GMV NGV A3 Installation, Use And Maintenance Manual

GMV SPA

FLUID DYNAMICS EQUIPMENTS
AND COMPONENTS FOR LIFTS

UNI EN ISO 9001
Certified Company

1.05

ENG

English

NGV A3 VALVE

NGV A3 VALVE MANUAL

INSTALLATION, USE AND MAINTENANACE

1 0991 483 EN

AVAILABLE WITH TANK TYPE

GL, F1, T2, T3, T4, MRL-T, MRL-H

1 0991 483 EN - 21.12.2011

ENG

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NGV A3 VALVE MANUAL

INSTALLATION, USE AND MAINTENANCE

INDEX

0 GENERAL SECTION 5

0.1 INTRODUCTION INFORMATIONS 5

0.1.1 DEFINITIONS 5

0.1.2 TERMS AND SYMBOLS USED 5

0.1.3 RULES REFERENCE 5

0.2 DOCUMENTS RELATED WITH INSTALLATION 5

0.3 SAFETY PRECAUTION DURING INSTALLATION 5

0.4 TOOLING 5

0.5 GENERAL ORDERS 6

1 FEATURES AND REQUIREMENTS 7

1.1 THE NGV A3 VALVE 7

1.2 THE FLUID 7

1.3 HOW THE NGV A3 WORKS 8

1.4 THE DOUBLE SAFETY 9

1.5 MAIN FEATURES 9

2 INSTALLATION OPERATIONS 10

2.1 HYDRAULIC CONNECTIONS 10

2.1.1 MINIMUM DIMENSIONS AND HOLES FOR POWER UNIT 10

2.1.2 INPUT AND OUTPUT -POWER UNIT SIDE 11

2.2 HYDRAULIC CIRCUIT 11

2.3 ELECTRICAL CONNECTIONS 12

2.3.1 CONTROL PANEL REQUIREMENTS 12

2.3.2 INTERVENTION TIME 12

2.3.3 FAULT SCHEMAS 13

2.4 OPERATIONS PRELIMINARY TO CONNECTION 13

2.5 SCHEMAS OF THE CONNECTIONS TO CONTROL PANELS 14

2.5.1 MAIN SCHEMA 14

2.5.2 CONNECTION SCHEMAS FOR SIGNALS 15

2.5.3 CONNECTION SCHEMAS FOR POWER 15

2.6 CONNECTIONS TO THE TERMINAL 16

2.7 CONNECTIONS TO THE CARD 16

2.8 CONNECTION OF HYDRAULIC PIPES 17

2.8.1 CONNECTION WITH FLEXIBLE HOSE 17

2.8.2 CONNECTION WITH A RIGID PIPE 17

3 NGV A3 CONTROL BOARD 18

3.1 ELECTRICAL FEATURES 18

3.2 PERFORMANCES 18

3.2.1 SIGNALLERS 18

3.3 CONNECTIONS 19

3.3.1 CONTROL PANEL INTERFACE 19

3.3.2 VALVE INTERFACE 20

3.3.3 USER INTERFACE 21

3.4 SIGNALS AND COMMANDS SEQUENCE 22

3.4.1 UPWARD DIAGRAM 22

3.4.2 DOWNWARD DIAGRAM 23

3.5 DECELERATION DISTANCES 24

4 ADJUSTMENTS AND TEST 25

4.1 ADJUSTMENT OF THE OVERPRESSURE VALVE (OPP/MPS) 25

4.2 RAM PRESSURE ON THE VSMA ADJUSTMENT 26

4.3 PIPE RUPTURE VALVE (VC) TEST 26

4.4 TEST OF DEVICES THAT PREVENT UNCONTROLLED MOVEMENT 26

4.4.1 PREREQISITES 26

0.1.1 26

4.4.2 TEST IN UP DIRECTION 27

4.4.3 TEST IN DOWN DIRECTION 27

4.5 TEST OF THE DOUBLE SAFETY SYSTEM 28

4.5.1 SIMULATION OF THE VRP FAULT 28

4.5.2 SIMULATION OF THE VB FAULT 29

4.5.3 TEST OF THE MONITORING SYSTEM 29

4.6 FAULT SIMULATION ON OUTPUT RDY AND RUN 30

4.6.1 TEST RUN ALWAYS ON 30

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4.6.2 TEST RDY ALWAYS OFF 30

