GLOBAL CONTROLS

G4 CONTROLLER

HANDBOOK

Version 2 - Modified by C.Gordon 23.1.2003

 GLOBAL G4 CONTROLLER

IMPORTANT

The information provided in this

handbook is intended to provide
only a general description of the
G4 Controller. In order to meet your
specific requirements, some design
or manufacturing changes may
have to be applied. In all cases you
should refer to the KCD’S and CD
wiring diagrams supplied with the
controller for accurate information
regarding that controller.

Global Control Technology Limited

reserve the right to alter, modify or
otherwise change the design or
component parts of their products
without notice.

OUR TECHNICAL HELPLINE IS OPEN:

0830 to 1630 Monday - Thursday

0830 to 1600 Friday
Telephone: 01642 702170
Fax: 01642 702189
E-mail: dave.belshaw@gct.co.uk

When Calling:
Please have the controller serial number available
CONTENTS

SECTION

1 General Guideline - External Connections & Suppression

2 Control Fuses

3 General Description of Controller Components

4 Speech Unit

5 Display Codes

6 Dip Switch Settings

7 Reset Mode

8 Auto Call Mode

9 Installation Test Mode

10 Standard Inputs & Outputs

10.1 Inputs
10.2 . Outputs

11 Understanding wiring diagrams

12 Shaft layout

13 Modifying or Adding Circuits

Please Note:

Your Global G4 (EMC Compliant) Controller has been carefully designed,

manufactured and tested to ensure many years of reliable service. Before
proceeding with installation, please read these notes carefully.

1. GENERAL GUIDELINES - EXTERNAL CONNECTIONS &

SUPPRESSION.

In order to avoid induced voltages affecting the operation of the microprocessor the following
preventative action should be taken:

When planning the trunking/conduit and wiring layout, ensure that the mains and motor
wiring runs are kept separated from the low voltage wiring.

Mains trunking/conduit entries into the controller enclosure should be made either in the
underside or in the lower half of the enclosure side. Keep mains wiring within the controller
enclosure away from the microprocessor.

Separate trailing cables must be used for high and low voltage circuits. The trailing cables
must not be tied or tie wrapped together except at the hanging point and entry into the
controller and car top/half way terminal box.

IMPORTANT

Any spare cores in the trailing and harness cables should be stripped and connected to earth at
both ends.

Suppression filters will be required for some external equipment connected to or located
within close proximity of the control panel, such as motors including door motors and cooling
fans, brake and retiring ramp coils. The supply of suppression devices for this equipment is
the responsibility of the installer, however provided we are made aware prior to despatch of
the controller our recommended types of filters will be shown on the CD wiring diagrams
against each item requiring suppression. If you require any further assistance please contact
our Technical Helpline.

In all cases suppression devices must be connected at the terminals of the external equipment
and not in the controller, half way or car top terminal boxes, e.g., a varistor, will be required
for a DC brake coil, this must be fitted across the coil terminals in the brake housing.
Similarly a 3 phase snubber or snubbers will be required for the main motor, these must be
fitted across the motor terminals. If any other high voltage of high current drawing equipment
is to be located within the vicinity of the lift machine room or shaft this may have to be
suppressed. If in doubt contact our Technical Helpline for advice.
Care must be taken when connecting the external wiring diagram to the control panel. If a
high voltage is connected to a low voltage circuit this may cause irreparable damage to the
microprocessor. Please note that shaft and car wiring high voltage terminals are coloured
GREY and low voltage terminals are coloured ORANGE.

Global Control Technology does not accept any liability whatsoever for damage caused to
equipment due to incorrect wiring.

2 CONTROL FUSES

The fuses fitted to the control panel must be correctly rated in accordance with our
instructions. Under no circumstances should indicated fuse ratings be exceeded.
Global Control Technology Limited will not except any responsibility for damage caused by
the incorrect fusing of the equipment.
3 GENERAL DESCRIPTION OF CONTROLLER
COMPONENTS.

