ANTHONY_GARDINER_TAGLIFTING_201212

Transcription

1 º Unidrive SP Lift Speed Control System Document code: Version: 4 Last revision: 21/07/2009

2 INDEX INDEX INDEX INTRODUCTION DRIVE OPERATION MODELS AND SIZES OVERVIEW ADDITIONAL CARDS INTERNAL PROGRAMMING CONNECTIONS POWER CONNECTIONS ENCODER CONNECTION CONTROL CONNECTIONS USER INTERFACE KEYPAD PLUS CONNECTION TO ORONA CONTROLLER SMARTCARD ADVANCE PARAMETER ADJUSTMENT INTERNAL OPERATION MOTOR CONFIGURATION ENCODER CONFIGURATION OPERATING SEQUENCE SPEED PROFILES INERTIA COMPENSATION SPEED CONTROL CURRENT CONTROL (TORQUE) START COMPENSATION BRAKING RESISTANCE RESCUE OPERATION RFC MODE FUNCTIONS INVERSION OF DIRECTION OF ROTATION MOTOR AUTO TUNING SM-APPS.LITE SPECIAL FUNCTIONS PROBLEM SOLVING PROGRAMMING PROBLEMS DISPLAYING STATUS VARIABLES PERMANENT MAGNET SYNCHRONOUS MOTORS FREQUENT PROBLEMS DRIVE FAULTS CABLING ADVICE INDEX OF ELECTRICAL DIAGRAMS REPLACEMENT PARTS EQUIPMENT REPLACEMENT ADDING AN SM-APPS.LITE CARD REPLACEMENT CODES DEFAULT PARAMETERS INSTALLATION TYPES PARAMETER LISTS FOR EACH INSTALLATION Unidrive SP Lift Speed Control System 2/83

3 INTRODUCTION 1. INTRODUCTION The Unidrive SP controller is a frequency drive made by Control Techniques that provides control for asynchronous and synchronous motors. As regards Orona, this drive can be used to control the following types of vertical lift motor: Geared Asynchronous motors (O-140, O-170, SASSI) with closed loop control (with encoder). Gearless synchronous motors: M33, M33 optimised, M34, Nuevo Renova Electrico, Zetatop (Ziehl-Abegg) and Z6 or Z10 (Leroy Somer) DRIVE OPERATION The drive is based on an Insulated Gate Bipolar transistor (IGBT) based frequency converter that works in Pulse Width Modulation (P.W.M.) with an elevated switching frequency (3-16kHz, 8kHz by default), ensuring silent operation. This system allows motor supply voltage and frequency to be controlled, providing precise control over speed and torque for any motor operating state. At the supply input, the Unidrive SP has a diode bridge to convert three-phase alternating current into direct current, which is what is required to supply the transistors. This DC bus contains capacitors to prevent the voltage oscillating. DANGER: Accumulated Load in Capacitors The voltage accumulated by the capacitors is potentially mortal. After disconnecting the power supply, wait 10 minutes before connecting/disconnecting power cables (power supply, motor, DC bus or braking resistor). When the lift moves in the load direction, the energy returned by the motor has to be dissipated by a brake resistance so as not to damage the DC bus capacitors. Where this resistance fails or is not connected, the drive is automatically disconnected before the capacitors can be destroyed. To guarantee electromagnetic compatibility (EMC), the drive requires an anti-interference filter at the power supply input and the use of shielded and ferrite cables at the motor output (as described in section 6.6). The control unit is based on a digital microprocessor system, that uses information about motor speed (read from the encoder) and power consumption (internal drive reading) to control motor speed and torque at all times engine to achieve an optimum speed profile under any load condition MODELS AND SIZES Drive size and specific model can be identified from the label on the front panel (see point 1.3): Model and size Control Techniques serial number Within the drive model, the first number indicates its physical size (at Orona sizes 1 to 4 are used). Within each size, there are various alternatives depending on motor voltage that can be controlled: Unidrive SP Lift Speed Control System 3/83

4 INTRODUCTION Model Size Drive Power Rated Current (acc. manufacturer ) Rated Current (Orona application table) kW 7.6 A 7.5 A kw 9.5 A 9.5 A kw 13 A 12 A kw 16.5 A 15.6 A kw 25 A 23.6 A kw 29 A 26.6 A kw 32 A 30.3 A kw 40 A 37.8 A kw 46 A 43.5 A kw 60 A 56.8 A kw 74 A 68 A kw 96 A 85 A Brake resistance models depend on lift type and power, consult section OVERVIEW All sizes: SmartCard slot Serial connection Encoder connector Status LED Label Slot 1 Slot 2 Slot 3 Control signal connectors Alarm signal connector Additional card slots Off: controller powered off On: controller operational Blinking: controller faulty Unidrive SP Lift Speed Control System 4/83

5 INTRODUCTION Sizes 1, 2 and 3: Brake resistance (DC2/+DC BR) Supply (L1,L2,L3) y motor output (U,V,W) Size 4: Supply (L1,L2,L3) Motor output (U,V,W) * * * * Brake resistance (+DC BR) (*) Internal filter: Removed at factory because not compatible with external filter Unidrive SP Lift Speed Control System 5/83

6 INTRODUCTION 1.4. ADDITIONAL CARDS The Unidrive SP can carry diverse optional cards to provide additional features. These cards are placed in the slots under the front cover, and up to 3 cards can be inserted per drive. There are a great variety of cards that allow, for example, inputs and outputs to be added to the drive, special encoders to be controlled, etc. Each of these cards can be identified by its colour. When the drive starts up and detects that a card has been removed or added, it gives an (SL.rtd) fault that can be reset from the Keypad Plus or from the Drive menu on the Maintenance Terminal (TMR). ATTENTION To install or remove a card, disconnect the power from the drive and wait at least one minute SM-Apps.Lite card The card most used by Orona is the SM-Apps.Lite, which can be identified by its white colour. This card contains a microprocessor and memory independent from those inside the drive. The program it contains (factory installed) allows additional features to be added as described in later sections. Must be inserted in lowest slot (slot 3). This card is being installed in all drives from April 2009, although it can also be installed in older drives SM-I/O Plus card This card allows additional inputs and outputs to be added to the drive. It is only used in ARCA I lifts where an original M33 machine has been replaced with an optimised M33 machine. Provides the drive with a brake contact reader (as the ARCA I controller doesn t have one). Does not contain a program, menu 17 which corresponds to slot 3 is simply programmed, which is where the card should be inserted. Installation of this card is described in instruction IIM (M33 Machine kit and throw frame) INTERNAL PROGRAMMING Basic parameters All Unidrive SP drives are configured using a series of parameters distributed on menus. These parameters have a type denomination, which means parameter 40 of menu 12. These parameters can be bits (on/off), whole numbers or numbers with decimals. Some of these are read only and serve to display the state of certain internal signals. In these instructions, references to drive parameters will be preceded with Pr (for example, Pr 0.14). Section 3 describes how to access these parameters. Parameter values can be recorded and recovered to/from the SmartCard or a PC (via CTSoft software). Programming of these parameters is different depending on the type of installation, the load and the speed Unidrive SP Lift Speed Control System 6/83

7 INTRODUCTION PLC Software: In addition to these parameters, the drive contains a small internal automaton called a PLC to better adapt the product to the application (in Orona's case, the lift). This PLC software is recorded on all Unidrive SP drives except the "original" M33. The PLC can be recorded and recovered to/from the SmartCard or a PC using SYPTLite software. There are 2 different software programmes, one for asynchronous motors and the other for synchronous motors DPL Software The SM-Apps.Lite card, like the PLC, enables native code to be developed, called DPL, to adapt the drive to the lift, but its memory and processing capacity is very much superior. The DPL software recorded on the card performs the same functions as the PLC and provides additional features (described further on). Drives with the factory installed SM-Apps.Lite card, will have a programmed but deactivated PLC and the operating sequence will be handled by the software on the SM-Apps.Lite card. The software on the card does not change with the appliance type, although in time new versions of the software will appear (this can be queried via parameter Pr 20.17). In the event of a card fault, it can be stopped and the PLC activated whist it is replaced, as described in section The DPL software on the SM-Apps.Lite card cannot be recorded or recovered from the SmartCard. A PC and Winflasher software are necessary for recording. Lift type Basic parameters PLC Software M322 YES Asynchronous Machine room YES Asynchronous M33 original YES NO M33 extended YES Synchronous M33 optimized YES Synchronous MRL Ziehl-Abegg / Leroy-Somer YES Synchronous M34 YES Synchronous DPL Software Only if SM-Apps.Lite card inserted ATTENTION: IF THE DRIVE HAS AN Apps.Lite CARD The PLC and DPL programs are recorded on the drive, but they can no operate simultaneously. The SM-Apps.Lite card (DPL) program deactivates the PLC automatically on start up. Parameters exist for displaying the status of the PLC and DPL software, which can be accessed via the Orona MT or the Keypad Plus: Software and status Keypad Plus Orona MT PLC Software Pr Status Not recorded 0 No Stopped 1 Stop Running 2 Run DPL Software Pr Status Not recorded none (0) No Manually stopped StoP (1) Stop Running Run (2) Run Stopped due to an error trip (3) Av SM-Apps.Lite card not installed Menu 17 doesn t exist No Unidrive SP Lift Speed Control System 7/83

8 CONNECTIONS 2. CONNECTIONS Frequency drive IGBT switching causes electromagnetic interference. To minimize its effect it is essential that the electrical connections are made as indicated in this section and in section 6.6. The location of all terminals described is displayed in section POWER CONNECTIONS DANGER: Accumulated Load in Capacitors The voltage accumulated by the capacitors is potentially mortal. After disconnecting the power supply, wait at least 10 minutes before connecting/disconnecting power cables (power supply, motor, DC bus or braking resistor). The drive must be supplied from a V three-phase supply via terminals L1, L2, L3. To ensure compliance with lift regulations an electromagnetic compatibility filter, a circuit breaker and a residual current device must be employed. The braking resistor must be connected between terminal BR and terminal DC2 or DC+ (the name changes depending on drive size) and the cable-set that joins the drive with the resistor must be shielded, and the mesh must be fastened to the plating via metallic straps at each end. The power output (terminals U,V,W) goes to power contactor C1. This stretch of cable, to minimise electromagnetic emissions, is short and is would 2 or 3 times around some ferrite. The cable from the contactors to the motor is connected using shielded cabling for the same reason, and the mesh must be fastened to the case via metallic straps at each end ENCODER CONNECTION The Unidrive SP uses an encoder reading to control motor rotation speed. A good signal is fundamental for guaranteeing proper system operation. To ensure this shielded cable is used which is connected to the front of the drive via a Sub D-15 connector. PRECAUTION The encoder cable should be protected by separating it as much as possible from the motor power cables and it is recommended that it be replaced if damaged or cut CONTROL CONNECTIONS The controller controls drive operation (and thereby that of the motor) via a set of control signals: Secure Disable: this signal indicates to the drive that it should apply current to the motor output because the contactors have operated. Rescue: indicates that the emergency EMC contactor has operated and that the drive should operate in rescue mode (see section 4.11). Speed levels B1, B2, B3: these 3 digital signals set movement speed via a binary code (see section 4.5.1). Ascend/Descend: these 2 digital signals set the movement direction. ATTENTION For the up signal to work there must be a bridge between terminals 3 and Unidrive SP Lift Speed Control System 8/83

9 CONNECTIONS The cabling for these inputs is shown in the table: Signal Termin al Common (24V internal) 22 Secure Disable 31 Ascend 5 Descend 8 B1 Speed level 29 B2 Speed level 28 B3 Speed level 27 Rescue 26 Connection (*) These 1kΩ resistances go to the internal drive 0V (terminals 11 and 23) and make inputs more robust as regards electromagnetic interference. In the case M33, M33 extended, M33 optimized, Leroy-Somer or Ziehl-Abegg lifts, a car load level reading is also used to open the car brake as soon as it moves and achieve optimum comfort: Signal Terminal Type Weight level (+) 7 A 0-10V (PQ Orona) or 0-20mA (Micelect LM3D) signal can be Weight reference (-) 3 used. See section 0 In addition, the drive has the following outputs to the controller: Signal Terminal Use Drive alarm (relay contact) Brake opening (24V transistor) Advance door opening (24V transistor) Relay contact that opens if the drive is faulty, indicating to the controller that it should not attempt to move. 24 (+) y 11 (-) Allows the drive to control brake opening to improve comfort (see section 4.4). 25 (+) y 11 (-) Only ARCAI lifts. Activates if car speed is less than 0.3m/s (allowing doors to open). To see the status of these inputs and outputs, see section C1 C2 EMC K3 5 K4 8 * 11 K5 27 K6 28 K7 29 PBCM * 23 Unidrive SP Unidrive SP Lift Speed Control System 9/83

10 USER INTERFACE 3. USER INTERFACE 3.1. KEYPAD PLUS The Keypad Plus is a Control Techniques tool that allows internal drive parameters to be displayed and modified, faults to be resolved, etc. It connects to the serial port on the drive front panel via a standard straight RJ45 cable: The Keypad contains several pushbuttons, the most important being: Mode: to change between different modes: status, parameter display and parameter editing Reset: enables the equipment to recover from faults and also serves to execute certain special functions (see further on). Help: a brief description of the parameter selected appears on screen when pressed. Arrows: for navigating parameters and menus, and changing parameter values. This is described in the section on Using the Keypad Plus. The keypad display consists of 3 alphanumeric horizontal lines: The top line displays: The parameter selected or the drive status in the left corner. The parameter value or the current fault in the event that the drive is faulty, in the right corner. The 2 bottom lines display a description of the parameter (or the help text if the Help key has been pressed). Status indication When first connected to a drive, wait at least one minute for it to update itself (will indicate Reading Data Base and Programming Flash). The keypad is in Status Mode by default, that is, it displays drive status: inh: the drive is not faulty but does not apply power (because the controller has not indicated that it should do so via the SecureDisable input). run: the drive is applying power to move the motor. StoP: the drive applies power to keep the motor stopped. Appears when Direction, Speed and SecureDisable set points are removed next to Dec (decelerating). PLC: PLC software is running (see section 1.5.2). This indication blinks every 10 seconds or so Unidrive SP Lift Speed Control System 10/83