4.6.3 TEST RUN ALWAYS OFF 30

4.6.4 TEST RDY ALWAYS ON 30

4.6.5 EXIT RUN-RDY TEST 30

5 PROGRAMMING 31

5.1 SYSTEM PARAMETERS 31

5.2 COMPLETE MENÙ 32

5.3 MENÙ 33

- 1 - DIAGNOSTICS 33

- 2 - ALLARM 33

- 3 - ALARM AND FAULT RESET 33

- 4 - ADJUSTMENTS 34

- 5 - SETTINGS 35

- 6 - UPWARD PARAMETERS 36

- 7 - DOWNWARD PARAMETERS 36

- 8 - OUTPUT FUNCTIONS 37

- 9 - TEST 37

- 10 - ADVANCED PROGRAMMING 38

5.4 CHART OF OUTPUT PROGRAMMABLE FUNCTIONS 38

5.5 CHART OF FAILURES 39

5.6 ACCESSORIES 39

6 MAINTENANCE AND FAULT ANALYSIS 40

6.1 PROGRAMMED MAINTENANCE 40

6.2 PERIODICAL MAINTENANCE AND CHECKS TABLE 40

6.3 MAINTENANCE SCHEDULES 40

6.4 FAULT ANALYSIS 42

6.4.1 TROUBLESHOOTING 43

6.5 ADJUSTING THE SENSORS 45

6.5.1 SENSOR S1 45

6.5.2 SENSOR S2 45

6.5.3 SENSOR S3 45

7 CERTIFICATES 46

ENG

All rights reserved.
Any kind of exploitation in any form and by any means is forbidden without a written permission of GMV Spa.
GMV Spa, within technical or manufacturing progress, reserves the right to modify parts or this manual without notice.
Drawings, descriptions and data included in this manual are indicatives.
For all the data not included in this manual refer to the documents of any single part.
To guarantee the products security, do not use spare parts not genuine or not approved by GMV Spa.
GMV Spa will not assume any responsibility if the instructions included in this manual are not observed.

/c2

DT 21/12/2011

2C

CR 21/12/2011

2c6

GF 21/12/2011

Information and support:

FLUID DYNAMICS EQUIPMENTS AND
COMPONENTS FOR LIFTS

UNI EN ISO 9001
Certified Company

GMV SPA

Via Don Gnocchi, 10 - 20016 PERO – Milano (Italy)
TEL. [phone] - FAX [phone]

http://www.gmv.it - e-mail: [e-mail]

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NGV A3 VALVE MANUAL

INSTALLATION, USE AND MAINTENANCE

Main acronyms and abbreviations

# Description

1

Pressure safety valve adjustment (pressure limiter)

2

Pressure safety valve adjustment (hand pump)

3

Ram pressure adjustment (only 2:1 acting jacks)

4

Shut-off valve for pressure gauge exclusion

5

Screw for rupture valve test

AF

Valve to prevent ropes slacking

BOX

Interface box (NGVA3 / Control panel)

C1

Chamber of the VRP

C2

Inlet chamber

C3

VB outlet chamber

C4

Chamber of the VRP pilot spool

CARD

NGV A3 control card

D

Downward signal

DN

Downward

FLT

Filter

ISP

Inspection gauge fitting

J

Jack

K

Non-return valve

M1

Spool of the VRP

MAN

Pressure gauge

ML

Manual lowering button

M, MP

Motor / pump

MPS

Maximum pressure spool

NGV-A3

NGV A3 Valve (Complete)

OFF

Not powered

ON

Powered

OPP

MPS pilot valve

P

VRP pilot spool

PAM

Hand pump

PT

Pressure transducer

RDY

Ready - Ready signal (card output to control panel)

RO

Oil heating resistance

RT

Motor thermistors

RUN

Run - Start signal (card output to control panel)

S1 (VRP)

Sensor to control the VRP closing

S2 (VBC)

Sensor to control the VB closing

S3 (VBO)

Sensor to control the VB opening

SM

Stepping motor

TO

Oil thermostat

TT

Temperature transducer

UP

Upward / Up - command of starting upward (card to control panel)