Motor Overload O/L Thermal Overload. Always test at lowest setting

first and adjust upward to achieve correct trip time.

Phase Failure PFRR Phase Failure and Reversal Detection Unit

& Reversal Relay incorporating thermistor connections.

Power Unit PU This provides a stabilised +24v DC voltage supply to the

control circuits.

Transformer T1 This provides a 9v AC supply to the G4 microprocessor

board which converts this into a regulated +5v DC supply for
on board use.

CONTACTORS

Fast Contactor F Contactor energises after the up or down contactor is

energised, provided that the safety relay main lock relay,
and the inspection relay are energised.

Slow Contactor S Contactor energises when the up or down contactor is

energised and provided that the main lock relay and
safety relay are energised.

Up Contactor U Contactor energises when the up relay is energised or

up test buttons are held in, provided that the safety relay
and main lock relay are energised and the up inspection
limit is made when attempting to run in test mode.
Contactor is electricity interlocked with the Down
Contactor.

Up Aux Contactor UA Contactor energises via N/O contact on U contactor and

provides protection against mechanical failure of U
contactor.

Down Contactor D Contactor is energised when the down relay is energised

or down test buttons held in provided that the safety
relay and the main lock relay are energised and the down
terminal limit switch is made. Contactor is electrically
interlocked with the UP Contactor.
CONTACTORS FOR STAR/DELTA MOTOR STARTING

Star Contactor ST Energised with UP Contactor until Delta Timer times in

(normally 2 secs). Electricity and mechanically
interlocked with the Delta Contactor.

Delta Contactor DT Energised after the Delta Timer timed in (normally 2

secs). Electrically and mechanically interlocked with the
Star Contactor

RELAYS

Inspection Relay IR Relay is energised when in normal mode, and

de-energises when the test switch on the car top control
is switched to test position.

Down Slow & DSR Relay is energised when the down slow limit switch is
Reset Relay in the made position.

Up Slow &
Reset Relay USR Relay is energised when the up slow limit switch is in the
made position.

Final Limit Relay FLR Relay is energised when the up final limit is in the made
position.(Hydraulic Lifts only)

Gate Lock Relay GLR Relay is energised when all landing lock contacts and car
door contacts are made.

Floor Zone Relays FZ1/2 Relays are energised via zone switches which
make when the lift car is in the door unlocking zone.

Levelling Relay LR Relay is energised via LRA and a Floor Zone switch
which makes just before floor level, the switch should
set such that the lift car stops level as the magnet comes
off the switch. In order to provide a fail safe system both
the Floor Zone relays and the LR relay have to be
energised before the lift will attempt re-levelling.

Fault Relay FT The purpose of the relay is to prevent the lift operating
with a faulty levelling or zone switch, e.g. contact
welded together.

Power Supply Relay PSR Relay is energised after the main safety circuit. It
switches the 240V AC Supply to the 24V DC Power
Unit.
PILOT RELAYS

All pilot relays are energised via a command from the microprocessor. Each has a single
normally open contact. When energised a red LED adjacent to each relay illuminates to
provide confirmation.

Up Relay UR Contact is wired in series with the UP Contactor

coil.

Down Relay DR Contact is wired in series with the Down Contactor

coil.

Fast Relay FR Contact is wired in series with the Fast Contactor

coil.

Slow Relay SR Contact is wired in series with the Slow Contactor coil.

Door Open Relay DOR Contact provides a door open signal.

Door Close Relay DCR Contact provides the door close signal.

Safety Relay SAF Contact is in series with the speed and direction
contactors and prevents movement of the lift car if an
error occurs.

Matrix Indicator
Relays A-B-C These relays provide the binary output codes to
the Dot Matrix car position indicator.