11 USER INTERFACE trip: the drive detects a fault and will not apply power to the motor until it has been resolved. The screen also displays a fault code (see section 6.5). Auto / TunE: blinks during auto tuning (see section 5.2). rdy: when a SecureDisable signal is present, but no operating signals (direction or speed). The drive does not provide output. This should not arise in Orona applications, but if it were to appear, cabling should be checked and the error location established. no link: when the keypad Plus is remotely connected (with network cable) and an operation is being performed (record to/from Smartcard, etc...). Despite the appearance of this message, the operation is executed correctly. Using the Keypad Plus: Status Mode The top left hand side indicates drive status (doesn t blink). The top right hand side indicates the fault code (only where present, in which case it blinks). Parameter Mode The top left hand side indicates parameter selected (blinks). The top right hand side indicates the value for this parameter. This mode serves for navigating the different drive menus and viewing its parameter values. After a while in this mode without pressing a button, the keypad automatically returns to Status Mode. Editing Mode The top left hand side indicates parameter selected. The top right hand side indicates the value for this parameter. The digit to be modified blinks. This mode serves to modify parameter values. After a while in this mode without pressing a button, the keypad automatically returns to Status Mode. (*) Some drive parameters are Read Only, and therefore access to Editing Mode may not be possible. inh 0 To access Parameter Mode, Press or Use the vertical arrows to change parameter To access Edit mode, press * Use the horizontal arrows to select the digit you wish to change To return to Status Mode, press again To return to Parameter Mode, validating the new parameter value, press Use the vertical keys to change the digit value Unidrive SP Lift Speed Control System 11/83

12 USER INTERFACE Advanced Menu Access By default, only menu 0 parameters (Pr 0.XX) can be accessed from the Keypad Plus. If Pr 0.49 is changed from L1 to L2, the rest of the menus can be accessed when pressing left and right keys (parameters for menu 1 are Pr 1.XX, menu 2 are Pr 2.XX ). Fault recovery If the drive has a fault, the screen will display trip and a fault code. Section 6.5 provides descriptions for all the faults that can be cause them. To recover, press the reset button. Parameter recording If a parameter has been modified, by pressing the M button it is only stored in volatile memory, and it will therefore be lost following a power down. To permanently record parameters, enter value 1000 for Pr x.00 (in any menu) and press the reset button CONNECTION TO ORONA CONTROLLER The drive can be customized and monitored via the Orona Maintenance Terminal. To do so the Arca II controller communicates via 485 through the serial port on the front of the drive (such as on the Keypad Plus). This communication is not possible with original and extended M33 lifts. For the rest this can be performed in two ways: Directly from the main board. Only main boards (June 2009) are prepared for this. Via a loadweights board ( ), which acts as a translator from CAN bus to RS485. This communication is used on the Optimized M33, Leroy-Somer and Ziehl-Abegg. Drive access from the MT On the Orona MT, the Unidrive SP drive is a controller node. From the Main Menu, enter Current and then Drive. If there are no Unidrive SPs connected (or there is a communications fault) nothing will appear, to the contrary the following menus will be available: 1. FAULTS: can be used to see if the drive is faulty or not, and to recover faults. 2. HISTORIC: this menu allows the last 10 faults registered by the drive to be displayed. 3. VARIABLES: this menu displays the status of some of the drive s internal variables, speed readings and motor voltage and the status of inputs and outputs. 4. FUNCTIONS: this menu provides access to different drive assembly and maintenance utilities, described in section 5. This menu also includes SmartCard recording and reading functions (see section 3.3). 5. PARAMETERS: any drive parameter can be changed via this menu (as described in section 4). It is important to highlight that the MT (unlike the Keypad Plus) cannot operate with decimals, and therefore many parameters appear in tenths (d), hundredths (c) or thousandths (m). For example, current is in decimals and therefore to program a current of 12A, the parameter should be adjusted to [120]d. In this standard, references to parameters on these menus takes the form TMR 5.2 Vmax. IF a parameter only refers to the Keypad Plus (for example, Pr 1.27) the parameter can only be accessed from TMR 5.8 Manual Parameter. Parameter recording After modifying parameters (menu 5) or using functions (menu 4), enter TMR 4.3 Store Parameters = [YE] to not loose changes when the power is turned off Unidrive SP Lift Speed Control System 12/83

13 USER INTERFACE 3.3. SMARTCARD All drives come with a SmartCard. At the factory all drive parameters and PLC software for each installation are recorded on the card, which can therefore be used to restore original parameters in the event of undesired modifications, or drive substitution by a new unit. The card should be inserted with the contacts facing the right side of the drive. There is no need to turn off the power when inserting or removing the card. ATTENTION The DPL program on the SM-Apps.Lite card is not recorded on the SmartCard. This card can only be recorded to at the factory or on a PC. If a fault occurs during any dumping process, observe fault code and consult section 6.5. To recover the fault: Using the Keypad Plus: program parameter Pr x.00=0 + Using the Orona MT: TMR 1 Fault recov. = YES Drive programming from the SmartCard When performing this operation drive parameters and PLC program are deleted and are recorded from the contents of the SmartCard: Using the Orona MT: a. Recover only parameters: TMR 4.4 Read SM = YES b. Recover parameters and PLC: TMR 4.4 SM -> Inverter = YES Using the Keypad Plus: c. Recover PLC program: Pr x.00= Attention: the 'Original' M33s (i.e. not extended or optimized) did not have a PLC, and therefore this operation should not be performed (would cause an error). d. Recover parameters: Pr x.00= e. Record parameters: Pr x.00= Record drive data to SmartCard When performing this operation factory recorded parameters are lost, but if any encoder or machine modifications have been made (or if an auto adjustment has been performed) it is recommended that the new data be recorded to the card. Using the Orona MT: f. Record parameters only: TMR 4.4 Actualise SM = YES g. Record parameters and PLC: TMR 4.4 Inverter -> SM = YES Using the Keypad Plus: h. Unprotect SmartCard: Pr x.00= i. Delete SmartCard: Pr x.00= j. Save PLC software: Pr x.00= Attention: the 'Original' M33s (i.e. not extended or optimized) did not have a PLC, and therefore this operation should not be performed (would cause an error). k. Record parameters: Pr x.00= l. Protect SmartCard: Pr x.00= Unidrive SP Lift Speed Control System 13/83

14 ADVANCE PARAMETER ADJUSTMENT 4. ADVANCE PARAMETER ADJUSTMENT 4.1. INTERNAL OPERATION Most drives require the use of PLC or DPL software (see section 1.5). If the drive has the SM-Apps.Lite card, the DPL software must be running: Using the Keypad Plus: Pr = run Using the Orona MT: TMR Status = run If the drive does not have the SM-Apps.Lite card and is not an original M33" (see section 4.2), the PLC software must be running: Using the Keypad Plus: Pr 11.48=2 Using the Orona MT: TMR Status = run If the correct software is not running, it can be started as described in section MOTOR CONFIGURATION CONTROL MODE Parameter Pr 0.48 (or TMR 5.1 Mode) determines the type of motor controlled by the drive. The Control Techniques drive can control 2 types of motor: Gearless asynchronous motors: Pr 0.48=C.L.VECt (TMR 5.1 Mode = V.L.Closed) Gearless synchronous motors: Pr 0.48=SERVO (TMR 5.1 Mode = SERVO) However, changing the drive control mode (changing Pr 0.48) requires entering a code in Pr 0.00 and resetting all parameters to the default values used by Control Techniques. Given that these values are not valid for the Orona application, do not change the control mode in this manner. If you wish to change the drive control mode (because it does not correspond to the motor installed), you can: Use a SmartCard: the card should be programmed for the correct type of installation. Section 0 describes how the process should be performed. Using the SM-Apps.Lite card: if the drive contains this type of card (or if one is installed), the reset to default parameters function can be used (see 5.3.3) to program all parameters with the correct values for the installation GEARED ASYNCHRONOUS MOTORS The following motors are asynchronous motors that rotate at high speed ( rpm) and therefore require gearing to adapt to the lift pulley rotation speed. To control them, the drive should be configured in Closed Loop Vector mode: Using the Keypad Plus: Pr 0.48=C.L.VECt Using the Orona MT: TMR 5.1 Mode = Closed L.V Unidrive SP Lift Speed Control System 14/83

15 ADVANCE PARAMETER ADJUSTMENT M233 MACHINES WITH C.T. FROM JULY 2005 The M322s are geared asynchronous motors and drum brakes. The Control Techniques began to be used in the ARCA II controller (contactors and shaft drive). Lift type TMR Nom current Pr 0.46 TMR Resistance Pr 5.17 TMR Inductance Pr 5.24 TMR Poles Pr 0.42 TMR Nom. Voltage Pr 0.44 TMR rpm nominal Pr 5.08 TMR Pow. factor Pr 0.43 TMR Gain.P.curr Pr 0.38 TMR Gain.I.curr Pr p 1000rpm 107d m m p 1000rpm 132d m m p 1500rpm 91d m m p 1500rpm 125d m m p 1500rpm 232d m m m m m m m O-170 or SASSI MACHINES WITH C.T. FROM JULY 2005 Geared asynchronous machines and drum brakes are used in lifts with machine rooms, which can be Orona (O-170) o SASSI (MF82 or MF94). Only used with Control Techniques with controller ARCA II. If the data is not displayed in the table, program: Pr 0.42=4 and Pr 0.44=380 Pr 0.46 and Pr 5.08 according to rating plate. Perform a static auto tuning to obtain the rest (see section 5.2.2). Lift type TMR Nom current Pr 0.46 TMR Resistance Pr 5.17 TMR Inductance Pr 5.24 TMR Poles Pr 0.42 TMR Nom. Volt. Pr 0.44 TMR rpm nominal Pr 5.08 TMR Pow. factor Pr 0.43 TMR Gain.P.curr Pr 0.38 TMR Gain.I.curr Pr 0.39 O cv 130d m m O cv 160d m m O cv 230d m m MF82 16cv 280d m m MF82 21cv MF94 16cv 320d 32 28d m 415m m 3189m MF94 22cv 330d m m MF94 25cv 386d m m MF94 31cv 550d m m MF94 34cv 580d m m m m d m m m m m m Unidrive SP Lift Speed Control System 15/83

16 ADVANCE PARAMETER ADJUSTMENT PERMANENT MAGNET SYNCHRONOUS MOTORS The following motors are permanent magnet synchronous motors that do not require gearing. These motors are technologically more complex than asynchronous motors, as described in section 6.3. To control them, the drive should be configured in SERVO mode: Using the Keypad Plus: Pr 0.48=SERVO Using the Orona MT: TMR 5.1 Mode = Servo ORIGINAL M33 MOTORS JUNE 2003 JUNE 2007 The original M33 are gearless synchronous motors supplied by Reivaj. They can work with an ARCA I controller (in which case a contactor box is raised above the machine as in the figure) or an ARCA II (contactors on drive board). The drive is always on a shaft board. They always use Warner drum brakes. These brakes require overexcitation, that is, a high voltage to open (205Vdc) and a lower voltage to keep open without getting hot. Brake plates (ARCA I) and (ARCA II) are used to achieve this. These are the only cases where the drive operates without PLC software. Lift type TMR Nom current Pr 0.46 TMR Resistance Pr 5.17 TMR Inductance Pr 5.24 TMR Poles Pr 0.42 TMR Nom. Voltage Pr 0.44 TMR rpm nominal Pr 5.08 TMR Gain.P.curr Pr 0.38 TMR Gain.I.curr Pr p 1m/s 92d m m p 1.6m/s 148d m m p 1m/s 124d m m p 1.6m/s 179d m m p 1m/s 180d m m p 1.6m/s 280d m m Unidrive SP Lift Speed Control System 16/83

17 ADVANCE PARAMETER ADJUSTMENT EXTENDED M33 MOTORS OCTOBER 2004 DECEMBER 2006 Extended M33 motors are also gearless synchronous motors supplied by Reivaj. They use Warner round disk brakes (require overexcitation, plate ). Always ARCA II controller (contactors and drive in shaft). Lift type TMR Nom current Pr 0.46 TMR Resistance Pr 5.17 TMR Inductance Pr 5.24 TMR Poles Pr 0.42 TMR Nom. Voltage Pr 0.44 TMR rpm nominal Pr 5.08 TMR Gain.P.curr Pr 0.38 TMR Gain.I.curr Pr p 1m/s 201d m m p 1.6m/s 321d m m p 1m/s 260d m m p 1.6m/s 435d m m OPTIMIZED M33 MOTORS FROM OCTOBER 2006 Optimized M33 motors are gearless synchronous motors, but supplied by Lancor. They all use Mayr square disk brakes, with the encoder located between the brakes, and the brakes do not require overexcitation (plate ). Always ARCA II controller (although the electrical installation is quite different from the 2 previous cases) and cover the same load and speed ranges. Lift type TMR Nom current Pr 0.46 TMR Resistance Pr 5.17 TMR Inductance Pr 5.24 TMR Poles Pr 0.42 TMR Nom. Voltage Pr 0.44 TMR rpm nominal Pr 5.08 TMR Gain.P.curr Pr 0.38 TMR Gain.I.curr Pr p 1ms 80d m m p 1.6ms 125d m m p 1ms 105d m m p 1.6ms 170d m m p 1ms 165d m m p 1.6ms 260d m m p 1ms 215d m m p 1.6ms 320d m m p 1ms 255d m m p 1.6ms 410d m m Unidrive SP Lift Speed Control System 17/83

18 ADVANCE PARAMETER ADJUSTMENT M34 MOTORS FROM APRIL 2009 M34 motors are also Lancor gearless synchronous motors, although their layout is different, with the pulley between the motor and brakes. They use Mayr square disk brakes (no overexcitation, plate ). Work with ARCA II controller, but in this case the drive is located on the control board. Lift type 4-6p 1m/s 8p 1m/s TMR Nom current Pr 0.46 TMR Resistance Pr 5.17 TMR Inductance Pr 5.24 TMR Poles Pr 0.42 TMR Nom. Voltage Pr 0.44 TMR rpm nominal Pr 5.08 TMR Gain.P.curr Pr 0.38 TMR Gain.I.curr Pr d m m d m m Unidrive SP Lift Speed Control System 18/83

