51109 Köln St. Asaph, Denbigshire LL17OLJ

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1 Commissioning the Digital Shaft Copier (DSC) Kollmorgen Steuerungstechnik KOLLMORGEN LIFT CONTROLS Broichstraße 32 Unit 17, St. Asaph Business Park Köln St. Asaph, Denbigshire LL17OLJ Telefon +49 (0) United Kingdom Telefax +49 (0) Telephone Fax info@kollmorgen.de KOLLMORGEN Steuerungstechnik Köln / 18. August 2000 / Do_ds3ke

2 Contents 1 Short introduction Commissioning Checking the connections of the signals Checking the basic settings Inputting the travel height Setting the speed of the learning travel Activating the learning travel Setting the slowdown distances Determining the V-fast off slowdown distance Determining the V-intermediate off slowdown distance Determining the V-slow switch off values Setting the minimum distance for starting with V-fast or V-intermediate Checking the ride quality Measuring the floor level difference Correcting the floor level values Setting the relevelling ranges Activating relevelling Cecklists of the Commissioning Checklist for learning travels Checklist for correcting floor level values Checklist for re-leveling settings Appendix Position graph Configuration of the Digital Shaft copier (DSK) DSC connection types Overview of the DSC module Description of the DSC LEDs Selecting the incremental encoder and speed governor Notes on signal routing August

3 18. August Short introduction commissioning DSC Steps of the commissioning DSC (Detailed description see: commissioning DSC -> Chap....) Check this signal connections. (-> Chap. 2.1) Check this basic settings. (-> Chap. 2.2) Set the travel high [cm]. (-> Chap. 2.3) Confirm the sp. of the learning travel. (-> Chap. 2.4) Start the learning travel. (-> Chap. 2.5) A1* Basic setting lift no. of stops... total high... cm learning travel speed... learning activated 13 A Terminals (control) shaft copier signals 13 B Basic setting lift 15 A** type of selector select. values: V-slow V-intermediate V-fast 15 B** S 71 S 72* * only by safety circuit ** pre-limit switch only by short distances at top- / bottom- level Basic setting lift type of drive... 1 Short introduction MPK 3000

4 18. August Set the slowdown distances (Upward-and downward- direction) (-> Chap. 2.6) Set the minimum distances for starting with V-fast / V-intermed. (-> Chap. 2.7) Enter the floor level difference (Upward-and downward- direction). (-> Chap. 2.9) Start the correction of the floor level values. (-> Chap. 2.10) Set the releveling ranges (Upward-and downward- direction) (-> Chap. 2.11) Set the function "releveling active" to "Yes". (-> Chap. 2.12) V-fast off UP start speed V-fast from floor level difference Lev. 1 down... mm floor level correction releveling releveling UP on vs. fl. lev.... mm releveling active YES V-intermed. off UP start speed V-intermed. from Drive to each floor in the upward and downward direction. Mearsure the floor level deviation. ( Take care that the relevelling is not active!) (-> Chap. 2.8) floor level difference Lev.... down... mm Drive to each floor in the upward and downward direction and check the floor level. Repeat the steps 8-10 if necessary. releveling releveling UP off vs. fl. lev.... mm V-slow off UP These settings are necessary, if the shaft contens "short distances". This function need a saftey circuit! MPK 3000

5 2 Commissioning Note: The DSC already contains test values entered during a preliminary check. These are not default values for the DSC and must be changed! 2.1 Checking the connections of the signals Correction switches (13A /13B) installed und connected short distance at the bottom level: pre-limit switch (15B) installed and connected short distance at the top level: pre-limit switch (15A) installed and connected zone switch S71 or S71 & S72 installed and connected (see 4.3 and electrical drawings) outputs A/B of the encoder connected (see 4.3 and electrical drawings) 2.2 Checking the basic settings Before the values for the incremental DSC are set, the configuration of the lift system must be checked using the following basic settings. Changes made under these menu items only become effective after a RESET. Furthermore, the drive values in the main menu "" must be matched carefully as they decisively influence the running characteristics. Number of stops Check the number of stops Table of entrances Check the door openings are correct for door side 1&2 Type of selector Check that the selector type is set to Digital selector Type of drive Check that the drive is set correctly ie AC variable freq. Basic setting Default setting Lift No. of stops 2 table of entrances Type of selector Type of drive Auto with limit switch Profile copier Cable, open-loop 18. August