Auxiliary
Levelling Relay LRA Contact in series with Levelling Relay enables
the microprocessor to initiate levelling if the
levelling conditions are correct.
4 SPEECH UNIT
The Global G4 has the facility to provide binary outputs plus a trigger signal for the
GLOBAL Clarity voice reproduction unit. This is wired internally in the controller with a pair
of terminal provided for an external speaker.
5 G4 DISPLAY CODES

The display codes are split into three categories which give information on Lift Status, Events
and Errors (failures)

Either may be displayed on it’s own but in most instances of events and failures the display
will flash between Status and Event or Error, dependant on the code, in order to provide the
information to the Site Engineer.

Examples:

Display flashing 21 and 77 would indicate that the lift is going down fast in the Auto Call
mode.
Display flashing 12 and 90 would indicate that the lift was going up in slow speed and the
running timer had expired.

STATUS CODES

CODE LIFT STATUS

11 Lift moving up fast.

12 Lift moving up slow.
13 Lift stopped. Last direction up.
14 Doors opening. Last direction up.
15 Doors open. Last direction up.
16 Doors closing. Last direction up.
17 Doors closed. Last direction up.
18 Lift waiting. Last direction up.
19 Lift levelling up.
21 Lift moving down fast.
22 Lift moving down slow.
23 Lift stopped. Last direction down.
24 Doors opening. Last direction down.
25 Doors open. Last direction down.
26 Doors closing. Last direction down.
27 Doors closed. Last direction down.
28 Lift waiting. Last direction down.
29 Lift levelling down.
34 Door C opening. Last direction up.
35 Door C open. Last direction up.
36 Door C closing. Last direction up.
37 Door C closed. Last direction up.
44 Door C opening. Last direction down.
45 Door C open. Last direction down.
46 Door C closing. Last direction down.
47 Door C closed. Last direction down.
EVENT CODES

CODE EVENT CODES

64 Auto fire return (If evacuation is also on lift)

65 Gate locks open (Manual gates)
68 Lift moving to home floor.
69 Evacuation/Auto fire return.
70 Lift on inspection.
72 Waiting for Pre-Locks to make.
74 Lift going to fire floor.
75 Lift on fireman’s control.
77 Automatic call generator operating.
79 Doors held open. ( D.O.push, photocell, door hold etc )
83 110% weight switch operated.
86 Lift resetting.
88 Priority control.
95 Priority control - Side C
99 Doors held open more than 25 seconds. ( D.O. Push, Photocell etc )

ERROR CODES

CODE ERROR CONDITION

50 Detect circuit error at slowing point.

51 Detect circuit error at floor level.
52 Detect circuit error while levelling. ( Hydraulic lifts only )
53 Short on lock circuit while doors open.
54 Thermistor tripped.
60 EN81 door unit failure.
67 Manual gates opened whilst lift moving.
71 Pre-locks failed to make up.
76 Pre-locks opened whilst lift moving.
78 Locks made with SAF relay de-energised.
80 Safety circuit open.
81 Door lock opened while lift moving.
82 Doors closed but door lock failed to make.
84 Final limit re-made. ( Hydraulic lift only ).
85 Fault limit de-energised at floor level.
87 Final limit open. ( Hydraulic lift only ).
89 Safety chain open.
90 Running timer expired.
91 Door open protection timer operated.
92 Door locks failed to make after three attempts.
93 Door close protection timer operated.
94 24V Missing.
95 Contact monitor fault
96 Levelling timer operated.
97 Stop button operated.
98 Stop button, locks, low pressure opened whilst running.
6 DIP SWITCH SETTINGS

Note!
Whenever Dip Switch changes are made set the numbers of floors, the system must be reset
by pressing the reset button, otherwise any changes will be ignored.

There are two sets of Dip switches located on the Global G4 Microprocessor Board. These are
marked SW2 and SW3.