19 ADVANCE PARAMETER ADJUSTMENT GEARLESS LEROY-SOMER MOTORS FROM FEBRUARY 2007 Leroy-Somer Z6 and Z10 machines are permanent magnet synchronous motors that are distinguished by having the rotating part of the motor on the outside. They have Warner calliper brakes (2, 3 or 4 depending on load) that require overexcitation (plate ). Lift type TMR Nom current Pr 0.46 TMR Resistance Pr 5.17 TMR Inductance Pr 5.24 TMR Poles Pr 0.42 TMR Nom. Voltage Pr 0.44 TMR rpm nominal Pr 5.08 TMR Gain.P.curr Pr 0.38 TMR Gain.I.curr Pr kg 1ms 313d m m kg 1.6ms 310d m m kg 1.6ms 466d m m kg 1.6ms 520d m m kg 2.5ms 350d m m GEARLESS ZIEHL-ABEGG MOTORS FROM JANUARY 2009 Ziehl-Abegg Zetatop machines are also permanent magnet synchronous machines. Depending on load they use Mayr or Warner square or round disk brakes but always with no overexcitation (plate ). Lift type TMR Nom current Pr 0.46 TMR Resistance Pr 5.17 TMR Inductance Pr 5.24 TMR Poles Pr 0.42 TMR Nom. Voltage Pr 0.44 TMR rpm nominal Pr 5.08 TMR Gain.P.curr Pr 0.38 TMR Gain.I.curr Pr kg 1ms 230d m m kg 1ms 300d m m kg 1ms 430d m m kg 1ms 430d m m kg 1.6ms 540d m m Program according to speed table under If the motor is not listed in the table: Rated current: as indicated on motor rating plate. Number of poles: 32 Rated rpm: according to table Rest: perform static auto tuning (see 5.2.2) If the motor is not listed in the table: Rated current: as indicated on motor rating plate. Number of poles: 20 Rated rpm: according to table Rest: perform static auto tuning (see 5.2.2) Unidrive SP Lift Speed Control System 19/83

20 ADVANCE PARAMETER ADJUSTMENT 4.3. ENCODER CONFIGURATION As a function of the type of motor to be controlled, the following encoders are used: Parameter TMR Type Pr 3.38 TMR Lines Pr 3.34 TMR Tension alim. Pr 3.36 TMR Detec.error Pr 3.40 Increment al Stegman Absolute Stegman Absolute AB SC Hiper SC EnDat * 2048 * 15V ** 8V ** 5V ** Cable INCREMENTAL ENCODER fase Unidrive SP Lift Speed Control System 20/83 fase 3 Used to control all asynchronous machines. Almost always Heidenhain and there are 2 models that only differ in their assembly method: ERN430 (hollow axle, used in M322) and ROD436 (overhanging axle, used in the rest). This encoder only measures speed, it cannot determine the position of the motor rotor STEGMAN ABSOLUTE ENCODER The Stegman SRS50 encoder is used in all M33 original, M33 extended, M33 optimized and M34 lifts. This encoder has a type of communication known as Hiperface with the drive which automatically adjusts Pr 3.33, 3.34 and This encoder is absolute, and therefore in addition to speed it measures absolute rotor position. This is necessary to control synchronous motors, as described in 6.3. There are two codes (see 8.3.8) because the mechanical union can be with a splinted (M33 original or extended) or conical shaft (rest), but are electrically identical HEIDENHAIN ABSOLUTE ENCODER The ECN413 absolute encoder is used on all gearless Leroy-Somer and Ziehl-Abegg lifts. It is very similar to the Stegman, but Heidenhain uses a different communications protocol (called EnDat). Pr 3.33, 3.34 y 3.35 are also automatically configured OPERATING SEQUENCE (*) Adjusts automatically (**) Attention: incorrect adjustment of this paramter can damage the encoder. There are two different operating sequences: one for the M33 original (as it does not use PLC or DPL) and another for the rest. Adjustment of the drive operating sequence is quite delicate as it has to be ensured that: When opening the brake that the motor has sufficient current to not be overwhelmed by the load. When dropping the contacts current must be 0 (or a strong noise heard in the car) When closing the brake that the car is totally immobile (and therefore must wait until it has closed before lowering the current to 0).

21 ADVANCE PARAMETER ADJUSTMENT NORMAL OPERATING SEQUENCE A B Sequence Stages The sequence starts when the drive receives a direction set point, Secure-Disable and speed level distinct from Vnull (in the example, Vmax) from the controller. In the case of asynchronous motors, it waits until the motor is magnetized. With synchronous motors it jumps directly to point B. The torque ramp signal is activated (Pr 19.47). This raises the current limit (Pr 0.06) from 0 to the maximum permitted (Pr 0.58) for a length of time called Torque_T. (Pr 0.52). If this ramp is not used and the current is applied suddenly there would be noise and vibration in the car. C After a period of time Brake_open_T. (Pr 0.51) has elapsed since B, the brake open signal is activated (Pr 0.22). The brake will still then take some time to open mechanically, and it is important that when it opens completely that the ramp has completed otherwise the imbalance could overwhelm the car. D E F G H I J A Brake_Open_T* Torque_T * Trip_Start_T * Torque_T * After a period of time Trip_Start_T. (Pr 0.53) has elapsed since B, the motor is allowed to accelerate. The brake must now be completely open, otherwise drag will be felt. The drive decelerates to approach speed (commanded by the controller) The drive decelerates to zero speed (commanded by the controller) When the speed descends below a value (Pr 12.45) the stop sequence is initiated. C1+C2 Inputs Ascend/Descend Inputs B1, B2, B3 Inputs T contactor drop (controlled by Vmax V0 VNULL Par max Vmax V0 controler) Trip_End_T * Brake_Fall_T * B C D E F H I J G Secure-Disable (Pr 0.29 or TMR 3.1 Secure-Disable) Speed Level (Pr 0.14 or TMR 3.1 Level) Torque ramp (Pr 19.47) Brake activation (Pr 0.22 or TMR 3.2 Brake output) Current limit (Pr 0.06) (*) These times can be changed on TMR or Keypad Plus (see next page) Speed reference (Pr 0.11) After a period of time Brake_Fall_T (Pr 0.54) has elapsed since G, the brake output is disconnected (Pr 19.46). It must be borne in mind that the mechanical closing of the brake will take a little longer. After a period of time Trip_End_T (Pr 0.55) has elapsed since the start of stage G, the torque ramp signal is disconnected (Pr 19.47). This ensures that the current limit (Pr 0.06) goes down to 0 the same as in B. It is important that the ramp not start until the brake is completely closed or the car could move due to imbalance. The current limit reaches 0 and therefore there ceases to be current in the motor. K The controller disconnects the contactors after the Caída Cont. [Cont. Drop] time has elapsed following point F Unidrive SP Lift Speed Control System 21/83

22 ADVANCE PARAMETER ADJUSTMENT The table displays the default values and how to make time adjustments. For example, if Brake_Open_T is increased, Trip_Start_T must be increased by the same amount: Parameter TMR Brake_Open_T Pr 0.51 TMR Trip_Start_T Pr 0.53 TMR Brake_Fall_T Pr 0.54 TMR Trip_End_T Pr 0.55 TMR Torque_T Pr 0.52 M33 Opt, M34 200m 200 8d 0.8 0d 0 200m 200 6d 0.6 Adjustment of sequence times L.Somer Z.Abegg 200m d 1 5d m 200 6d 0.6 M33 Ext 500m 500 8d 0.8 2d m 250 6d 0.6 M322 y SM 0m 0 5d 0.5 3d m 500 0d 0 Contactors Drop Time 15d 20d 20d 15d M33 ORIGINAL OPERATING SEQUENCE Adjustments to perform if the parameter value is changed (always by the same amount) If increased, increase Travel_Start_T. If reduced, reduce Torque_T. If reduced, reduce Torque_T and Brake_Open_T If increased, watch out for sliding faults. If increased, increase Contactors_Drop_Time. If reduced, watch out it doesn t fall during operation If increased, increase Contactors_Drop_Time. Never reduce it (may produce hits at stop) If increased, increase Contactors_Drop_Time, Trip_Start_T, Brake_Open_T. If reduced, increase Trip_End_T. Can be increased, never reduced. This parameter is in TM CONTROLLER The operating sequence for the M33 original was simpler. It doesn t use a torque ramp on start or stop, and therefore the current limit (Pr 0.06) is always fixed at 175%. On start, the drive activates the brake output upon receipt of the SecureDisable signal. When the brake opens mechanically, the B1,B2,B3 speed signals arrive and acceleration commences: Time it takes the brake to open * On stop, the brake output is deactivated for a time (Pr 0.23) after the controller removes levels B1,B2,B3. This period should be less that the controller contactor drop period to ensure that the brake is closed when current ceases to be applied MTControl: Contactor Drop Time = 12d Pr 0.23 = (*) In M33 ARCA I lifts, the brake micro switches cut levels B1,B2,B3 (see ), and therefore in this area levels are at 000 (until the brake opens). Ref. Speed (Pr 0.11) SecureDisable Input B1,B2,B3 Inputs Brake output (Pr 0.22) Ref. Speed (Pr 0.11) SecureDisable Input B1,B2,B3 Inputs Brake output (Pr 0.22) Unidrive SP Lift Speed Control System 22/83

23 ADVANCE PARAMETER ADJUSTMENT 4.5. SPEED PROFILES SPEED REFERENCES The controller chooses the speed at which the motor should operate at each moment via 3 digital inputs as follows: Selected speed level Terminal Value Pr 0.14 TMR 3.1 Level Lift stopped Vnull Fine isoleveling V00 Creep Speed V0 Inspection/Emergency Vinsp Intermediate speed V1 Intermediate speed V2 Intermediate speed V3 Maximum Speed Vmax The speed levels for each of them can be modified in the following parameters: Speed level Keypad Parameters TMR (mm/s) Original (rpm) Copy (m/s) * Stopped (should be 0) Pr 1.21 Doesn t exist 5.2 Vnull Fine isoleveling Pr 0.15 Pr V00 Creep Speed Pr 0.16 Pr V0 Inspection/Emergency Pr 0.17 Pr Vinsp Intermediate speed 1 Pr 0.18 Pr V1 Intermediate speed 2 Pr 1.26 Pr V2 Intermediate speed 3 Pr 1.27 Pr V3 Maximum Speed Pr 0.19 Pr Vmax The following table contains speed values for gearless motors: MT MT 5.2 (mm/s) Lift Rated Pulley rated V00 V0 Vinsp V1 V2 Vmax model speed diam. Susp rpm varía (m/s) (mm) Pr 5.08 Pr 0.15 Pr 0.16 Pr 0.17 Pr 0.18 Pr 1.26 Pr 0.19 Nuevo Renova M M33 Opt M33 Original M33 Ext Leroy Somer Ziehl-Abegg (*) This copy is only avialable in drives with SM- Apps.Lite. See section It must be borne in mind that the maximum values for these parameters are limited by Pr 0.02 (TMR rpm max). This parameter is always set at 10rpm above the motor rated speed (Pr 5.08 or TMR rpm nominal) Unidrive SP Lift Speed Control System 23/83

24 ADVANCE PARAMETER ADJUSTMENT The following table contains speed values for geared motors: TMR TMR 5.2 (mm/s) TMR 5.3 (mm/s2 y mm/s3) rpm V00 V0 Vinsp V1 V2 V3 Vmax Accel/ Decel Jerk travel Speed No. Reduc Diam. max varies (m/s ) po les pulley (mm) Susp Pr 0.02 Pr 0.15 Pr 0.16 Pr 0.17 Pr 0.18 Pr 1.26 Pr 1.27 Pr 0.19 Pr 0.03, 0.04 Pr 0.20, : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : ,9: It is important to first adjust parameter Pr 0.02 (TMR rpm max) because it limits the value of the other parameters ACCELERATIONS AND JERKS The values for acceleration, deceleration and jerk determine how speed varies from one level to another when the controller changes the speed set point. These values can be modified within a margin: Increasing acceleration requires more torque from the motor, and it is therefore not recommended it be increased more than 0.1m/s 2 above the default value. Reducing deceleration (and also acceleration, to a lesser extent) forces deceleration distances to be increased for all speeds (MT Control, Dist.Dec.). Jerk influences both comfort during speed changes and deceleration distances and stopping precision. Do not lower it below 1m/s 3 or raise it above 3m/s Unidrive SP Lift Speed Control System 24/83

25 ADVANCE PARAMETER ADJUSTMENT The following figures illustrate the effect of these parameters: Speed profile (no jerk limit) Speed profile (with jerk limit) Acceleration Deceleration Travel Jerk (*) The stop jerk is controlled from a different parameter depending on the type of machine: For M33 extended lifts, M322 lifts or lifts with a machine room: Pr 2.18 For M33 original lifts: Pr 0.20 (cannot be adjusted separately from travel jerk). For the rest (Optimized M33, M34, Leroy-Somer and Ziehl-Abegg). Pr In addition to the Keypad Plus, these parameters can be modified in TMR 5.3 Acceleration, Deceleration (mm/s 2 ), Jerk Travel and Jerk Stop (mm/s 3 ). Remember that M33 originals and M33 extended cannot perform this communication. Default values for geared synchronous machines appear in the table on the previous page. If it is necessary to modify these values, do so as follows: Pr 0.03 or 0.04 = table value x 0.8/acceleration desired (in m/s 2 ) Pr 0.20 or 2.18 = table value/jerk desired (in m/s 3 ) For gearless synchronous motors, acceleration and jerk values are as follows: Lift model: M34, M33 M33 M33 Leroy- Renova Opt. Original Ext. Somer Ziehl-Abegg Pulley diam. (mm) Suspension Acceler. and deceleration (mm/s2) Jerk travel and stop (mm/s3) Default values are shaded (note that the default value in M33 original and extended lifts is 2m/s 3 and in the rest it is 1m/s 3 ). In lifts with the SM-Apps.Lite card, a coy of the programmed values can be queried (as described in section 5.3.5): Pr 2.12 / 2.13: acceleration/deceleration in m/s 2 Pr 2.14 / 2.15: jerks travel/stop in m/s 3 * Unidrive SP Lift Speed Control System 25/83

26 ADVANCE PARAMETER ADJUSTMENT 4.6. INERTIA COMPENSATION Car and counterweight inertia in the lift application is very large. This can make the motor struggle to keep up with the set point, as illustrated in the following image: If an inertia value (in kgm 2 ) is programmed and inertia compensation is activated (Pr 4.22=1), the drive applies more torque during speed changes (the greater the more inertia programmed), allowing the speed profile to follow the set point. This function is factory programmed on optimized M33, Leroy Somer, Ziehl-Abegg and M34 lifts SPEED CONTROL The Unidrive SP drive always attempts to adjust motor speed (which it reads via the encoder) as best as possible to the reference (generated by the set point selected by the controller with drive programmed acceleration/deceleration ramps). This tracking is adjusted via the Speed Control parameters. TMR Keypad Plus Lifts with M.Room M322 M33 Original, M33 Opt, M34 M33 Extended Leroy-Somer Ziehl-Abegg Gain P. Pr (210m) 0.12 (120m) 0.21 (210m) (300m) Gain I. Pr (200c) 0.1 (10c) 1 (100c) 1 4 (400c) Enc. filter Pr ms 1ms 1ms 1ms 1ms PRECAUTION Changing these parameters may cause very strong oscillations in the car, and it is therefore recommended that the default values are used. If motor noise or cabin vibration problems are present, consult section CURRENT CONTROL (TORQUE) Velocidad Actual real speed Set point speed Velocidad Torque Consigna required Par requerido To ensure that motor speed adjusts to the set point, what happens is that the drive adjusts output current, because this translates into torque. That is, if the drive sees that the speed is below the reference, it applies more current (torque) to the motor for it to reach it Unidrive SP Lift Speed Control System 26/83