6 2.3 Inputting the travel height The travel height is calculated from to the distance between the sill on the lowest level and the sill on the highest level. The travel height should be calculated (in cm) as precisely as possible, as it is used as a basis for determining the resolution of the incremental encoder. Digital selector Total high 2.4 Setting the speed of the learning travel Specify the speed of the learning travel. Note that not every drive motor is designed for learning travels at low speed (Advised setting V-... (intermediate)). Attention: Select v1 for the learning travel if switches S15A and / or S15B are present. If the learning travel starts with v2 (default setting) the lift may overtravel the terminal floors. Digital selector Learning travel speed 2.5 Activating the learning travel The learning travel is for precisely recording the positions of each zone in the shaft (S71 or S71 & S72). It can be activated irrespective of the status of the lift car. Digital selector learning activated 18. August

7 The learning travel consists of three phases: Phase 1: Phase 2: Travel to the lowest zone if the lift is not already in the zone. Upward travel to highest zone The start of every zone is registered with the corresponding counter reading (S71 or S71 & S72). Phase 3: Downward travel to lowest zone The start of every zone is registered with the corresponding counter reading (S71 or S71 & S72). The learning travel can be aborted by activating the test/normal switch (insection). Errors not related to DSC operation (e.g. a lock interruption, tacho fault) also cause the learning travel to be aborted. After an abort, the learning travel cannot be continued, and must be reactivated from the menu. After the learning travel has been executed correctly, the message "Lift ready to travel" appears on the lift status display. If the learning travel has been aborted or its results are invalid, the message "Blocked due to dig. selector" appears on the lift status display. The cause of the error is stored in the event log. If the lift has already made a successful learning travel it will keep these values until a full completion of all three phases of a new learning travel overrides them. This keeps the lift ready for operation even when a learning travel is aborted. The pulses from the incremental encoder and the travel height are used to calculate the encoder s resolution which is required for subsequent settings. In a first approximation, the DSC positions the floor level points in the middle of the recorded zones. A learning travel must always be activated after the positions of the zone magnets in the shaft have been changed. 18. August

8 2.6 Setting the slowdown distances After the learning travel has been completed successfully, set the slowdown distances for the individual speeds. There are three types of slowdown distance V-fast off, V-intermediate off and V-slow off (see 4.1 Position graph). V-fast off :- Slowing distance when travelling on high speed. V-intermed. off :- Slowing distance when travelling on intermediate speed. V-slow off :- Switch off point of levelling speed just before floor level. In general, excessively large values (in mm s) for V-fast and V-interm lead to long levelling distances. Also large switch off values for V-slow lead to bad floor levels, such incorrect settings do not cause the lift to produce an uncontrolled stop. But, excessively small values cause overtravels beyond the floor level points and zones. In response to such faults an error will be displayed in the event log. It is advisable to set large slow down distances when commencing DSC installation. When entering a slowdown distance, you specify a base value. This base value is identical to the corresponding slowdown distances on all levels. But, you can also set values for individual levels. This value is based on the corresponding base value and is used for fine adjustment of the slowdown distances (see 4.1 Position graph). Note that any change to the base value causes a change in the corresponding level values Determining the V-fast off slowdown distance The slowdown distance can be determined from the graph on page 10. The graph shows the drive s minimum braking distance according to the deceleration rate. Enter this value as the base value for "V-fast off up" and "V-fast off down" (also see 4.1 Position graph). The base value of V-fast off is equal to the braking distance of V-fast! Digital selector V-fast off up V-fast off down 18. August

9 Example of determining the base value of V-fast off for a Variable freq. AC drive:- According to the graph below, the drive has a minimum braking distance of 1.2 m at V-fast = 1.0 m/s and a deceleration of 0.8 m/s². Braking distance m 5.0 Retardation 0.6 m/s m/s m/s m/s Speed V-fast m/s Diagram of the braking distance The resulting base value for V-fast is: Base value V-fast off = 1.2 m = 1200 mm Remark: The deceleration rate or retardation can often be guess work because most motors do not display the rate of deceleration on the data plate, but for frequency drives such as the Thyssen MFC 16 or the Ziehl-Abegg 1DF/FU show the rates in the parameter settings in m/s². By using this setting you can then set your slowdown distance! Determining the V-intermediate off slowdown distance When entering the intermediate speed, proceed as in Section and enter the values. Digital selector V-intermed. off up V-intermed. off down 18. August