V0

Speed : high

V1

Speed : medium

V2

Speed : inspection

VAL

Valve NGVA3 (Valve only)

VB

Main flow adjustment valve

VC

Rupture valve

VMD

Downward solenoid valve

VR

Non-return valve (flow)

VR1

Non-return valve (inlet)

VR2

Non-return valve (outlet)

VRP

Non-return valve - controlled

VS

Upward signal

VS1, VS2

Pressure safety valve

VSMA

Lowering valve manual / electrical

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0 GENERAL SECTION

0.1 INTRODUCTION INFORMATIONS

0.1.1 DEFINITIONS

In this manual are used the definitions in EN81-1, EN81-2: Safety rules for the construction and installation of
lifts, EN81-28: Remote alarms on passenger lifts, EN1050: Safety of machinery - Principles for risk
assessment, ISO3864: Safety colours and safety signs, and the following apply:

0.1.2 TERMS AND SYMBOLS USED

NOTE

Indicates information which contents must be seriously taken in consideration.

WARNING

Indicates that the described operation is likely to cause, damages to the system or physical damages
if performed without complying with the safety standards.

0.1.3 RULES REFERENCE

For all definitions not included in this manual please refer to rules and local laws in force, following,
particularly:
EN 81-2: Safety rules for the construction and installation of lifts,
EN 1050: Safety of machinery - Principles for risk assessment,
ISO 3864: Safety colours and safety signs.

0.2 DOCUMENTS RELATED WITH INSTALLATION

The documents to use for the installation are those required by the EN81-2:1998 and by the rules in force,
particularly the following:

- THIS INSTALLATION MANUAL

- WIRING AND HYDRAULIC DIAGRAMS (EN81-2:1998 16.2 A) 6 AND 7).
All the documentation for a correct and safe installation, must be stored by the installation responsible.
Please remember that this documentation is considered part of the plant and must be complete, well stored
and unabridged in every part.
In order to maintain the readability, the documentation shouldn’t be damaged and shouldn’t have missing
parts. Moreover, do not tear or deteriorate sheets during consulting.

0.3 SAFETY PRECAUTION DURING INSTALLATION

WARNING

Before start all kind of installation operation.
ALWAYS verify that al the safety devices, mechanical or electrical, are active and working properly.

0.4 TOOLING

Use standard building-yard tooling for the installation.

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INSTALLATION, USE AND MAINTENANCE

0.5 GENERAL ORDERS

The valves shall be maintained in good working order in accordance with the European Standards.
To this effect, regular maintenance of the installation shall be carried out, to ensure, in particular, the safety
of the installation.
The safety of an installation shall take into account the ability to be maintained without causing injury or
damage to health.
Regular maintenance of the installation shall be carried out to ensure the reliability of the installation.
The access and the associated environment shall be maintained in good working order.
The competence of the maintenance person within the maintenance organization shall be continuously
updated.

NOTE

We inform the owner of the installation that the qualification of the maintenance organization needs to
be in conformity with the rules applicable in the country in which the installation operates; if no rules
exist, the qualification can be ensured by a certified EN ISO 9001 quality system supplemented if
necessary to take into account the specific features of the installation.

¥"

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1 FEATURES AND REQUIREMENTS

1.1 THE NGV A3 VALVE

The NGV A3 Valve with:

· the new Fluitronic digital technology.

· the “Stepping System” device

· the possibility to use ecological fluid or traditional mineral oil

· the working pressure between 12 and 45 bar

Guarantees :

- Increased reliability of the control system

- Best performance

- Reduction of costs

- Reduction of the installed power (up to 20%)

- Reduction of consumptions up to 40% (*)

- Reduction of the travel time

- Reduced use of heat exchangers

- Constant downward speed regardless of the load

- Compliance with various regulatory and environmental requirements

(Ex. compliance with the Directive 2006/118/EC on the environment)

- More safety thanks to double lock, already integrated in the product
conforms to the rule EN 81-2:2010

Offer:

- Ideal solution for renovation and MRL systems

- The most advanced system of control for lift

- Technology in line with the latest trends in the control field

- Speed up to 1 m/s

- Downward speed greater than the upward up to +20%

- Ride comfort comparable to a VVVF electric and no consumption in
standby mode

- Maintenance speed adjustable

(*) Maximum value reached under optimal conditions and in combination
with other products GMV

- The driving option

INTERNAL FEED BACK (CAR LOAD / TEMPERATURE)

The choice to immediate savings, interfaced with all, existing and
new systems
Not require encoder, reduce consumption up to 20% *
The valve, stored the operating characteristics, reading changing of
pressure and temperature, make the appropriate corrections to
obtain car speed profiles with low deviations from the ideal profile.