27 ADVANCE PARAMETER ADJUSTMENT PRECAUTION The parameters that adjust this control (gain and filter) are delicate and it is not recommended that default values are changed. Gain changes for each motor and therefore appear in section 9.2. The switching frequency affects the waveform of the voltage applied by the drive, which causes resonance in the motor coils and can be heard as a sharp whistle. If it is increased to 12-16kHz the sound becomes inaudible but electromagnetic emissions get worse. The torque limit can be increased to attempt to unwedge the lift, but for normal operation the default value should not be raised. TMR or (depends on motor type) Keypad Plus Geared Motor (M322 and SM) M33 Original M33 Ext, M34, M33 Opt, Nuevo Renova Leroy-Somer Ziehl-Abegg Filter curr. Pr (20d) (20d) Conmut. Freq Pr kHz Torque Limit Pr 0.58* (*) On M33 original lifts this parameter was Pr 0.06 instead of Pr START COMPENSATION To achieve good start comfort, "normal" speed control is not sufficient, because due to the imbalance between the car and the counterweight the lift can move a lot (even touching a limit stop if at a terminal floor). This movement is greater in gearless lifts. Speed reference Actual speed Current Secure-Disable POSITION CONTROL This type of strategy does not require loadweights, but does not achieve such a good in-car comfort level (a small bump can be felt on start). It consists of correcting any movement by rapidly applying a current impulse, so that the axis hardly moves. Used as standard in all M34, Nuevo Renova, M322 and Machine Room lifts. For the rest it can be activated if there are problems with loadweights, although comfort is lost. It is possible to adjust Pr to attempt to make control more or less rigid. Can only be used in drives with firmware version 1.05 or later (Pr 0.50 or TMR 3.1 Software). The figure illustrates how, without load compensation, movement is produced in the car at the start. 2 strategies can be employed: load compensation or position control (the latter is not available for M33 original lifts). Both strategies only influence the start (until the drive commences the acceleration profile). To activate load compensation, program TMR Position Control = [NO] (Pr 0.57=0). To deactivate it and use position control, set it to [YES] (Pr 0.57=1) Unidrive SP Lift Speed Control System 27/83

28 ADVANCE PARAMETER ADJUSTMENT LOAD COMPENSATION Load compensation requires loadweights (Micelect or Orona) that tell the drive how much load the car contains via an analogue input (0-100%). Thereby, when the drive opens the brake, it is already applying appropriate current to compensate the imbalance (as displayed in the figure) and the pulley hardly moves. This type of strategy is used in all M33 lifts (original, extended, optimized), the Leroy-Somer and Ziehl- Abegg. It is important to highlight that the analogue signal from the Micelect loadweights takes the form of current (0-20mA) whilst for Orona loadweights it is voltage (0-10V). To invert the compensation performed by the loadweights: Using the Keypad Plus, change the sign for Pr 0.26 and invert Pr 7.13 Using the TMR, invert Comp. sign Default compensation and adjustment values must be sufficient to ensure good comfort, and can be consulted in section 9.2. Parameter TMR Keypad Plus Left lifts Right lifts Compensation with empty lift Compensation Pr 0.26 Positive value* Negative value* Ramp signal: Comp. sign Pr Ramp slope: Adjust Pr 0.27 Value Analogue signal type AI Mode Pr mA (Micelect) or Volt (Orona) (*) When using TMR, the sign is already included in the parameter Comp. sign Calibration of load compensation: The default parameters programmed for the drive should be sufficient. If there is a lot of counter travel on opening the brake, first check that the loadweights measures correctly and that the counterweight is properly setup. If despite all this it is necessary to calibrate compensation: 6. To calibrate 0 (compensation with car empty): a. Position the empty car at the top floor, place in emergency. b. Set inspection speed at 0 (TMR 5.2 Vinsp or Pr 0.17). c. Press descend on the operating panel, wait 3 seconds and make a note of the torque value and sign Pr 0.24 or TMR 3.1 Torque and Sign Torque). d. With this result, program Pr 0.26 (or TMR Compensation and Sign.Comp). e. If the signal was positive, program Pr 7.13=1. If not, Pr 7.13=0 (with TMR not necessary, is automatically configured when changing Sign.Comp). 7. To calibrate the ramp (compensation per kg of load): a. With the car at the top floor and inspection speed set to 0, insert full load. b. Press descend on the operating panel, wait 3 seconds and make a note of the torque value (Pr 0.24 or TMR 3.1 Torque). c. Add the value obtained from Pr 0.26 (TMR Compensation), ignoring the signs obtained, and divide it by 80. d. Program the result from the operation in Pr 0.27 (or in TMR Adjustment, but multiplying by 1000 because the MT is in thousandths). 8. Undo change to Pr 0.17 and record parameters Unidrive SP Lift Speed Control System 28/83

29 ADVANCE PARAMETER ADJUSTMENT BRAKING RESISTANCE The braking resistance is responsible for dissipating the energy recovered by the motor when the car moves due to the load. To avoid the resistance burning itself, the drive controls the energy that it dissipates and gives a fault if this is excessive. Parameter TMR T.resist.frein. (Pr 10.30) regulates how much it can dissipate before providing the fault. The default value is 4. If the drive gives errors IT.Br and counterweight is correct, this value can be increased RESCUE OPERATION When the lift has an autonomous rescue system it uses a SAI (Uninterruptible Power Supply based on batteries) to power the drive in the absence of power supply. An autotransformer is necessary to raise the output voltage from the SAI from 220V to 380V (otherwise the drive will indicate a UV fault). SUPPLY The values that play a role in a rescue are: Pr 0.34 (TMR Load Favour.dir): must be set to 1 (yes). When the drive reads that the rescue input is active, it automatically chooses the most favourable direction (depending on the car load). Cannot be set to 0 (no) if the SAI is not sized for this (special cases). Pr 0.59 (TMR Torque Limit): indicates the torque percentage that can be provided to the motor during the rescue operation. By default 100%, should never require a higher value (otherwise probably attempting to go against the load). Pr 0.23 (TMR 3.2 Rescue): indicates if the drive detects that input 26 has been activated (which indicates that rescue mode is operational) RFC MODE RFC mode allows the drive to control asynchronous motors without an encoder, estimating motor speed based on internal current and voltage readings. It is not recommended that it be used, other than to rule out problems with an encoder, because the comfort obtained is not optimum. Under no circumstances can it be sued with permanent magnet synchronous motors. To activate it: UPS Transf. DRIVE CONTACTORS C1 & C2 Using the Keypad Plus: Pr 3.24=1 (activates the mode), Pr 3.40 = 0 (so drive does not give encoder faults). Using TMR Without enc. = Yes Unidrive SP Lift Speed Control System 29/83

30 FUNCTIONS 5. FUNCTIONS 5.1. INVERSION OF DIRECTION OF ROTATION Depending on the location of the machine in the shaft, it is necessary to change the rotation direction so that the car movement agrees with the controller signal M322 LIFTS AND LIFTS WITH MACHINE ROOMS To invert the direction of rotation in these lifts, it is sufficient to invert parameter TMR 4.2 Change Direction or Pr M33 EXT, M33 OPT, LEROY-SOMER AND ZIEHL-ABEGG LIFTS In these cases it is necessary to invert, in addition to operating orders, the compensation that is applied as a function of the signal from the loadweights: Parameter Left Right Effect of changing Pr 0.33 ON OFF Inverts the direction of rotation Pr 7.13 ON OFF Pr 0.26 Positive value Negative value Inverts the compensation provided by the loadweights when the car has load Inverts the compensation provided by the loadweights when the car is empty The 3 parameters are automatically inverted if TMR 4.2 Rotation is inverted M34 LIFTS In these cases loadweights are not used, and therefore to invert the direction of rotation it is sufficient to change Pr 0.33 or TMR 4.2 Rotation. ATTENTION As the M34 is orientated differently depending on its position, these should always be programmed with TMR 4.2 Rotation = Izq [LEFT] (Pr 0.33 = On) ORIGINAL M33 LIFTS Here, as no PLC is present, it is necessary to change the following parameters: Parameter Left Right Effect of changing Pr Inverts the direction of rotation when controller orders Ascend. Pr Inverts the direction of rotation when controller orders Descend. Pr 7.13 ON OFF Pr 0.26 Positive value Negative value Inverts the compensation provided by the loadweights when the car has load Inverts the compensation provided by the loadweights when the car is empty Unidrive SP Lift Speed Control System 30/83

31 FUNCTIONS 5.2. MOTOR AUTO TUNING The auto tuning or auto adjustment process serves to calculate: Motor parameters (TMR or 5.5.2): resistance (Pr 5.17), inductance (Pr 5.24) and: In the case of asynchronous motors: power factor (Pr 0.43). For synchronous motors: encoder reference angle (Pr 0.43). This parameter is fundamental for correctly controlling these motors, see section 6.3. Control parameters (TMR or 5.6.2): Gain.P.curr (Pr 0.38) and Gain.I.curr (Pr 0.39). These parameters are very important to motor control, and the values calculated by the auto tuning tend not to be ideal, and therefore it is recommended to: Use those indicated in this standard for that motor or a similar one. Divide by 2 (motor up to 22kW) or 4 (motor over 22kW) the values calculated by the auto tuning where there is no data for a similar motor. If the drive has been changed auto adjustment is not necessary (it is sufficient to copy the parameters from one to the other using the SmartCard or using the SM-Apps.Lite card reset to default parameters function). However, auto adjustment should be carried out when: The motor is special and therefore its electrical parameters do not figure in the tables. A synchronous motor encoder has been manipulated (rotated or replaced) ROTARY AUTO TUNING To perform this auto adjustment the traction cables must be unhooked because the motor needs to be able to rotate freely. For synchronous motors, this can be attempted with a balanced load in the centre of the shaft, but the estimated angle will be imprecise. For asynchronous motors it is impossible to perform directly with cables (it takes too long and it would crash). The rotary auto tuning process is as follows: 1. Put the lift in emergency mode. 2. If using the TM, program TMR 4.1 Type = [Rot] and Execute = [YE] If using the Keypad Plus, program Pr 0.40=2 and Pr 8.11=on (the latter should not be performed for original M33 lifts). 3. Press an emergency pushbutton (up or down) and keep it pressed until the drive finishes the auto tuning (approx. 40s). This can be observed because TMR 4.1 Status will change to inactive or the Keypad screen will display rdy. 4. Make a note of the values obtained (especially the angle) and correct the gains. 5. If Pr 8.11 has been modified, reset to off. 6. Check for correct motor operation before hanging cables. A synchronous motor should consume (Pr 0.12) less than 1A, and an asynchronous one approximately half its rated current. Record parameters and SmartCard. If the auto tuning was performed with the Keypad Plus and it fails because the brake opens and closes repeatedly, repeat the entire process with Pr 8.11=off and setting Pr 8.21=8.09+ in step 2. Upon completion of the process, reset 8.21= in step STATIC AUTO TUNING This auto adjustment doesn t need the motor to move and therefore cables don t have to be unhooked. However, it doesn t calculate the encoder reference angle (synchronous motors) and its power factor estimate (synchronous motors) isn t as precise as with rotary auto tuning Unidrive SP Lift Speed Control System 31/83

32 FUNCTIONS To perform static auto tuning: 1. Put the lift in emergency mode. 2. If using the TM, program TMR 4.1 Type = [est] and Execute = [YE] If using the Keypad Plus, Pr 0.40 = 4 (synchronous motor) or 1 (asynchronous). 3. Press an emergency pushbutton (up or down) and keep it pressed until the drive finishes the auto tuning (approx. 2s). This can be observed because TMR 4.1 Status will change to inact or the Keypad screen will display rdy. 4. Make a note of the values obtained and correct gains if necessary. Store parameters SM-APPS.LITE SPECIAL FUNCTIONS This section describes functions that are only available due to the software contained on the SM-Apps.Lite card. If the drive did not originally include this card, it can be added to provide these functions (in the case of original M33 lifts, the only function that can be used is reset to default parameters) ANGLE ESTIMATE (ONLY SYNCHRONOUS MOTORS) This function allows the encoder reference angle to be estimated (Pr 0.43) on a synchronous motor, in the same manner as when performing a rotary auto tuning but without having to unhook the traction cables. A certain amount of imbalance is required for the estimate, therefore it is important to ensure that the brake opens and that the car and counterweight are not balanced (a good way of doing this is to test using manual rescue, the car moves). To perform the angle estimate: 1. Put the lift in emergency mode with the car empty. Leave a certain distance from the edges (the process will fail if the counterweight or car rest on the buffers). 2. Set Pr to 1 3. Press an emergency pushbutton to initiate the process. 4. During the process, the motor tends to become unstable, and therefore the drive and the lift controller report O.Spd errors. This doesn t mean that the process has failed (these faults are automatically recovered and the process continues). The emergency pushbutton must remain pressed until the process finishes correctly (Pr returns to 0) or the drive display shows a Tune fault (which indicates that the process has failed). 5. If the process completes correctly, Pr returns to 0 and the lift starts to move normally. Release the pushbutton to stop. 6. Check that motor current consumption (Pr 0.12) is normal. With the car empty downwards, the value for Pr 0.12 should be approximately 80-90% of nominal motor current. To the contrary counterweight is incorrect or process has failed. If the process fails continually with Tune or Tune2, it could be due to incorrect wiring of the output. Exchange two wires in the inverter output (for example, U and V) and try again. This function only provides an estimate and is therefore less precise than rotary auto tuning. If in doubt, unhook the cables and perform rotary autotuning. Having checked that the lift works perfectly with the new calculated angle, it is recommended it be phased to 0 as described in the following section Unidrive SP Lift Speed Control System 32/83