10 2.6.3 Determining the V-slow switch off values Enter the distance that the lift requires to come to a stop after its approach speed V-slow has been deactivated (see 4.1 Position Graph). First select identical values for the upward and downward directions. Whether the lift comes to a stop outside of exact floor level is not important as the floor level values can be corrected later. Digital selector V-slow off up V-slow off down 2.7 Setting the minimum distance for starting with V-fast or V-intermediate You need this function only, if you have to use V-intermediate for the traveling between two levels. When the system accepts a call the DSC calculates the distance to be travelled, it is then necessary to decide which speed the lift will travel at. With referance to the example below, the minimum distance for the lift to accelerate, travel at constant speed, decelerate and stop comfortably is 2.8 meters. Therefore, the parameter value 2800mm is then stored in Start speed V-fs from as a referance for the calculation. Digital selector Start speed V-in. from (V-intermediate) Start speed V-fs from (V-fast) Example: For the lift to start with V-fast and correctly process the selected slowing points, the following calculation is made: Acceleration distance : 1.2 m + Deceleration distance m (see example in ) + V-fast constant : 0.4 m = Minimum distance of 2.8 m (2800 mm) between two levels For the lift to start with V-intermediate and correctly process the selected slowing points, the following calculation is made: Acceleration distance : 0.6 m + Deceleration distance : 0.6 m + V-intermed. constant : 0.2 m = Minimum distance of 1.4 m (1400 mm) between two levels If you don t use these functions, the value of the functions have to be 0! 18. August

11 2.8 Checking the ride quality In reference to the settings of the deceleration and the acceleration rates inside the inverters it may be necessary to adjust the values for the slowing distances e.g. V-fast off, V-intermediate off and V-slow off. To check this drive the lift on V-fast and V-intermediate speed to make sure you reach floor level with levelling speed. If levelling speed is not reached and the lift stops abruptly increase your slowdown distance. In opposite, if the levelling speed is reached too early and the lift creeps to the floor level, decrease the slowdown distance. For performing these corrections, use the menu items in Sections Measuring the floor level difference The DSC is designed to make it as easy as possible to make adjustments to levelling accuracy without adjustments to the shaft magnets. As described before the DSC sets the floor level in the middle of the measured zone (S71 or S71 & S72) by default. It may then be necessary to change these base values to have correct stopping at each level. Drive to each floor in the upward and downward directions. Measure the floor level deviation and enter the values separately for each direction of travel in the table provided in the appendix of this manual. The following chart illustrates the relationship between the actual floor level points and the stopping points for each direction. Deactivation point v slow Downward Stopping point during downward approach d AB Actual flush position of the level d AUF Stopping point during upward approach Deactivation point v slow Upward The distances between the actual floor level points and stopping points are defined as d DOWN and d UP for both directions. If the lift stops below the actual floor level point, the measured value is a minus sign. If the lift stops above the actual floor level point, the measured value is a plus sign. 18. August

12 Example of correcting the floor level values: Lift with 4 floors The base switch off values for V-slow off up and V-slow off down is 20 mm from floor level point The following values of floor level difference have been measured: Level Downward approach: d DOWN Upward approach: d UP 1-5 mm (too low) mm (too high) +2 mm (too high) 3-10 mm (too low) -20 mm (too low) mm (too high) 2.10 Correcting the floor level values Enter the floor level difference values for every level. Digital selector Floor level difference After completing the entries, check all these values again to ensure that the correction is performed without any errors. Then select the following menu item. Digital selector Floor level correction Press OK, the display then shows are you sure?, press OK and then the system will recalculate the floor levels. 18. August

13 2.11 Setting the relevelling ranges The relevelling function consists of mainly four settings, these are shown below. When the lift moves away from the floor level due to loads moving in and out of the lift car the lift may require to relevel back to floor level. Enter the relevelling ranges for each direction. The set values apply to all levels (see diagram below). Relevelling Relevelling up on Relevelling up off Relevelling down on Relevelling down off The following chart shows the relevelling positions. Zone range Releveling down on Releveling down off Floor level Releveling up off Zone range Releveling up on Example of setting the activation and deactivation values for relevelling: Relevelling is to be activated in the upward and downward directions 20 mm from the floor level point and deactivated 10 mm from the floor level point. Relevelling On Off Downward 20 mm 10 mm Upward 20 mm 10 mm 2.12 Activating relevelling To activate relevelling, set the following menu item to "YES" (settings -> relevelling -> active -> YES). 18. August