* Compared to a traditional valve

1.2 THE FLUID

GMV use and recommend an hydraulic fluid ISO VG 46 that :

· Thanks to classification as category HEES, as rule ISO-UNI 6743-4 and
its biodegradability index > 90%, according to standard CEC L33-A­93, is acceptable from an environmental point of view.

· Thanks to the synthetic base (ISO VG 46 ) and its viscosity index
(>140), higher than the traditional mineral oil, allowing greater stability,
ensuring better performance against wear and aging on systems as
lifts for persons and goods, in accordance with the environmental
directive 2006/118/EC.

· Thanks to a flash point above 220°C compared to the 140°C of the
traditional mineral oil it is safer and reduces the risk of fire.

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NGV A3 VALVE MANUAL

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1.3 HOW THE NGV A3 WORKS

The valve NGV is made with a non-return valve VR, a control spool VB controlled by a stepping motor and by
a system with pilot operated non-return valve VRP - P
(moved in opening by the electro-valve VMD)

Valve VR

It is a valve that prevent , during the downward, the oil inlet to the pump.
It forces the oil that comes from the VRP C2 to pass through the spool VB and then in the
C3 and in the tank T1.

Valve VRP-P

It is the pilot operated non-return valve, requested by rules.
During upward the valve works only as ON/OFF, the spool VRP opens or closes
depending on the oil that comes. Its position is determined by the ratio between the
pressure that develops in the chamber C2 and the one that occurs in chamber C1
During downward, instead, it opens the oil way to the valve block (chamber C2).
Its opening is made by the pushing of the piston P that is opened by the pilot operated
valve VMD

Spool VB

It’s the main part of the control block.
It adjusts the oil quantity that should be discharged and determines all the movements of
the car
Its movement is controlled by a stepping motor coupled to the spool VB, through a screw­nut coupling (necessary to transform the rotatory motion into translatory).
The spool adjusts both the upward phase (with a direct control of the oil that should be
discharged and, indirectly the oil for the cylinder) than that of downward (directly)

All the other valves have features of safety, pilotage, etc. For example :

MPS+OPP

Maximum pressure valve with pilot

5

Overspeed screw

VSMA

Emergency lovering valve

S1

S3

VMD

J

VB

VSMA

3

PT

FLT

VR

P

C4

C2

S2

C1

M1

OPP

MPS

C3

T1

VRP

5

BHBLS

505152

V-VSV0V1V2V3V+

A+PEA-A-

D+D-E+E-

1

3

NGV-A3-01

EXP VMD

D-E+E-

111221223132

4142

X14

X15

X12 X11 X10 X9 X8

X7

X13

A-

+ - T+ T- P+ P-+ -+ -

X1

X3

X4 X6X5

X2

J2 J3

J6

J1

131

3

SM

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1.4 THE DOUBLE SAFETY

For the double safety the system has two spools in series, the VRP and the VB.
Both work together to stop the car in different ways between upvward and downward

UPWARD

The spool VB controls acceleration and deceleration.
During the approach to the landing, the spool VB, will be almost fully open to discharge a quantity of oil
equal to:

Qt = Qp - Qc

where

Qt = Oil sent to the drain through the VB, Qp= Pump flow

Qc= Flow to the cylinder, corresponding to the car speed

The car stop at the landing is made by opening completely the VB and bringing the value of Qt = Qp. As a
result Qc becomes zero.
The car stops when the pressure of the chamber C2 become equal to the pressure of the chamber C1
(Static pressure of the system). In this case,

the VRP spool closes, because is pushed by the pressure and

by the spring, and the car stops at the landing.