33 FUNCTIONS ENCODER PHASING TO 0 (ONLY SYNCHRONOUS MOTORS) This function moves the shaft of a synchronous motor to the position calculated by auto tuning (or angle estimate) above (position recorded in Pr 0.43) and phases the encoder to 0 in this position. In this manner, following execution, the angle to be set for Pr 0.43 to control that motor becomes 0. This operation is carried out at the factory for all motors. However, if rotary auto tuning or angle estimate has been performed because the encoder has been changed or moved, phasing to 0 can also be used. To execute this function: 1. Put the lift in emergency mode. Leave a certain distance from the edges (the process will fail if the counterweight or car rest on the buffers). 2. Set Pr to 1 3. Press an emergency pushbutton (ascend or descend) to initiate the process. 4. During the process, the motor will move by approximately one turn to place itself in the phasing position. 5. If the process completes correctly, Pr phases to 0, Pr returns to 0 and the lift starts to move normally. To the contrary the drive returns a Tune fault. Once finished, check that motor current consumption (Pr 0.12) is normal. Supposing the car is empty, use the emergency control panel to move the car down, the value for Pr 0.12 should be approximately 80-90% of nominal motor current RESET TO DEFAULT PROGRAMMING The SM-Apps.Lite card memory contains a saved copy of default parameters for each Orona installation type. To restore them, proceed as follows: 1. Stop the lift (place in emergency mode). 2. Program the lift type in Pr 19.14: Type M33 original M33 ext. M33 opt. Leroy- Somer Ziehl- Abegg M34 Machine room M rpm M rpm Pr Program installation type in Pr 19.15: Asynchronous motors with machine room Synchronous M322 Motors Red. Susp Speed Pulley Mot. M. speed Reg.pow Pr Persons m/s mm Pow. (cv) (rpm) (kw) Pr Only standard parameters, upon completion of reset, have to program motor, speed, acceleration and jerk. rest :2 2: :1 1: :2 1: :1 1: Unidrive SP Lift Speed Control System 33/83

34 FUNCTIONS Speed 1 1,6 Persons Direction M33 original M33 ext. M33 opt. M Left 1 1 Right Left 3 3 Right Left 5 5 Right Left 1 7 Right Left 3 9 Right Left 7 11 Right Left 9 13 Right Left Right Left 5 17 Right Left 7 19 Right 8 20 Gearless Leroy-Somer Machine Gearless Ziehl-Abegg Machine Load Load Pulley Speed Susp. Speed (kg) Direction Pr (kg) (mm) Direction Pr Right :1 318 Right Right :1 318 Right Right :1 318 Right 3 1.s Right :1 392 Right :1 395 Right :1 444 Right 6 These parameters are generally recorded at the factory for each type of installation, but it is important to check them before resetting. 4. Set Pr 0.00= Set Pr 19.40=on to initiate reset. 6. The reset lasts approximately 30 seconds, on completion Pr automatically returns to off. During the process faults may arise that will reset upon completion of the process (doesn t mean it has failed). If after 1 minute Pr continues at on, the process has failed. Program Pr = off, restart the SM-Apps.Lite card (Pr x.00= ) and restart from point After the resetting to default parameters, the SM-Apps.Lite card must be reset: Pr x.00= After confirming that the lift works properly and that the programming is correct, parameters for Pr 0.00= should be recorded. This reset to default programming function CAN be used with M33 original lifts (if an SM-Apps.Lite card is added to the drive) Unidrive SP Lift Speed Control System 34/83

35 FUNCTIONS FILTERING OF DIGITAL INPUTS The controller controls the drive via 5 digital signals: 2 for direction and 3 for speed level. If due to electromagnetic problems one of these signals changes value, albeit briefly, the drive responds by starting a ramp. If this occurs near a speed change point, the lift can overrun its stop. Using the calculation capacity of the SM-Apps.Lite card, these inputs are filtered, ignoring any change lasting less than 8ms UNIT CONVERSION The units used by the Control Techniques drive for speed, acceleration and jerk parameters are more geared to machine tools than lifts. To better see what effect these parameters have on the car, unit conversion has been implemented in the card (from rpm to m/s). To perform this conversion, the following input parameters are necessary (factory adjusted for most installations): Data Keypad Plus Suspension Pr : Pr Reduction Pr : Pr Pulley diameter (mm) Pr (*) For example, a lift with 2:1 suspension should be Pr 19.18=2 and Pr 19.19=1 The speed copy parameters in m/s are described in section Copies of accelerations (m/s 2 ) and jerks (m/s 3 ) are described in It must be borne in mind that all these copy parameters are read only COUNTERWEIGHT CALCULATION (ONLY GEARLESS MOTORS) On all lifts it is essential that the counterweight is correctly setup, because otherwise there may been problems with excessive heating or even destruction of the motor, the drive or (more commonly) the braking resistances. It is also important, especially to achieve good car comfort, that mechanical system assembly (guides, side bars, cables) is the best possible. This tends to measured by a variable called mechanical efficiency (a good value is 80% for M34 and 85% for the rest). This function allows mechanical efficiency to be calculated approximately and how much weight needs to be added to the counterweight without having to place a balanced load in the car. This can only be used in gearless lifts. This function requires the following parameters to be programmed (factory adjusted for most installations): Data Keypad Plus Correct value Suspension Pr : Pr :1 for M34, 2:1 for M33 opt, variable (rest) Reduction Pr : Pr :1 in all cases (they are gearless) Pulley diameter (mm) Pr (M34), 160 (M33 opt), variable (rest) Counterweight factor (%) Pr % (M34), 50% (rest) Motor rated torque (Nm) Pr Variable, get from rating plate Lift rated load (kg) Pr To use this function: Unidrive SP Lift Speed Control System 35/83

36 FUNCTIONS 1. Lock the doors from the Maintenance Terminal. 2. Set the load in the car during the test (by default 0, empty car) in Pr Set Pr to 1 4. Make 2 calls from the MT to travel the entire shaft (on up and one down, or the other way round). If a full run is not possible, an emergency manoeuvre can be performed (at lest 4 seconds each run) but measurement precision will be reduced (it is recommended that the manoeuvre be performed half way up the shaft to correct the effect of traction cable weight). 5. At the end of the second run, the function finalises and returns Pr to 0 again and returns results for: - Efficiency (Pr 20.30): if less than 80%, it is important that the installation be mechanically inspected (guides, guide bars, traction cables, etc.). - Weight in kg that has to be added to the counterweight (Pr 20.31). If it is negative, remove instead of add. It is recommended that the function is run after doing so to see how it has ended up, especially if the weight entered or added is very large. This calculation is an estimate, if in doubt the best thing is to place a balanced load in the car and measure consumption on ascent and descent, which should be approximately the same (1A difference) IMPULSE TO UNWEDGE The drive programming has been conceived to achieve a soft speed profile and good in car comfort. This programming isn t ideal for unwedging. This function allows the drive to apply the motor with a maximum possible current impulse to try to unwedge it. To activate this function, enter 1 for Pr For protection, the function automatically deactivates after 120 seconds, giving a T050 fault, that must be reset Unidrive SP Lift Speed Control System 36/83

37 PROBLEM SOLVING 6. PROBLEM SOLVING 6.1. PROGRAMMING PROBLEMS If there are any problems during lift start, first check that the configuration corresponds to the installation type, in accordance with the following table: Lift type M33 Original M33 Extended M33 Optimized Gearless Leroy-Somer Gearless Ziehl-Abegg M34 O-170 / SASSI M rpm M rpm SM- Apps.Lite? Control Mode Pr 0.48 TMR 5.1 Mode Basic parameters Pr PLC status Pr TMR Status DPL status Pr TMR Status NO 0 (no) Doesn t exist 101 ** (NO) YES 0 (no) 2 (run) NO 2 (run) Doesn t exist 111 ** (NO) YES 1 (stop) 2 (run) NO 2 (run) Doesn t exist 121 ** (NO) YES 1 (stop) 2 (run) SERVO NO 2 (run) Doesn t exist 131 ** (NO) YES 1 (stop) 2 (run) NO 2 (run) Doesn t exist 141 ** (NO) YES 1 (stop) 2 (run) NO 2 (run) Doesn t exist 161 ** (NO) YES 1 (stop) 2 (run) NO 2 (run) Doesn t exist 201 ** (NO) YES 1 (stop) 2 (run) NO 2 (run) Doesn t exist C.L.Vector 211 ** (NO) (V.L.Closed) YES 1 (stop) 2 (run) NO 2 (run) Doesn t exist 221 ** (NO) YES 1 (stop) 2 (run) (*) These installations never include a card, but one can be installed to provide additional functions. (**) This parameter has only existed since April 09. If 0 (it is prior to this date), check: Lift type M33 Original Control Mode Pr 0.48 TMR 5.1 Mode No. Poles Pr 0.42 TMR Poles Rated Speed Pr 5.08 TMR 5.5.X rpm nom. Encoder type Pr 3.38 TMR Type 12 (6) 191 or 306 SC.Hiper M33 Extended 12 (6) 239 or 383 SC.Hiper M33 Optimized 16 (8) 239 or 383 SC.Hiper Gearless Leroy-Somer SERVO 32 (16) Varies SC.Endat Gearless Ziehl-Abegg 20 (10) Varies SC.Endat M34 16 (8) 147 SC.Hiper O-170 / SASSI 4 (2) AB M rpm C.L.Vector (V.L.Closed) 6 (3) AB M rpm 4 (2) AB Having checked lift type, check programming corresponds to installation load and speed by verifying rated current and rpm in tables and Unidrive SP Lift Speed Control System 37/83

38 PROBLEM SOLVING Change of Control Mode If the control mode does not correspond to that contained in the table, it must be changed. This involves resetting the control mode and programming each parameter one by one. As this operation is very laborious it is easy to commit errors, instead proceed as follows: Recover the parameters from a SmartCard (see section 3.3). Use a PC and CTSoft to record the corresponding file (ask tech. support) If there is an SM-Apps.Lite card reset to default parameters (5.3.3) can be used. If the parameters on the SmartCard do not correspond to the installation either, request an SM- Apps.Lite or SmartCard from the factory indicating the type of installation Change to basic programming If the file programmed on the drive does not correspond to the installation type: Recover the parameters from a SmartCard (see section 3.3). If there is an SM-Apps.Lite card reset to default parameters (5.3.3) can be used. Use CTSoft to record the corresponding file (ask at factory). Manually program the parameters with the values in section PLC deactivation If the PLC is active (Pr 11.48=2 or TMR Status = Run) and it is to be deactivated (for example because it was an M33 ARCA I, and shouldn t have one), it can be deactivated as follows: Using the Keypad Plus: Pr 11.47=0 Using the Orona MT: TMR Activate = NO If the lift is an M33 ARCA I, the PLC will have unconfigured some of the parameters, therefore set: Pr 14.16=2.07, Pr 0.06=175, Pr 4.06=175, and record them (Pr 0.00= ) PLC activation If the lift requires PLC (that is, it isn t an M33 original, nor does it contain an SM-Apps.Lite card) and the PLC is recorded but stopped (Pr 11.48=1 or TMR Status=Stop), it can be activated: Using the Keypad Plus: Pr 11.47=2 Using the Orona MT: TMR Activate = YES Check the value of the following parameters: - Pr 8.24= Pr 8.25= Pr 8.26= Pr 14.16=4.07 Alter the parameters must be recorded (Pr 0.00= ). If the PLC has not been dumped (Pr 11.48=0 or TMR Activate = No), its best to recover it from a SmartCard (Pr 0.00= ), and then activate as indicated above. ATTENTION 1. The SM-Apps.Lite card automatically deactivates the PLC because it performs the same functions. To activate, first deactivate the DPL. 2. Never activate the PLC on M33 original Unidrive SP Lift Speed Control System 38/83

39 PROBLEM SOLVING DPL deactivation The DPL software used by the SM-Apps.Lite card activates automatically when the card is inserted, deactivating the PLC. If the code is functioning correctly, parameter Pr 17.03=run (or TMR Status=run). If there has been a DPL fault (Pr 17.03=triP or TMR Status=AV) or the DPL has a problem that cannot be recovered, it can be deactivated and operate with the PLC, as follows: - Pr 17.13=OFF and Pr 0.00= (DPL ceases to work) - Pr 11.47=2 (to activate the PLC) - Pr 8.24= Pr 8.25= Pr 8.26= Pr 14.16=2.07 (M33 original) or Pr 14.16=4.07 (rest of lifts). - Record parameters Pr 0.00= This allows, for example, the car to be moved to access the drive if it is in the shaft and the SM-Apps.Lite card needs to be replaced DPL activation The DPL software used by the SM-Apps.Lite card activates automatically when the card is inserted, deactivating the PLC. However, if the code has been manually stopped (as described in the previous point), parameter Pr 17.03=1 (or TMR Status=stop). To reactivate it: - Pr 17.13=ON - Pr 0.00= (the PLC automatically deactivates) - Record parameters: Pr 0.00= Verify that the PLC has been deactivated (Pr 11.48=1 or TMR Status=Stop). If not, set Pr and Pr to the correct value (according to section 9.1) and restart the SM- Apps.Lite card (Pr 0.00= ) DPL faults If the SM-Apps.Lite card detects a problem, execution of the DPL software is halted and the lift stops. On the Keypad Plus or TMR 1 the associated drive fault is SL3.Er (?212). To recover it, set Pr 0.00= If the fault persists, disable the DPL and activate the PLC (see 6.1.5). If the fault is repetitive, obtain the value for the following parameters and consult the Technical Support Department: Parameter Pr Pr Pr Pr Pr Description SM-Apps.Lite card hardware version % of card resources used Type of error Code line where error detected DPL software version Unidrive SP Lift Speed Control System 39/83

40 PROBLEM SOLVING 6.2. DISPLAYING STATUS VARIABLES STATUS OF INPUTS AND OUTPUTS The activation and deactivation of inputs and outputs can be observed in the following menus: Inputs and outputs Up Input Descend Input B1 Speed Level Input B2 Speed Level Input B3 Speed Level Input Loadweights Input Rescue Input Brake Output Parameter TMR 3.2 Up Pr 7.01 TMR 3.2 Down Pr 7.03 TMR 3.2 Speed B1 Pr 8.04 TMR 3.2 Speed B2 Pr 8.05 TMR 3.2 Speed B3 Pr 8.06 TMR 3.2 Load Weight Pr 0.25 TMR 3.2 Rescue Pr 0.23 TMR 3.2 Brake Pr GENERAL STATUS VARIABLES Value OFF / ON 0 / 100% OFF / ON 0 / 100% OFF / ON 0 / 1 OFF / ON 0 / 1 OFF / ON 0 / % OFF / ON 0 / 1 OFF / ON 0 / 1 The following variables can also be viewed on the MT or Keypad Plus: Variable Parameter Value or unit Description Selected speed level Rotation speed Power consumption Secure Disable Motor torque Motor power DC bus voltage Mode Software Subsoftware Encoder position TMR 3.1 Speed ref. Pr 0.14 TMR 3.1 Real Speed Pr 0.10 TMR 3.1 Output Current Pr 0.11 TMR 3.1 SecureDisable Pr 0.29 TMR 3.1 Torque TMR 3.1 Sign. Torque Pr 0.24 TMR 3.1 Power TMR 3.1 Sign.Power Pr 5.03 TMR 3.1 Tension BUS Pr 0.13 TMR 3.1 Mode Pr 0.48 TMR 3.1 Software Pr 0.50 TMR 3.1 Subsoftware Pr TMR 3.1 Enc. Position Pr 3.29 Vnull, V00, Vmax 1,2 8 mm/s rpm tenths of A A OFF/ ON 0 / % pos /neg ±175% W pos /neg kw V V.L.Closed / SERVO CL Vect / SERVO Indicates the speed level selected, according to B1,B2,B3 decoding described in 4.5 Engine rotation speed measured from encoder. Marks reading of drive output current. Indicates if Secure Disable (also called Baseblock) input is activated Marks the amount of torque required from the motor to move the car. The drive estimates this based on measured current. Measurement of power consumed by motor. If negative indicative of power dissipating in braking resistance. Drive BUS DC voltage. Drive control mode. - Drive firmware version - Drive firmware sub-version Encoder position (only if absolute) Unidrive SP Lift Speed Control System 40/83