14 3 Cecklists of the Commissioning The following checklists supplement the documentation titled Commissioning the Digital Shaft Copier. They assist mechanics on-site by providing additional information on commissioning. 3.1 Checklist for learning travels Before beginning a learning travel, clarify the following points. Are all the shaft signals required for the digital shaft copier present? Correction switches Top and Bottom At short floor distances in the end floors: the corresponding pre-limit switches Top and Bottom. Zone Do the zone, correction and pre-limit switches operate correctly? Check the switching response using the test adapter function in the menu or with the help of an actual test adapter. Are the real floor level positions located in the individual zones? The real floor level positions should be located in the middle of the individual zones. Is the distance between the zones in the shaft sufficient? The following relationship governs the minimum distance between two zones: min. Zone spacing [m] = 0.05 s * v Fast [m/s] Example: v Fast = 1.5 m/s min. Zone spacing = 0.05 s * 1.5 m/s = m Are the zones in the shaft sufficiently long? The following relationship governs the minimum length of zones: min. Zone length [m] = (0.8 s * v [m/s] + switch-off travel v [m]) * 2 Slow Slow condition: min. zone length > 0.05 s * v Fast [m/s] Example: v Fast = 1.5 m/s, v Slow = 0.15 m/s; Switch-off travel for v Slow = 0.04 m min. Zone length = (0.8 s * 0.15 m/s m)*2 = (0.012 m m)*2 = m condition: min. zone length > 0.05 s * 1.5 m/s = m min. zone length m > m 18. August

15 Are the zones of the end floors located in the respective correction-switch areas? Only the zone of the end floor must be located in the area of the corresponding correction switch. Are the correction switches set so that the elevator is retarded correctly at the end floors? The correction switches must be positioned so that the elevator does not travel beyond the floor level positions at the end floors. However, the correction switches should not be positioned too far, as this would make it impossible to fine-adjust the travel at the end floors. Are the pre-limit switches at short floor distances in the end floors set so that the elevator is retarded correctly at the end floors? The pre-limit switches should be positioned so that the elevator does not travel beyond the floor level positions at the end floors. Are the incremental-encoder channels A and B connected correctly with the central unit? If channels A and B are exchanged, the learning travel is aborted and the messages "No count signal" or "Counter over run" are output. The shield of the incremental-encoder line must be connected with the PE line on one side (shielding against interference). Does the DSK (digital shaft copier) board function properly? If the error message "Card fault DSK modul", "DSK initialization" or " DSK connection" is present in the event register after the MPK control has been switched on, it was not possible to establish a connection with the DSK card. In this case, check whether the DSK card is fitted properly on the central unit. If the fault still occurs after that, observe the service LED on the DSK card (s. 4.5). It should light up briefly during switch-on. If it stays lit continuously or does not function at all, the DSK card needs to be replaced. If a safety circuit is present, does it function correctly? If a safety circuit is not present, is the corresponding input on the central unit (terminal 37) connected firmly with terminal 200 (+24V)? Has the correct transport height (total travel) been set in the menu? A test value was set in the menu at the factory; this value need not be identical to the actual transport height of the elevator. Readjust the value as required. Have you set the correct learning travel speed? The learning travel should be performed at v Slow, provided that the drive is designed for this. Note that not every multi-speed drive is designed for a slow learning travel and that such drives are in danger of overheating at this speed. Errors occurring during a learning travel are stored in the event register. A description of the errors can be found in the documentation titled "MPK 4000 Short introduction". 18. August

16 3.2 Checklist for correcting floor level values Observe the following points before correcting floor level values: Note that the re-leveling is switched to the inactive state for measurements to correct the floor level values. Are the upward and downward switch-off values of v Fast and v Medium set for each level so that the elevator has a constant v Slow in the zone? For proper automatic correction of the switch-off values of v Slow, the elevator must have a constant v Slow in the zone of the destination floor. If this is not the case, you must increase the switch-off value for v Fast and v Medium. Are the upward and downward switch-off values of v Slow set for each floor so that they lie within the respective zone? For proper operation of the DSK and proper correction of the switch-off values of v Slow, these values must lie within the respective zone. If this is not the case, you must decrease the switch-off value for v Slow or increase the length of the zone. Note that a new learning travel must be performed after the zone length has been changed. Does the elevator fail to stop floor level with one or more levels even after correction of the floor level and switch-off values for v Slow? Have you entered the floor level correction values with the right sign? If the elevator floors too high, the value must be positive. If the elevator floors too low, the value must be negative. Again check the conditions in the first two questions of this chapter. If these conditions have not been met, perform the stated instructions. Then repeat the procedure for correcting the floor level values. Record the non-floor level values on every level. 18. August