The first set of dip settings are for a controller with a door gear, the second being for manual
gate jobs. These are typical dip settings and may differ, if this is the case the dip settings
should have been provided with the drawings.
 DEFINITIONS OF G4 DIP SWITCHES

SW2

DIP1 DIP2 No of Floors

OFF OFF Two
ON OFF Three
OFF ON Four

DIP3
OFF No approach opening
ON Approach opening

DIP 4 Not connected.

SW3

DIPS 1
OFF Homing floor set to 0 (The lowest floor is always designated 0)
ON Homing floor set to 1

DIPS 2 (Normally OFF)

OFF On run
ON No on run (GMV)

DIP3 DIP4 DOOR LAG TIME

OFF OFF 5 seconds
ON OFF 10 seconds
OFF ON 15 seconds
ON ON 30 seconds

DIP 5 (Normally OFF)

ON Installation test mode (Power on only)
OFF Normal lift operation

DIP 6 (Normally OFF)

ON Display off
OFF Display on

DIP 7 (Normally OFF)

OFF Auto-call mode OFF
ON Auto-call mode ON

DIP 8 (Normally OFF)

OFF Display lift status
ON Display floor position
Note - this dip does not work if the test dip 5 is on.
 DEFINITIONS OF DIP SWITCHES G4 - MANUAL GATES

SW2

DIP 2 DIP 1 No. of floors

OFF OFF Two
ON OFF Three
OFF ON Four

DIP 3 Not connected.

DIP 4 Not connected.

SW3

DIP 1 (Normally OFF)

OFF Homing floor 0
ON Homing floor 1

DIP 2 (Normally OFF)

OFF On-run
ON No on-run (GMV)

DIP 3 not used.

DIP 4 Gate open alarm dip switch

OFF Gate open alarm sounds after timer expired.
ON Gate open alarm sounds after timer expired and push pressed.

DIP 5 (Normally OFF)

ON Installation test mode on power on reset
OFF Normal lift operation

DIP 6 (Normally OFF)

ON Display off
OFF Display on

DIP 7 (Normally OFF)

OFF Auto-call mode OFF
ON Auto-call mode ON

DIP 8 (Normally OFF)

OFF Display lift status
ON Display floor position
Note - This dip does not work if the test dip 5 is on.
7 RESET MODE

The sequence of operation from switching the power supply on is as follows:

a) Lift at either Terminal floor level

On power up, the lift will reset immediately, if open, the doors will close and the position
indicator will display the correct floor legend. Reset is now complete.

b) Lift at or near Terminal Floor but not level

On power up, the doors will close and the lift will move to the opposite Terminal floor to
reset. On arrival at the floor the doors will open then close and the position indicator will
display the correct floor legend. Reset is now complete.

c) Lift positioned away from the Terminal Floors.

On power up the lift will descend to the lower Terminal floor to reset. On arrival at the floors
the door will open then close and the position indicator will display the bottom floor legend.
Reset is now complete.

NOTE!

During the reset cycle no car or landing calls will be accepted.

8 AUTO CALL MODE

Auto Call mode is a facility designed to help with testing the control system after
installation and is a useful aid for the Service Engineer when an obscure fault occurs.

To activate Auto Call mode switch SW3 DIP 7 ON, the display will flash 77 together
with the lift status code, e.g., flashing 77 and 18 indicates the lift is in Auto Call Mode
waiting at floor level after having travelled to that floor in the UP direction. Note! For
lifts with automatic doors, the doors will not open when the lift arrives at floor level.

Auto Call will place a call on the system 30 seconds after stopping and this will
continue for a period of one hour after which time the control system will revert to
normal operation. This feature was specifically designed to ensure that if the DIP is
left on accidentally, the lift would revert to its normal operation. For safety reasons
Auto Call cannot be reactivated after one hour cycle until DIP 7 has been switched off
and then on again, this ensures that the lift does not move unexpectedly.

On lifts with manual gates it is not possible to prevent people from opening the gates
and entering the lift, however there is an override feature such that if a car call is
activated within the thirty second waiting cycle, the lift will respond to the car call,
this would be particularly useful if you wished to keep lift disruption to a minimum
whilst monitoring the operation of the lift.