DOWNWARD

The downward phase is simpler and, after the opening of the VRP spool, the car speed is controlled by the
VB spool. To a more opening of the spool corresponds an higher speed of the car
The phase of arrival at the landing is determined by the following events:

The VRP spool is opened by the push of the spools P, controlled by the VMD pilot valve
The VB spool closes to stop the car

The VMD valve, raised the landing, is de-energized and consequently the VRP spool closes.
During standard operation of the system, both upward and downward, the proper working of the two
spools (VRP and VB) acting in series, is controlled by three switches :

One, (S1) installed on the VRP, to control the full close position.

Two (S2, S3) installed on the VB, to control the full close and the full open positions

During all phases the system control that the spools reach the correct open and close position.
If this do not happen, the system send an alarm to the control panel, which must turn the system into the
out of service status

WARNING

Needful prerequisite of the control panel, when the system is outside of the doors unlocking zone, is
that it does not send commands to the card and/or the motor / pump.

1.5 MAIN FEATURES

Valve Type

NGV A3

Minimum operating pressure

12 bar

Maximum operating pressure

45 bar

Test speed

1 m/s

Temperature operating range

5°C - 70°C

Rated pump flow range

55 - 300 l/min

¥"

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NGV A3 VALVE MANUAL

INSTALLATION, USE AND MAINTENANCE

2 INSTALLATION OPERATIONS

ATTENTION

During the installation never exclude the safety devices and never connect the motor/pump directly to
the power supply

2.1 HYDRAULIC CONNECTIONS

2.1.1 MINIMUM DIMENSIONS AND HOLES FOR POWER UNIT

135

113

8352

131

18

14

105

137

15

10

1557

Ø9 x 4 fori

35

61.5

Ø28

M6

M6

16.5 41.5

19

24

48

74

1"1/4 G IN

1"1/4 G OUT

11.5

54.5

43.577.5

6

6

310

340

393

310

400

1"

1

4

IN

1"

1

4

OUT

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2.1.2 INPUT AND OUTPUT -POWER UNIT SIDE

1"

1

4

OUT

M8

OUT

1"

1

4

IN

M8

OUT

M8

OUT

M8

OUT

M8

OUT

3

4

"

OUT

12x8
PAM

PAM 12x8 IN 1” ¼ OUT 1” ¼ OUT ¾” OUT M8

2.2 HYDRAULIC CIRCUIT

M

VS1

VB

VR1

VR

ML

VSMA

PAM

VR2

VS2

VC 3006/B

ISP

MAN

PT

4

2

1

5

3

SM

TT

VAL

CARD

J

NGV A3

VRP

K

VMD

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2.3 ELECTRICAL CONNECTIONS

2.3.1 CONTROL PANEL REQUIREMENTS

The control panel must send to the power unit at least the following signals:

Mark Signal/comand Features
VS

Upward signal

10…40mA 12…48Vdc

V0

Speed : High

10…40mA 12…48Vdc

V1

Speed : Medium

10…40mA 12…48Vdc

V2

Speed : Inspection

10…40mA 12…48Vdc

D+

Downward signal

12…48Vdc, 60…180Vdc

D-

Downward negative pole

12…48Vdc, 60…180Vdc

The control panel must to receive and to understand correctly at least the following signals:

Mark Signal/comand Features
RDY

Ready

10mA…2A

RUN

Run

10mA…2A

UP*

Up

10mA…2A

OVL

Overload

10mA…2A

*Command used only to interface control panels that need different signals to start upward or doward travels

Outputs RDY, RUN and UP

- report to control panel about the system state,

- determine when the control panel must start or stop the motor /pump

WARNING

The control panel, when receive a FAULT signal from the NGV-A3 card (RUN and RDY output),
should not send commando to the valve and/or the motor/pump
In FAULT condition the motor/pump group should NOT be active

WARNING

To detect the unintended movement of the car the system use the circuit required by paragraph 7.7.1
and 14.2.1.2 of the rule EN 81-2:2010. This circuit, if it detects a movement of the car, with doors not
closed, outside the unlocking zone, prevents the control panel to send any command to the valve.
The system restore should be performed only by an authorized and properly trained person.

