLU SRU

17

down step chain safety switch (right left)

CR CL

16
14
13

down handrail safety switch/middle skirt safety switch if with


KAS
handrial photoelectricleft
down handrail safety switch/middle skirt safety switch if with
KAX
handrial photoelectricright
motor thermal protection, phase order abnormality

KPHFRT

27

12

up and down panel or cover emergency stop action

Chatper 8

No.

Element

Model/specification

Quantity

IUDUIDDD

Electrical Sets

Remarks

No.

Big control
panel

20

Small control
panel

21

Key switch

GX-2

Photoelectric
switch

HDL-M30-15NAB

Micro-switch

D4MC-5000

4 fixing
nuts M6

22
23

2 more for
autowalk

24

Element
Model/specification
Fixing support for
photoelectric
switch
Support for drive
chain breakage
Support for step
chain breakage
Safety device for
step trap
Support for
handrail breakage

Quantity

Remarks

2sets
1set
2sets
2sets
2sets

28

Proximity
switch

Bell

Fluorescent
lamp

4sets

26

Support for throat


photoelectric

4sets

LX 25-11

ZR231/ZRA236

11

12 when in
two-speed
drive

27

Fixing support for


Binding
cable

TR231/TRA236

6 when in
two-speed
drive

28

Screw

UC-4-75

MW01-Y201/20W

M20
10

25

Support for skirt


board
micro-switch

TK-12 N4C

Travel switch

Option if
with
handrail
speed
meter

2sets

18

Plastic opening
M36

4 fixing
rectangle
supports
19 when in
two-speed
drive
4 when in
two-speed
drive

M435

42

Matrix AC13V

2sets

29

Indication light of
running direction

Round AC13V

2sets

30

Comb teeth light

AC13V

4sets

31

Throat
photoelectric

EQ34

With
screws
Subject to
length of
frame
46 when
in
two-speed
drive
Option

Option
for
intelligent
escalators

4sets

29

11

Inspection box

12

Static brush

1set
2

13

Travel lamp

1set

14

Single phase
plug

15

Belt

16

U-clamp

17

O-clamp

6-6copper contactor

18

Auxiliary
brake

AC220V

19

Cable

1 set of air
insert

200mm long
5mm wide
1-4fork copper
contactor

Including a
bulb of
36V/40W

12 for
two-speed
drive

6
1set

Option
Subject to
height and
angle

28

Chatper 9

Built-in Features of Control Cabinet

30

No.

Element

Control
transformer

3
4
5
6
7
8

Alternating
contactor
Mechanical
interlock
Over heating
relay
Phase order
relay
PLC
High switch
Main power
switch
Emergency stop
switch

BK-100

Qua
ntity
1

BK-100

Model/specification

LC1 D3201 AC110V

LA1 DN 22 C
LC1 D0601 AC110V

3
1

LA9-D09978C

3UA59/45A(SIEMENS)

JXD-A (2A/30V)

Omron CPM1A-30
DZ47-63 C3
DZ47-63 C6

1
4
2

LS-32/rated current 30A


LAY37PBC

1
2

Remarks

D4001 for
two-speed
drive

60A for
two-speed
drive

60A for
two-speed
drive

No.

Element

Model/specification
6copper cover

18

Cablepressing
cover

Quant
ity t
100

1copper cover

400

19

Non-core
rivet

410

30

20

Duct

55
M410

4m
32

M415

12

M315

M410

M4
M3
4

20
8
16

1 square
color group

100m

6 square
color group

5m

21

Screw

22

Thread
screw

23

Bolt

24

Gasket

25

Remarks

Cable

31

10

Air insert

11

P20411Q

3sets

26

3 phase socket

27

12

2 phase socket

28

13

Lock of cabinet
door

4-1

Fault
display
screen
Cable
pipe
Cable
shell

2
29

14

Wiring terminal

FJ-UKF-10B

10

15

Belt

5*200mm

300

30

16

Plug

14

31

17

Terminal cover

32

Nameplat
e
RC
capacitor
Terminal
white
piece
Metal
track

1
4

5m

10

0.5m

Main power switch /


inspection socket
220Vpower /
36Vpower / emergency
stop

LA4DA2U

Main terminal white


piece

10
1.5m

32