In Auto Call mode the control system places calls on in a set sequence, to ensure that
the lift travels to all floors.

Sequence of Call Generation

Lift serving 2 Floors =Calls are generated in this order: 0-1-0

Lift serving 3 Floors =Calls are generated in this order: 0-2-1-0

Lift serving 4 Floors =Calls are generated in this order: 0-3-1-2-0

9 INSTALLATION TEST MODE

Installation Test Mode is a useful facility for checking the external inputs to the
controller are correct.

Before switching to Test Mode the lift must be positioned floor level with the doors
closed. Test mode will not operate with the lift in any other position.

To activate the Test Mode, first make sure that the lift is at the bottom floor, with the
mains supply to the controller off. Next switch SW3 DIP5 ON position and switch
on the mains supply. If all the inputs are correct then the display will flash 00. If any
inputs are wrong, then the display will indicate the input code relating to the device
(see following section for input), e.g. if the display flashes 19 this indicates the up
slow limit is open, (up slow limit should be closed with the lift positioned at the
bottom floor). When the display flashes 00 all the inputs are correct.

The Test Mode can also be used for checking push wire connections, e.g., if the car
push 2 is pressed the display will show 02 providing the wiring connections are
correct.

All faulty inputs must be corrected and the display should be flashing 00 before
switching SW3 DIP 5 OFF, in which event the control system will reset.
10 STANDARD INPUTS & OUTPUTS

The table below indicates the microprocessor input and output codes which
correspond with the CN2 circuit board plug pins. All the inputs have a corresponding
green LED which illuminates to confirm the input is present. Whilst there are no
LED’s for the outputs on the main PCB, the outputs trigger relays on auxiliary
boards, each of which has it’s own red LED which is lit when the output is triggered.

Note! You are reminded to always check the KCD wiring diagrams for connections
on any particular lift controller as they may differ from those illustrated below.

All inputs switch positive +24 volts and the outputs switch negative to earth -VE.

10.1 INPUTS

Input Definition CN2 Plug PIN No. LED Illuminated Active

Car call 1 1P Green L1 +VE

Car call 2 2P Green L2 +VE
Car call 3 3P Green L3 +VE
Car call 4 4P Green L4 +VE
Landing call 1 5P Green L5 +VE
Landing call 2 6P Green L6 +VE
Landing call 3 7P Green L7 +VE
Landing call 4 8P Green L8 +VE
Up count & stop 9P Green L9 +VE
Down count & stop 10P Green L10 +VE
Floor zone switch 2 11P Green L11 +VE
FT circuit input 12P Green L12 +VE
DO push/Photocell 13P Green L13 +VE
Priority 14P Green L14 +VE
Inspection 15P Green L15 +VE
Auto fire return 16P Green L16 +VE
Gate locks 17P Green L17 +VE
Floor zone switch 2 18P Green L18 +VE
Up slow limit 19P Green L19 +VE
Down slow limit 20P Green L20 +VE
Final limit 21P Green L21 +VE
Door open limit 22P Green L22 +VE
Door close limit 23P Green L23 +VE
Move signal 24P Green L24 +VE
10.2 OUTPUTS

Output Definition CN2 Plug PIN No. Active

Car lamp 1 37P -VE

Car lamp 2 38p -VE
Car lamp 3 39P -VE
Car lamp 4 40P -VE
Landing lamp 1 41P -VE
Landing lamp 2 42P -VE
Landing lamp 3 43P -VE
Landing lamp 4 44P -VE
Position indicator A 45P -VE
Position indicator B 46P -VE
Position indicator C 47P -VE
Position indicator D 48P -VE
Speech A0 49P -VE
Speech A1 50P -VE
Speech A2 51P -VE
Speech A3 52P -VE
Speech A4 53P -VE
Speech enable 54P -VE
Direction departure UP 55P -VE
Direction departure DOWN 56P -VE
Safety relay 57P -VE
Up 58P -VE
Down 59P -VE
Fast 60P -VE
Slow 61P -VE
Door open 62P -VE
Door close 63P -VE
Level relay 64P -VE
SECTION 11 - UNDERSTANDING THE CIRCUIT WIRING
DIAGRAMS

The Key Circuit Diagrams (KCD’s) and the external wiring diagram (CD) are drawn
assuming the lift is at the lowest floor, with the doors closed and with the power
supply off.