41 PROBLEM SOLVING 6.3. PERMANENT MAGNET SYNCHRONOUS MOTORS For most applications without machine rooms permanent magnet synchronous motors are being used, which work at low speed, allowing gearing to be eliminated. This translates in less machine volume and weight and more comfortable and silent operation. These motors are comprised of a fixed part (stator) with the coils and a mobile part (rotor) with magnets that is joined to the motor pulley. In applying current to the coils, a magnetic field is created that drags the magnets and the rotor with them. However, for the motor to rotate it is necessary that the current (and with it the magnetic field) is created in the same position the magnets are orientated towards. If they loose synchronisation, the motor cannot provide torque and will be dragged by the load (with the drive reporting fault Enc10). For the motor to start this means: A drive that has been prepared to control this type of motor must be used. It is not sufficient to apply power direct from the power supply. The drive needs to use an absolute encoder to be aware of the shaft position at all times, to know where it should apply current to the coils. Given that the encoder mounts manually, an operation is required (called auto tuning or reference seeking) so that the drive can calculate the encoder mounting position. Reference seeking (auto tuning): The auto tuning operation allows the drive to calculate the position of the motor magnets with in relation to encoder position 0 (reference). This value is saved in parameter Pr 0.43 (TMR Angle). This operation is carried out at the factory for all motors. To avoid this parameter having a different value for each motor, an operation called phasing to 0 is also conducted at the factory, which consists of resetting encoder position 0 to the magnet position. Thereby, any motor phased to 0 can be controlled by a drive with Pr 0.43 (TMR Angle) set to 0 as long as phases U, V, W are respected. This phasing to 0 operation has been possible since the M33 optimized entered production, and therefore only the M33 original, M33 extended (plus those where an encoder or phase sequence has been changed followed by an auto tuning) require reference angle to be other than 0. Section describes how to perform an auto tuning. If an SM-Apps.Lite card is present, the position can be phased to 0 after auto tuning, as described in 0. ATTENTION: THE FOLLOWING IS FUNDAMENTAL TO GUARANTEE ITS OPERATION: Protect the encoder cable, removing it as far as possible from the power cables and avoiding cutting or extending it. If electromagnetic noise penetrates this signal, he motor will have problems. Never dismount the encoder. The encoder is joined to the motor shaft on one side and the machine casing on the other. If either were to move in relation to their fastenings, an auto tuning would be needed to recalculate the angle. Never change phases. Check that phases U,V,W coincide on the drive and the motor and correct if necessary. It is not sufficient to respect the order, U on the drive must coincide with U on the motor, V on the drive with V on the motor To invert the direction of rotation on the motor, use the functions described in 5, never invert the phase order Unidrive SP Lift Speed Control System 41/83

42 PROBLEM SOLVING 6.4. FREQUENT PROBLEMS This section describes some of the most frequent problems and provides advice on how to resolve them. Before referring to this section, it is important to check that the basic drive programming corresponds to the type of installation, as contained in table 6.1. It is also very frequent that problems are due to poor apparatus counter weighting or poor mechanical efficiency. If the drive has an SM-Apps.Lite card, an estimate is possible as described in Otherwise, a half load should be inserted in the car and the current consumption measured (Pr 0.12) in both directions. It should be the same in both directions and less than 70% of the rated value (geared asynchronous motors) or 20% (gearless). Short-circuit on output (OI.AC) The drive reports an OI.AC fault when it detects a current peak in excess of 225% above the motor rated value. As software limits current to 175%, this fault can only occur if there is a short-circuit at the power output (U,V,W) or motor control is lost (normally due to a problem with the encoder in synchronous motors). To attempt to see where the problem resides, we recommend: Attempting a static auto tuning (no need to unhook cables): in synchronous motors an angle error could produce this fault (although it is not common). If static auto tuning doesn t produce a fault, check Angle problems (synchronous motors). If it continues to report an error, continue with this section. Bridge contactors: run motor cables direct to drive, respecting the sequence U,V,W. In so doing a short-circuit in the contactor cable can be ruled out, or even a fault with one of its poles. Eliminate the short-circuit cable-set: in gearless lifts, motor phases are taken to the control panel where a contactor shorts them during the rescue operation. By removing the cable-set this avoids there a problem arising here. Check motor cable-set: measure the resistance between phases and ground with a Multimeter, although the value will vary a lot depending on motor power, it should always exceed 0.3 ohms. If cabling and customisation errors have been ruled out, it is probably a motor coil insulation fault. Check with an insulation meter, and replace the motor if necessary. Overload at output (IT.AC) To avoid the motor overheating, the drive reports an IT.AC fault if the output current exceeds the rated value (Pr 0.46) during a certain period (which is shorter the greater the current). This section describes what to look at if the motor starts to move (if it doesn t, consult the previous point) but this fault appears after a period of time. Rated current: check that Pr 0.46 (TMR 5.5.X Curr.nom) is correctly programmed (according to the tables in and 4.2.3). Counterweight: ensure that the apparatus is properly counterweighted. If the lift is gearless and has an SM-Apps.Lite card, carry out a test as described in If not half a load has to be inserted in the car and check that current consumption in both directions is similar (approximately 60% of rated motor current for asynchronous motors and 20% for synchronous). Efficiency: check that installation is mechanically correct: guide alignment, lubrication, traction cabling tensioning, pulleys, gearing, pulley friction brake, etc. Encoder angle (synchronous motors): if the encoder has moved or the angle (Pr 0.43) is poorly set, the motor looses torque. If the error is substantial the drive reports other faults (motor looses control), but if it is small this fault can be produced (the drive is capable of controlling the motor but having lost torque requires more current) Unidrive SP Lift Speed Control System 42/83

43 PROBLEM SOLVING The motor doesn t move The motor doesn t rotate or starts moving and stops shortly thereafter. Some errors can be produced such as IT.AC. Check in the following order: Control signal activation: check that SecureDisable, Ascend/Descend, speed level signals are correctly activated (see 6.2.1). In M33 original ARCA I lifts, if the speed levels do not activate, the brake micro switches may be faulty. That the drive is not disabled: ensure Pr 6.15=1. That torque is not limited: - M33 original: torque limits (Pr 4.05, Pr 4.06 and Pr 0.06) should be set to 175%. Also check that Pr 14.16= Rest of lifts: when the lift starts the torque limit (Pr 0.06) should increase from 0 to 175%. If it doesn t, check that the PLC or DPL are active (see 6.1) and that Pr 0.58=175. If no SM-Apps.Lite card, check that Pr 14.16=4.07. Check output cabling: check that the 3 phases (U,V,W) arrive at the motor correctly. Perform a static auto tuning (if it produces an RS fault then one or more phases are probably not arriving, fix cabling). If it is a permanent magnet motor, perform checks in section on Angle problems (synchronous motors). That brake output activates: the brake should activate (see 6.2.1) in accordance with the normal operating sequence. With asynchronous motors, if it does not activate check that current (Pr 0.12 or TMR 3.1) increases above half rated (if it doesn t there may be a problem with the motor output cabling). That the brake opens electronically: use a Multimeter to check that voltage reaches the coils (Attention: on m33 original, m33 extended and Leroy-Somer lifts voltage measurements using a Multimeter will give strange readings, although it will be possible to see if there is some voltage). Another way of checking it is to see if the brake-micro switch status changes (if present). If they don t open, check cabling, coils and brake disk. That the brake disk or machine have not seized up: attempt to perform rotary auto tuning (not necessary to remove cables), if it reports a tune1 fault (which means that the shaft cannot rotate during the auto tuning) this is probably the problem. This may be due to the brake having become stuck (has occurred in some M33 optimized where the machine has been exposed to a very damp environment) or to excessive wear in gears, bearings, etc. Consult Authorised Technical Support. That the encoder reads the speed: check that when the shaft moves, that the encoder measures the speed (Pr 3.27 and Pr 0.10). If either does not see speed, check menu 3, encoder cabling and assembly. On synchronous motors RFC mode can be activated (see section 4.12) to operate provisionally without encoder and see if there problem lies there. Load overwhelms motor (synchronous magnet motors): If on opening the brake, the car is always dragged by the counterweight, the motor is not providing sufficient torque. It will probably be accompanied by fault Enc10, IT.AC. It is recommended trying in each direction and mid-shaft, leaving a few seconds to make sure there are no loadweight adjustment problems or that the direction of rotation is inverted. Check in the following order: That the drive is not disabled: ensure parameter Pr 6.15=1. That torque is not limited: - M33 original: current limits (Pr 4.05, Pr 4.06 and Pr 0.06) should be set to 175%. Check that Pr 14.16= Rest of lifts: when the lift starts the current limit (Pr 0.06) should increase from 0 to 175%. If it doesn t, check that the PLC or DPL are active (see 6.1) and that Pr 0.58=175. If no SM-Apps.Lite card, check that Pr 14.16=4.07. That there is power in the motor: can be seen in Pr 0.12 or TMR 3.1 Current. If 0, this means there is an output connection error or the contactor doesn t go in. That the motor is not feed to 2 phases: check the output cabling, attempt a static auto tuning (if it produces an RS fault then one or more phases are probably loose) Unidrive SP Lift Speed Control System 43/83

44 PROBLEM SOLVING Ensure counterweight is correct: if the counterweight is very badly constructed, the motor may not have sufficient torque to retain the car. Test inserting more load in the car. Perform checks in section Angle problems (synchronous motors). Load overwhelms motor (asynchronous motors): If on opening the brake, the car is always dragged by the counterweight, the motor is not providing sufficient torque. It will probably be accompanied by fault O.SPd or IT.AC. Check in this order: That the drive is not disabled: ensure parameter Pr 6.15=1. That torque is not limited: current limit (Pr 0.06) should increase from 0 to 175% when the lift starts. If it doesn t, check that the PLC or DPL are active (see 6.1) and that Pr 0.58=175. That there is power in the motor: can be seen in Pr 0.12 or TMR 3.1 Current. If 0, this means there is an output connection error or the contactors doesn t go in. Ensure counterweight is correct: if the counterweight is very badly constructed, the motor may not have sufficient torque to retain the car. Test inserting more load in the car. Angle problems (synchronous motors) Fault Enc10 The drive reports an Enc10 fault when it detects that is loosing control over a synchronous motor. This tends to occur when there is a problem with the angle or the encoder. If the fault is constant (as soon as motor is started), check: Output phases: check that phases U,V,W correctly arrive from the drive to the motor without crossing. Encoder cabling: check encoder cabling for cuts, remove from power cables as far as possible. Encoder angle: check that Pr 0.43 or TMR Enc.Angle has that correct value (0 in the majority of cases). Encoder mechanical assembly: ensure that the fixed part of the encoder doesn t slide in relation to the rear machine cover. Recalculate encoder angle: an angle estimate can be produced if the drive has an SM- Apps.Lite card, if not traction cables will have to be removed and a dynamic auto tuning performed. If the fault occurs occasionally, especially during abrupt stops (for example with the inspection operating panel), check: Encoder cabling: check encoder cabling for cuts, remove from power cables as far as possible. Encoder mechanical assembly: ensure that the fixed part of the encoder doesn t slide in relation to the rear machine cover. Program an auto reset: as described further on. Counter movement on start The lift works OK, but there is counter movement on start or it is slightly dragged by the load (if it touches a limit stop it stops). If it shifts or seems to loose control, consult Load overwhelms motor. This may be due to the drive not controlling the brake relay (in which case the brake enters and drops with the controller contactors, and therefore when the brake opens there is no current in the motor and the load overwhelms). If this is happening, it is probably also accompanied by a bump on stop. Check that Pr 0.22 (or TMR 3.2 Brake) change to 0 on arrival at the floor before the controller removes the contactors. If it doesn t, check Pr 8.21=19.46 (on m33 original, must be Pr 8.21=9.02). If it does, check rtf relay cabling and brake disk Unidrive SP Lift Speed Control System 44/83