17 3.3 Checklist for re-leveling settings Are the values for re-leveling specified? The values " re-leveling downward on" and " re-leveling upward on" determine the deviation point from the floor level position at which the elevator commences re-leveling. The values " re-leveling downward off" and " re-leveling upward off" determine the re-leveling switch-off point with respect to the floor level position. Note that the stopping accuracy at the specified switch-on and switch-off positions of the releveling depends on the tolerances of the drive. For this reason, you should locate the switch-off positions close to the turn-on positions when performing initial settings. Correct the switch-off position after every re-leveling process until the ideal value is attained. Is the re-leveling function active? Activate re-leveling via the menu. Re-leveling active YES The questions in the checklists merely supplement and do not substitute the "Commissioning the Digital Shaft Copier". 18. August

18 4 Appendix 4.1 Position graph V-fast V-intermediate Retardation V-fast Retard. V-intermed. V-fast off down (initial value) V-fast off down (level value) V-intermediate off down (initial value) V-intermediate off down (level value) Zone range V-slow downward off (initial value) V-slow downward off (level value) floor level Zone range V-slow upward off (level value) V-slow upward off (initial value) Retard. V-intermed. Retardation V-fast V-intermediate off up (level value) V-intermediate off up (initial value) V-fast off up (level value) V-fast off up (initial value) V-fast V-intermediate 18. August

19 4.2 Configuration of the Digital Shaft copier (DSK) Travel high [cm] (total travel) V fast V intermediate Min. dist. for starting [mm] on off Relevelling down [mm] Relevelling up [mm] V fast V intermediate V slow slowing values down [mm] slowing values up [mm] Table for the correction of the floor level - values: + = Car stands too high [mm] = Car stands too low [mm] Deviation in down direction: d DOWN Deviation in up direction: d UP Level 1. Measurement 2. Measurement 1. Measurement 2. Measurement August

20 4.3 DSC connection types 1. DSC connection using a protective circuit (safety module SM ) Increm. encoder Safety module SM S71 S71 S S72 MPK A DSC module Ter. DSC control Ter DSC zone 36 safety circuit zone 83 incrementer channel A 37 safety circuit 84 incrementer channel B A1 Relevelling on/delay (free prog. terminal W9F) 2. DSC connection without a protective circuit Increm. encoder S71 S71 MPC DSC module Ter. DSC control Ter DSC zone 36 safety circuit zone 83 incrementer channel A 37 safety circuit 84 incrementer channel B A1 Relevelling on/delay (free prog. terminal W9F) 18. August

21 4.4 Overview of the DSC module Service-LED EPROM 4.5 Description of the DSC LEDs DSC pulses A and DSC pulses B: The LEDs display the pulses from the incremental encoder. One or both LEDs may be lit at a standstill, depending on the position of the encoder. While the lift is moving, the signals are switched so rapidly that the LEDs appear to be lit constantly. The individual signals can only be distinguished briefly when starting and stopping. DSC zone: The LED illuminates when the DSC zone (S71or S71 & S72) signal is supplied. DSC status: The LED indicates communication between the MDSK and the inverter for a direct into floor signal. Service LED: By removing the front cover of the MPK the DSC board is marked MDSK 01-V1. If the board is functioning correctly, the LED flashes briefly when the control is switched on. If the LED does not light up or remains constantly lit, a hardware error has occurred (e.g. no EPROM present, incorrectly fitted EPROM or defective board). The service LED is located on the DSC module. The LED s "DSC pulses A", "DSC pulses B", "DSC zone" and "DSC status" are integrated in the LED display of the MPK 3000 control. 4.6 Selecting the incremental encoder and speed governor A resolution of approx. 1mm is sufficient for floor level positioning. Improving the resolution (less than 0.5mm) does not result in more precise floor level positioning. Incremental encoders with resolutions higher than 1.2mm are too imprecise for floor level positioning Speed supplied governor by BODE: The incremental encoder is driven by a toothed belt with a transmission ratio of 1:4 (the axle of the incremental encoder turns four times faster than the axle of the speed governor). Speed governor. Diameter [mm] Speed governor circumference [mm] Trans. ratio Encoder resolution [pulses/rev.] Resolution [mm] Pulses per m : : August

22 Speed governor supplied by Jungblut: The incremental encoder is mounted via a coupling to the shaft of the speed governor, resulting in a transmission ratio of 1:1, or mounted via a tooth belt with a transmission ratio of 1:4. Speed governor. Diameter [mm] Speed governor circumference [mm] Trans. ratio Encoder resolution [pulses/rev.] Resolution [mm] Pulses per m : : ,9 1:4 72 1, ,06 1: , Notes on signal routing A line length of 100m does not impair the signal quality for frequently used speeds, like 1m/s, 1.6m/s, 2.5m/s, 3m/s. Any screened, 4-wire data cable can be used for connecting the incremental encoder with the DSC terminal. The screen must be connected to the PE terminal. 18. August