The KCD is produced on A3 size sheets and every effort is made to detail all the
auxiliary equipment. KCD/1 generally details high voltage (240V AC) and KCD/2
low voltage (24v DC) circuitry.

A layout is also provided showing the position of all components in the control panel,
this is also on a A3 sheet.
SECTION 12 - SHAFT LAYOUT

The following is an example of a shaft layout and may differ from your controller so should be only
used as a overview of a typical switch operation.

B B B
B

CEILING (HEADROOM)
UP
3 R FINAL

2m TO SHAFT
R LIMIT
R R

UP SLOW
LIMIT &
R RESET

UP INSP.
LIMIT
(NO EFFECT
B ON NORMAL
RUN)

B B B
B
2 R
R R R

B Slowing
Distance

DOWN SLOW
LIMIT &
RESET
B

Set to Stop
Slowing Level RETIRING
Distance R RAMP ON
CAR
Must B B
B DOWN
B Overlap FINAL/ TERMINAL
1 R
Stop LIMIT
R Switches. R R

DOWN UP
COUNT ZONE ZONE
COUNT
STOP & SWITCH SWITCH
STOP &
LEVEL 1 2
LEVEL

Sample Shaft Layout for 3 Floor Controller

The previous drawing shows magneto switches with Red and Blue magnets arrangement as above to
make/break the switch which in turn operates a contact on the microprocessor board.

Example of operation

At Floor 1
Down Count Stop & Level (DCS) contact made.
Up Count Stop & Level (UCS) contact made.
Zone Switch 1 (FZ1) contact made.
Zone Switch 2 (FZ2) contact made.
Down Slow Limit (DSL) contact broke.

Call allocated for floor 2 - Lift sets off in UP FAST

DCS breaks  UCS breaks  FZ1 + FZ2 break  DSL makes
 DCS makes/breaks  UCS makes (count increments, lift slows)
 UCS breaks  FZ1 + FZ2 make  DCS makes (Doors approach open if set)
 UCS makes (lift stops, doors open if no approach)

Lift at 2, Call allocated for 1

DCS breaks  UCS breaks  FZ1 + FZ2 break
 UCS makes/breaks  DCS makes (count decrements, lift slows)
DCS breaks  DSL breaks FZ1 + FZ2 make  UCS makes (Doors approach open if set)  DCS
makes (lift stops, doors open if no approach)

Reset
Lift resets to lowest floor unless at lowest floor but not at floor level then reset to next floor up. Will
reset to top floor if at top floor level or will reset down to next floor if not at floor level. Reset will be
forced into slow at the Up/Down Slow & Reset limit.

Leveling (Hydraulics only)

If lift sink UCS breaks and up slow valve will open and motor will run up slow until UCS re-makes. If
lift rises above floor level DCS breaks opening down slow valve until lowering lift until DCS re-
makes.

Inspection
Will travel up slow until hits up inspection limit or down slow until hits down terminal/final limit.
SECTION 13 - MODIFYING OR ADDING CIRCUITS

Each controller produced is carefully tested using the particular KCD’S and CD
produced for it. If the controller does not perform in the manner you would expect or
if an auxiliary item is to be included post installation of the controller, DO NOT
attempt to modify the circuitry without first obtaining information from Global
Control Technology that the modification required can be incorporated within the
circuitry. Failure to do this may invalidate the guarantee.