· Distance of setting: ± 200 mm

· Maximum time for the intervention of the circuit 270 ms

For other data or signals sequence see next paragraphs of this manual

2.3.2 INTERVENTION TIME

0

Origin

1

Car speed in the instant of
intervention of the bracking
device ≤ 1,3 m/s

2

Speed

3

Response time of the device that
detects the unintended movement
of the car ≤ 270 ms

4

Response time of the braking
devices ≤ 200 ms

5

Time

6

Time from start of the unintended
movement to the instant in which
the car sensor leaves the doors
area (dimension = ± 200 mm)

7

Stoping time of the car ≤ 500 ms

8

Point in which the car stops

0-8 between 0 and 8 the maximum

distance travelled is ≤ 100 cm

2

3

6

0

8

745

1

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2.3.3 FAULT SCHEMAS

A control panel installed with the valve NGV A3 must continuously monitor the signals RDY and RUN (UP)
that it receives from the card NGVA3-xx.
The control panel should go in error status, stop the system and do not send commands to the valve and / or
the motor / pump when, for more than 2s, signals RDY and RUN are simultaneously in the same condition.
The contemporary of the ON or OFF status require different behaviours, in particular:
If RDY and RUN are both in ON status, the control panel must detect the error, move the car to the nearest
landing and stop the system without allowing more travels;
If RDY and RUN are both in OFF status, the control panel must stop immediately the system and prevent any
further movement with the exception of the manual emergency operation.

FAULT

ALLOWED

ALLOWED

OK

OK

2s

2s

2s

2s

ON

ON

ON

ON

ON

ON

ON

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OUT : RDY

OUT : RDY

OUT : RDY

OUT : RUN

OUT : RUN

OUT : RUN

IN : VS / D

OK

RDY FAULT

RUN FAULT

2.4 OPERATIONS PRELIMINARY TO CONNECTION

0 - OFF

0 - OFF

+

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2.5 SCHEMAS OF THE CONNECTIONS TO CONTROL PANELS

In the following pages the schemas of the connections between valve / NGVA3 card and control panels

2.5.1 MAIN SCHEMA

T

TT
C°

BOX

QM

VAL

A3-Sxx-Wxx

UP

OVL

PMAX

PMIN

RUN

RDY

2A max

VSMA

VMD

PT

MAN

B

S1

SM

S3ò

S2ñ

3

5

1

4

ISP

PAMï

ML

BHBLS

505152

A+PEA-A-

D+D-E+E-

NGV-A3-01

EXP

µSD

COMM

PT01

111221223132

4142

X14

X15

X12 X11 X10 X9

X8

X7

X13

+ - T+ T- P+ P-+ -+ -

X1

X3

X4

X6

X5

X2

CAN BUS

D-D+ E+E-

VMD

X7

(1)

X6

D-E+E-

NGV-A3

S00 / S48 W25 / W50

CARD

¥"

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2.5.2 CONNECTION SCHEMAS FOR SIGNALS

Schema S00 Schema S48

V2

V1

V0

VS

QM

A+PEA-A-

D+D-E+E-

X4 X6

X5

CARD

S00

V+

J6

V2

V1

V0

VS

QM

A+PEA-A-

D+D-E+E-

X4 X6

X5

CARD

S48

J6

10...48 VDC

-

+

2.5.3 CONNECTION SCHEMAS FOR POWER

Schema W50 Schema W25

QM

A+PEA-A-

D+D-E+E-

X4

X6

X5

CARD

W50

J6

24 VDC = +/- 10%
50W

-

+

PE

EN81-2

J6=1-2
12- 48 VDC

QM

A+PEA-A-

D+D-E+E-

X4

X6

X5

CARD

W25

J6

-

+

24 VDC = +/- 10%
25W

PE

EN81-2

12- 48 VDC J6=1-2
60-180 VDC J6=2-3

VAL

NGV valve

QM

Control panel

BOX

NGV interface box

VSMA

Emergency downward valve

VS

Upward signal

CARD

NGV control card

VMD

Downward solenoid valve

V0

High speed

S1,S2,S3

Sensors (VRP,VBO, VBC)

SM

Stepping motor

V1

Medium speed

PT

Pressure transducer

D

Downward signal

V2

Inspection speed

(1)

Schema of the connections between D+D-E+E-VMD

TT

Temperature transducer

¥"