45 PROBLEM SOLVING It can also be the case that the motor does not have sufficient current when the brake is opened. To discount it, increase Pr 0.51 (TMR Open brake T) by 500ms and Pr 0.53 (TMR T start travel) by 0.5s and see if it disappears. Observe if Pr 0.06 reaches 175% before the brake output is activated, if not reduce Pr 0.52 (or TMR Torque T). If the motor shifts on start but then stops and remains at speed 0 (despite having a speed set point), it is probably at 2 phases (consult Motor doesn t move ). It may be due to the loadweights being poorly configured (in lifts that use them). To verify this: Activate the position control (Pr 0.57=1 or TMR Position Control = YES). If the problem persists, it is not due to the loadweights, consult Load overwhelms motor. Check that the loadweight measures correctly. Input (Pr 0.25 or TMR 3.2 Loadweight) should be 0% with car empty and approx. 100% with full load. If it isn t, loadweights must be configured properly. For Orona loadweights, check that Cancel Weighing = NO in menu 4.3 of the loadweight device. Also check the version (Menu of Loadweight device), it should 1.0 or later (update if not). For Micelect loadweights, check that internal bridges J1 and J2 are in position 2-3. Check the weight parameters (TMR 3.2 or using the Keypad Plus Pr 0.26, Pr 0.27, Pr 7.10 and Pr 7.13) are those that correspond for the installation. If they are ok, try simply inverting it changing TMR Sign.Comp. (or, if using the Keypad Plus, invert Pr 7.13 and the sign for Pr 0.26). If there is still counter movement, recalibrate the weight as described in Bumps on arriving at floor May be due to: Controller disconnecting contactors too soon: extend the contactor drop period (MT Control 5.3.3). The drive stops applying current too soon: extend the contactor drop period and the travel stop time (Pr 0.55 or TMR 5.4.1). The brake drops when the motor hasn t stopped yet. Increase the brake closing time (Pr 0.23 for m33 original, TMR or Pr 0.54 for the rest) and contactor drop time. The drive doesn t control the brake relay (the brake enters and drops with the controller contactors). If this is happening, it is probably also accompanied by a shift on start. Check that Pr 0.22 (or TMR 3.2 Brake) change to 0 on arrival at the floor before the controller removes the contactors. If it doesn t, check Pr 8.21=19.46 (on m33 original, must be Pr 8.21=9.02). If it does, check rtf relay cabling and brake disk. The car overruns the floor because the motor doesn t stop in time: check deceleration, jerk and floor approximation speed parameters. Controller faults 345 and 346 In optimized M33, M34, Nuevo Renova and gearless Leroy-Somer or Ziehl-Abegg lifts the controller reads the status of each brake via the micro switches. The majority of cases only have 2 brakes (MT Control Controller FR = [C_2]) but in Leroy-Somer machines there can be 3 or 4 brakes ([C_3] or [C_4]). In m33 original and extended lifts, there is just one reading and both contacts in series (MT Control Control FR = [C_1]). M33 ARCA I lifts did not read the brake micro switches (although they did cut speed signals, see ). In gearless Leroy-Somer lifts, the contacts are normally closed instead of open, and therefore should be programmed MT Control Logica.Ent.FR = [N_C]. In the rest it should be [N_O]. Micro switch activation and deactivation can be seen in MT Control, (attention, the logic of inputs E7, E8 and E9 is contrary to that of E6): Input E6: micro 1 (or both micros in series for M33 original and extended) Input E9: micro Unidrive SP Lift Speed Control System 45/83

46 PROBLEM SOLVING Input E7: micro 3 (only in Leroy-Somer machines with 3-4 brakes) Input E8: micro 4 (only in Leroy-Somer machines with 4 brakes) If fault 345 appears, try to move in emergency (which ignores contact status). If the car doesn t move, the brake probably isn t opening, consult The motor doesn t move. If the brake does open and the car moves, check that the base plate inputs are activated. If they fail, change the brake micros. If they manage to activate but despite this there are still occasional faults, extend the time T.Ret.FR. If fault 346 appears on arriving at the floor, check that the readings are deactivated. If they don t, check or change the brake micro switches. If they change, but the lift bumps on stop, extend the contactor drop period (MT Control 5.3.3) at 5d and travel stop time (Pr 0.55 or TMR 5.4.1) at 500m. If the bump and/or fault 346 occur occasionally, proceed in the same manner (increasing both times). The motor doesn t reach the speed it should Controller slipping faults (804) If controller slippage faults occur, check if the motor actually reaches the speed it should reach or if there is a detection problem (with the speed limiter encoder). See motor speed with Keypad Plus (Pr 0.10 in rpm). Can also be seen with TMR 3.1 Real Speed, but in mm/s (calculation made). If it reaches its correct speed according to table 4.5.1, check the detection levels set for the controller (MT Control 5.3.2). Use the speed reading function (MT Control 4.3.3) to see if the encoder reads properly from the speed limiter. If there are occasional errors, slightly reduce the parameter associated with MT Control 5.3.2: for example, if an optimized M33 every so often gives approximation speed slipping errors, reduce V0 from 7c to 6c. If the motor doesn t reach the speed it should, check: Speed parameter programming (according to tables in 4.5). That the drive is reading the reference properly indicated by the control (TMR 3.1 Ref. Speed or Pr 0.14 as indicated in 4.5.1). That the number of poles is correct. Special attention to M322 (4 poles 1500rpm motors and 6 poles 1000rpm motors). Rated speed from rating plate: doesn t relate to a 1m/s motor for a 1.6m/s installation, etc. That voltage isn t saturated (synchronous motors): with descending empty car, check that voltage (Pr 5.02 or TMR 3.1 Voltage) does not reach the rated value programmed for Pr 0.44 or TMR Voltage nom. (which should always be 390). If not, check the counterweight and if it persists consult Technical Support Service. Also note that the control gives an approximation speed set point when it is beyond end magnets CO and CU. There may be a problem with these magnets or the direction of rotation. The lift overruns the travel stop (on all trips) Check speed, acceleration, deceleration and jerk parameters according to tables in and The jerk can be increased for stronger deceleration (although comfort will be reduced, it is preferable to changing acceleration and deceleration). Check the deceleration distances programmed in MT Control (type II/III positioning) or the placement of speed change screens CS/CB (type I positioning). Increase them if necessary. Check the apparatus counterweight and the state of the braking resistance. The lift overruns the travel stop (occasionally) 2336 Anomalies The drive overruns the travel stop occasionally, probably due to electromagnetic noise problems in the CAN bus (which tend to produce 2236 control anomalies). Check programming for Pr 2.04 = Fast. Check the cabling layout, attempting to follow the advice in Unidrive SP Lift Speed Control System 46/83

47 PROBLEM SOLVING Place resistances at the control signal inputs to make the more robust vis-à-vis emissions, as indicated in 2.3. Use a Gateway panel to insulate the bus from the power panel (consult with Technical Support Service). If the problem occurs at the ends on start, it may be due to poor loadweight reading which provokes a small counter movement and touches the limit stop. Activate position control to see if it disappears. th or ths fault This fault is due to the drive having a poorly programmed digital input (Pr 7.15 is set to th instead of Volt). Given that the default Control Techniques programming is Pr 7.15=th whilst the configuration used by Orona is Pr 7.15=Volt, this fault tends to occur when the drive has been reset to the Control Techniques default parameters (in which case the entire drive will have to be reprogrammed). It is recommended to check the drive programming according to table 6.1. If the programming is bad, the parameters will have to be recovered from the SmartCard or from SM-Apps.Lite. If the other parameters are ok and just the fault has to be recovered, program Pr 7.15=Volt, press and record parameters (Pr 0.00= ). Some of the parameters on menu 0 have strange values or are not accessible (Keypad Plus) The parameters in menu 0 are copies of parameters from other menus to make them more easily accessible. Review the control mode (Pr 0.48). If it is bad, recover parameters from the SmartCard or SM- Apps.Lite. Check the parameters for menu 11 and 22: Pr 11.01=3.01 Pr 11.02=4.01 Pr 11.03=5.05 Pr 11.04=1.50 Pr 11.05=1.22 Pr 11.06=1.23 Pr 11.07=1.24 Pr 11.08=1.25 Pr 11.09=1.28 Pr 11.10=18.27 [*] Pr 11.11=18.01 [8.02**] Pr 11.12=8.01 Pr 11.13=8.03 [9.09**] Pr 11.14=4.03 Pr 11.15=7.02 [4.08**] Pr 11.16=4.09 Pr 11.17=7.12 Pr 11.18=3.42 Pr 11.19=8.09 Pr 11.20=11.42 Pr 22.01=11.33 Pr 22.02=11.32 Pr 22.03=18.40 [no**] Pr 22.04=18.45 [11.30**] Pr 22.05=11.24 Pr 22.06=11.25 Pr 22.07=11.23 Pr 22.10=5.12 Pr 22.11=5.18 Pr 22.18=11.31 Pr 22.20=11.29 Pr 22.21=19.12 [no**] Pr 22.22=14.07 [no**] Pr 22.23=12.47 [no**] Pr 22.24=12.46 [no**] Pr 22.25=19.13 [no**] Pr 22.26=12.48 [no**] Pr 22.27=19.49 [no**] Pr 22.28=18.11 [no**] Pr 22.29=18.12 [no**] (*) This parameter is worth 2.13 on M33 originals and 2.17 on M33 extended or asynchronous motors (M322 and Machine Room) (**) These parameters had this other value for M33 originals (or didn t exist). Check that the Keypad Plus firmware version (Pr 40.02) is not , , , These versions can cause problems when modifying parameters on menu 0: a different parameter is modified from the correct one, for example: - When modifying Pr 0.17 value Pr 8.26 is modified instead of Pr When modifying Pr 0.19 value Pr 7.11 is modified instead of Pr 1.28 If you have one of these versions, consult the Technical Support Service. Versions and later do not exhibit this problem Unidrive SP Lift Speed Control System 47/83

48 PROBLEM SOLVING Motor noise and/or vibrations These problems may be caused by the drive control or by mechanical problems with the installation (poor guide alignment, wear, poorly aligned or tensioned traction cables, pulleys jumping, etc.). Check first that parameter Pr 0.06 does not oscillate during motor operation (should remain constant at 175% as indicated in the graphics for sequence 4.4.1). Check: M33 original lifts: Pr 14.06=2.07 Rest of lifts without SM-Apps.Lite card: Pr 14.06=4.07 Rest of lifts with SM-Apps.Lite card: Pr 14.06=0 Also check hat he PLC or DPL are working according to table in 6.1. If necessary, the DPL can be deactivated and it can operate with the PLC to rule out card problems. If the motor is asynchronous, RFC mode can be activated (see 4.12) to rule out encoder assembly problems. Check that the following parameters are programmed as stipulated: Asynchronous motor: TMR Current nom. (Pr 0.46), Poles (Pr 0.42), rpm nom (Pr 5.08), Power fact. (Pr 0.43). Synchronous motor: TMR Current nom. (Pr 0.46), Poles (Pr 0.42), rpm nom. (Pr 5.08). Encoder: TMR type (Pr 3.38), lines (Pr 3.34), Tension alim. (Pr 3.36). Speed control: TMR Gain P. (Pr 0.07), Gain I. (Pr 0.08), enc. filter (Pr 0.28). Current control: TMR 5.6.x Gain.P.curr. (Pr 0.38), Gain.I.curr. (Pr 0.39), Filter curr. (Pr 4.12). Check that indicated motor parameters coincide with the rating plate, if not make a note of original values and program parameters according to plate. Attempt to perform a static auto tuning (see 5.5.2) to calculate new control gains. If the problems persist, the control loops can be retouched but be aware that these adjustments are delicate. Lock the doors and always test without anyone in the car and with the stop button within hands reach, because the motor may become unstable and damage the installation. Change the current (Pr 4.12 or TMR 5.6.X Curr. Filter) and speed (Pr 0.28 or TMR Enc. filter) reading filters according to the following table: Parameter Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8 Test 9 Current filter 0ms 0ms 1ms 1ms 1ms 2ms 2ms 4ms 4ms Encoder filter If it is still not resolved, return to original setting and try: If the motor makes noise even when empty (no cables), try changing the current control parameters. If oscillations are noted in the car or motor, try changing the speed control parameters. The best way of evaluating the behaviour of these parameters is to use a PC and the CT-Scope tool to chart: Motor current (Pr 4.02) against required torque (Pr 4.03). Attempt to adjust current control parameters to avoid oscillations in the chart or excessive noise in the motor. Motor speed (Pr 3.02) against reference speed (Pr 3.01). Having ensured there are no current jumps, the speed loop parameters can be changed to see there are not oscillations in this chart. Attention to the in-car effect of these parameters: good tracking of set point speed does not guarantee good in-car comfort (the oscillation may be due to other parts of the mechanical system) Unidrive SP Lift Speed Control System 48/83

49 PROBLEM SOLVING There are also tools (e.g. SOINDAR) that allow the oscillations produced in-car to be measured and later analysed to determine what could be the cause of the oscillations. Consult Technical Support Service. Not all parameters visible or units not correct (using the Orona MT) Check the MT version in Menu MT Functions. Should be 8.0 or above. If communication is via loadweight plate, also check the version in Menu of the Loadweight device. Should be 1.10 or above. Fault Oht4.P This fault indicates excess temperature in the input rectifier. Can only occur in size 4 or larger drives. If it were to occur sporadically independent of load, could be a problem with noise in the temperature reading, in which case place 2 330nF 500V condensers in parallel between DC+ and GND (can be requested from Control Techniques, reference ). Another option is to program an auto-reset (see further on). If it occurs only under severe traffic conditions, check the counterweight and attempt to reduce the switching frequency (Pr 0.41 or TMR 5.6.X). Cannot modify parameters Check that parameter Pr 0.49 is at L2. If when attempting to modify a parameter the screen displays CODE, this means that a code has been entered by mistake to block parameter access. To unlock: 1. Turn off the drive. 2. Turn it on whilst pressing the blue button and the down arrow on the joypad. 3. Make a note of the code that appears for parameter Pr When CodE appears on the console, enter the code (Pr 0.34). 5. Lastly, modify parameter Pr 0.49=LOC L2 (Access to all menus). Differential jumps (occasionally) Check the connections for the ground cables. Check input power cabling. Measure insulation from ground for input power cabling and motor cabling with insulation meter (disconnecting main switch so there is no power). If problems persist, substitute the differential for one with high immunity. Auto reset If the drive presents a sporadic fault which doesn t appear to prejudice the operation of the device, an auto reset can be programmed (so that you do not always have to recover it) Unidrive SP Lift Speed Control System 49/83

50 PROBLEM SOLVING To do so, configure parameter Pr = 2 (to attempt two fault recoveries) and Pr = 5 (5 seconds between retries). If the fault persists after 2 retries, the drive will stop attempting to recover from it and will remain faulty. Problems with the SmartCard using the Orona MT Loadweight board software versions 0.80 and earlier can have problems reading and recording from the SmartCard. It is recommended to update them to the latest version using the MT. Speeds/accelerations/jerks displayed on TMR don t make sense The TMR converts the values from the drive (rpm) to show them in mm/s (a simpler and more logical unit of measurement to use in a lift). To do so, it equals the rated speed for the lift installation (data that is recorded in the controller, but can be consulted in TMR Rated speed) with: - Synchronous motors: Pr 5.08 (motor rated speed) - Asynchronous motors: Pr 0.02 (maximum speed) If the values displayed for speeds, accelerations and jerks don t seem to make sense, use the Keypad Plus to check them, because the parameters actually used by the drive are in rpm. Check the version of the Maintenance Terminal (8.0 or later) and loadweight board (1.10 or later), because in previews versions these parameters were in centimeters/second instead of milimeters/second Unidrive SP Lift Speed Control System 50/83

51 PROBLEM SOLVING 6.5. DRIVE FAULTS When the drive has a fault, the name appears in the Keypad Plus. If we have TM the name of the last fault can be seen in menu 1 (only the most frequent, the rest are marked as?xxx, with XXX being the fault code). With the fault name or code, the following table can be used to establish its cause and how to go about trying to resolve it: Fault and code cl2 28 cl3 29 CL.bit 35 ConF.P 111 dest 199 EEF 31 Enc1 189 Enc2 190 Enc3 191 Enc4 192 Enc5 193 Enc6 194 Enc7 195 Enc8 196 Enc9 197 Enc Possible cause Analogue input 2 is poorly configured Possible solutions Analogue input 3 is poorly configured Check Pr Programming error Check that Pr 6.43 = 0 Programming error Check that Pr = 0 Two or more parameters attempting to write the same parameter. Corrupt memory data Encoder fault: supply overload Encoder fault: cable cut Encoder fault: phase fault during movement Encoder fault: communication fault Encoder fault: checksum error Encoder fault: encoder detects a problem Encoder fault: initialization fault Encoder fault: initialization fault on start Check Pr Can be due to a problem with the Keypad Plus (see Frequent Problems) Programming Pr 0.00 = only parameters causing the problem will be visible. Correct them. Reset drive to default Control Techniques parameters (Pr 0.00= ), recover parameters from an SM- Apps.Lite or SmartCard and record parameters Check encoder supply voltage (Pr 3.36) and encoder cabling. If asynchronous, switch to RFC (see 4.12) and disconnect encoder. Check Pr 3.36 and encoder cable. Change encoder cable. If it persists, change the encoder. On asynchronous motors, RFC mode can be activated (see 4.12) Find breaks in encoder cable. Remove as far as possible from power cables. If it persists, change cable and/or encoder. Check Pr 3.36 and encoder cable. Change encoder cable. If it persists, change the encoder. Check encoder cable and replace it. Replace the encoder. Encoder fault: customization fault Check that Pr 3.26 = 0 Encoder fault: SERVO phase fault Check encoder parameters (Pr 3.36, Pr 3.38) and encoder cabling. If it persists, change cable and/or encoder. Check encoder parameters (Pr 3.36, Pr 3.38) and encoder cabling. If it persists, change the encoder. If it occurs during normal operation, encoder angle poorly programmed Pr Check U,V,W phase sequence. Perform a rotary auto tuning (no cables) or angle estimate. Enc Encoder fault: Sin/Cos signal fault If it only happens on sudden braking, simply recover the fault by pressing reset. Check encoder cable Unidrive SP Lift Speed Control System 51/83

52 PROBLEM SOLVING Enc Enc Enc Enc Enc Enc ENP.Er 176 Et 6 Encoder fault: encoder Hyperface initialization fault Encoder fault: Endat encoder initialization fault (wrong number of turns) Encoder fault: Endat encoder initialization fault (excessive number of turns) Encoder fault: customization error Encoder fault: initialization error (periods/revolution) Encoder fault: supply overload Error in executing encoder data recovery function Fault activated from digital input HF01-13 Hardware fault Replace the drive HF HF It.AC 20 It.Br 19 L.SYnC 39 O.CtL 23 O.ht1 21 O.ht2 ó Oht2.P 22 or 105 O.ht3 27 Oht4.P 102 OI.AC o OIAC.P 3 or 104 OI.br o OIbr.P 4 or 103 OIdC.P 109 Hardware fault Hardware fault Check encoder parameters (Pr 3.36, Pr 3.38) and encoder cabling. If it persists, change the encoder. Check encoder parameters (Pr 3.36, Pr 3.38) and encoder cabling. If it persists, change the encoder. Check encoder parameters (Pr 3.36, Pr 3.38) and encoder cabling. If it persists, change the encoder. Check Pr 5.36=0. If it persists, replace cable and/or encoder. Check encoder type (Pr 3.36, Pr 3.38) and encoder cabling. If it persists, change the encoder. Check encoder supply voltage (Pr 3.36) and encoder cabling. If it persists, replace it Reset the fault and program the data manually. Program Pr 0.00 = 12001, find what parameter has a value of and program to its correct value. Check braking resistance connection. If it persists, replace the drive. Replace the drive Overload at motor output Consult section on Frequent Problems (6.4) Braking resistor overload. Programming error Excess temperature of control plate Power state excess temperature (in thermal model simulation) Radiator excess temperature Drive excess temperature (in thermal model simulation) Check apparatus counterweight. If it is correct, increase Pr (TMR T.Resist.Frein) Check that control mode (Pr 0.48) is not REGEN. Recover default parameters (using the SM-Apps.Lite or Smartcard). Check that fans work and that ambient temperature is not excessive. Reduce switching frequency (TMR 5.6.X or Pr 0.41) Check lift counterweight. Reduce switching frequency (TMR 5.6.X or Pr 0.41) Check that fans work and that ambient temperature is not excessive. Reduce switching frequency (TMR 5.6.X or Pr 0.41) Check that fans work and that ambient temperature is not excessive. Reduce switching frequency (TMR 5.6.X or Pr 0.41) Rectifier excess temperature Consult section on Frequent Problems (6.4) Output short-circuit Consult section on Frequent Problems (6.4) Braking resistance short-circuit Short-circuit in IGBTs Check braking resistance cabling. Check ohms value for resistance with Multimeter. Measure ground insulation for resistance terminals. O.Ld1 26 Overload or short-circuit of 24V power supply. Measure insulation of output and motor cables. Check control terminal cabling. If ARCA, disconnect RAA and RTF relays to see if it disappears. For M33 opt, check cable-sets JM1 and JM2, above all that JM2-6 (rtf) is not crossed with JM2-(0V) Unidrive SP Lift Speed Control System 52/83

53 PROBLEM SOLVING O.SPd 7 OV o OV.P 2 or 106 PAd 34 PH o PH.P 32 or 107 PS o PS.P 5 or 108 PS.10V 8 PS.24V 9 SAVE.Er o PSAVE.Er 36 or 37 SCL 30 th o ths 24 or 25 Unid.P 110 UV 1 Excess speed Excess voltage in DC Bus Programming error Input voltage imbalance Error in internal power source The speed reading exceeds Pr 0.02 by 120%. If it occurs during travel, check the programming of this parameter. If the speed has not reached this value, check encoder mechanical assembly. If produced because the load overwhelms the motor, consult the section on Frequent Problems (6.4). Check braking resistance cabling and ohms (with the Multimeter). Check counterweight and deceleration (Pr 0.04). Check input voltage (L1,L2,L3). Check motor insulation. Check Pr 1.14=Pr so that drive controlled from digital signals. Check input voltage (L1,L2,L3), when car moves downwards. Check input cabling. Program Pr 6.47=1. If it persists, activate auto reset. If additional cards inserted, remove them and attempt to recover faults. If they recover, replace card with new one. If not, replace the drive. 10V output cabling error (terminal 4) Check that no cable connected to terminal 4. Excessive consumption internal 24V supply There has been a power cut whilst recording parameters Check digital input/output cabling. Simply warns that the changed parameters may have not been correctly saved. Recover it, check parameters and save again. 485 communication error 485 communication fault. Check RJ-45 cable. Replace Keypad Plus. Digital input configuration error Consult section on Frequent Problems (6.4) Internal drive connection error DC bus voltage below 350V (because L1,L2,L3 input below 250Vac). The following errors can only occur during auto tuning: Fault and code tune 18 tune1 11 tune2 12 tune3 13 tune4,5,6 14, 15, 16 Cause Auto tuning manually stopped before finishing Auto tuning fails because speed not read from encoder. Auto tuning fails because motor rotation does not correspond to encoder rotation. Encoder signals fail Incorrectly configured encoder Replace the drive Tends to occur whenever voltage removed. If it occurs during normal operation, check L1,L2,L3 input voltage with empty car descending (should be Vac). If it occurs during a rescue, check the status of the automatic VR. Ensure CEM contactor activates. Check SAI cabling and 220/380 transformer. Possible solutions Control has probably disconnected the contactors, removing Secure Disable signal. Recover fault and repeat auto tuning. Can be due to an encoder fault or shaft hasn t rotated (because cables not removed or brake not opened). Check U,V,W sequence. If its OK and the fault persists, exchange 2 phases. Check encoder cabling. Replace cable and/or encoder. tune7 17 Rotation speed doesn t coincide with theoretical. Check encoder parameters. If it persists, change cable and/or encoder. Check number of poles and encoder parameters Unidrive SP Lift Speed Control System 53/83

54 PROBLEM SOLVING rs 33 Stator resistance too great (or circuit open) Should only occur if one or more drive output phases not reaching motor. Check contactor cabling. SmartCard usage errors: Fault and code C.Acc 185 C.boot 177 C.bUSY 178 C.Chg 179 C.Cpr 188 C.dAt 183 C.Err 182 C.Full 184 C.Optn 180 C.Prod 175 C.Rdo 181 C.rtg 186 C.TyP 187 PLC errors Fault and code UP ACC 98 UP div0 90 UP OFL 95 UP ovr 94 UP PAr 91 UP ro 92 Possible cause Cannot read/write to SmartCard Incorrect parameter form writing attempt Cannot access SmartCard because it is being accessed from another location. Possible solutions Check SmartCard correctly inserted. Replace SmartCard Never program Pr = 3 (auto) or 4 (boot) Repeat the operation. If it persists, disconnect additional cards, and retry. The SmartCard is not empty Repeat deletion operation (Pr 0.00= ) SmartCard data doesn t coincide with parameters SmartCard doesn t contain the data that is being attempted to be recovered SmartCard data is corrupt The SmartCard is full. SmartCard data corresponds to different optional cards. Recover by pressing Insert SmartCard with data Check SmartCard correctly inserted. Replace SmartCard Use another SmartCard Recover faults and check parameters for menu 17. SmartCard data is not compatible Delete the SmartCard ( Pr 0.00 = ) Replace SmartCard SmartCard data is write protected Remove protection ( Pr 0.00 = ) SmartCard data is not compatible Delete the SmartCard ( Pr 0.00 = ) Replace SmartCard SmartCard data is not compatible Delete the SmartCard ( Pr 0.00 = ) Possible cause Access fault on recording PLC The PLC tries to divide by 0 The PLC takes up too much space in memory The PLC attempts to write a value above the max. for a parameter PLC attempts to write to non-existent parameter PLC attempts to write to read only parameter Replace SmartCard Possible solutions PLC could not be recorded because drive was enabled. Put the lift in emergency mode and retry. Should never occur. Recover PLC from a SmartCard Should never occur. Recover PLC from a SmartCard Should never occur. Recover PLC from a SmartCard Recover parameters and PLC from a SmartCard. UP So 93 PLC attempts to read a parameter that is read only Should never occur. Recover PLC from a SmartCard Should never occur. Recover PLC from a SmartCard Unidrive SP Lift Speed Control System 54/83

55 PROBLEM SOLVING UP udf Indeterminate PLC error Should never occur. Recover PLC from a SmartCard 97 UP user PLC program forces the drive to stop. Should never occur. Recover PLC from a SmartCard 96 The following errors relate to additional cards, such as the SM-Apps.Lite. The X that appears in the fault code stands for a 1, 2 or 3 depending on the slot where the card is installed. Fault codes also differ depending on the slot. Fault and code SLX.Er 202,207,212 SLX.HF 200,205,210 SLX.nF 203,208,213 SL.rtd 215 SLX.tO 201,206,211 SLX.dF 204,209,214 Possible cause The SM-Apps card in slot X has detected a fault Hardware fault for SM-Apps.Lite card in slot X The SM-Apps card in slot X has been removed Internal SM-Apps card error The Watchdog for the card in slot X has overflowed An SM-Apps card has been changed in slot X (one model for another) Possible solutions Check section 0 Check card installation. If it persists, replace it. Informational only. Recover faults and record parameters. Reset fault. If it persists, consult Technical Support Service. Should not occur (watchdog not used). Check that Pr 17.18=0. Recover fault. Informational only. Recover faults and record parameters. The following errors are provoked by the DPL code on the SM-Apps.Lite card when it detects a problem with lift operation: Fault and code t t t Possible cause Drive doesn t have a PLC recorded and is attempting to perform operation 5004 (Record PLC to Smartcard) Time has elapsed for unwedging the device (2 minutes) The protection against winding of the ropes has actuated Possible solutions If it is an M33 original it doesn t need a PLC, but other installations should have this program recorded, if this is not the case obtain a Smartcard from the factory. If more than 2 minutes are needed to unwedge, when this period has elapsed Pr (Activation unwedging mode) should be reset to 1. Increase the protection torque (Pr 19.16) or disable the protection (Pr 19.32=0) Unidrive SP Lift Speed Control System 55/83

56 PROBLEM SOLVING 6.6. CABLING ADVICE All electrical equipment emits electromagnetic signals and is susceptible to being affected by electromagnetic radiation. A frequency drive in particular, because of the way it works, is a piece of equipment that can emit electromagnetic radiation affecting other equipment. This electromagnetic emission can be transmitted by cables (conducted) or by air (radiated). Cable layout can amplify emission levels, and therefore it is essential that the installation be arranged according to ORONA criteria. It is equally important that the accessories used by the drive are defined in the ORONA product ELECTROMAGNETIC EMISSION REDUCTION ELEMENTS Input filter. Electrically installed prior to the drive and located as close to it as possible. The connection cable between the filter output and the drive input should be as short as possible. Earths should be connected. The filter should not be bridged. Output ferrite. The drive output power cable, prior to the contactors, contains a ferrite around which each of the three power conductors is wound 3 times (2 in the case of the M34). Motor power cable. This is a shielded cable, with good quality shielding (covering > 85%). The shield is fixed to earth at each end, using metallic clasps that fasten most of the shield surface. Motor rescue cable (only synchronous motors). This is a shielded cable, with good quality shielding (covering > 85%). The shield is fixed to earth at each end, using metallic clasps that fasten most of the shield surface. In future this shielded cable may not be so if Steward type 28B ferrite is used with three cable turns (or similar characteristics). Braking resistance cable. This cable is also shielded (like the motor power cable) and has similar characteristics. The cable should also be fixed to ground and both ends. Must be as short as possible. Supply cable for brakes with overexcitation. With this equipment, used only on M33 original, M33 extended y gearless Leroy-Somer machines, the cable has to be shielded and fixed to ground at each end. Motor encoder cable. This cable is shielded and its ground connections are made internally. This cable is today installed along with a Steward (or similar) ferrite 28A2025- OA0. Load resistances, drive inputs. 1kOhm resistances are placed on all drive inputs which act as a load and immunize against the coupling of damaging signals in these cables CRITERIA FOR CORRECT CABLING Use of shielded metallic cable-sets for all cables with a power noise signal (motor, synchronous motor rescue, over-excited brakes, braking resistance). Connected to shielding at each end. If running in parallel, the noise cables should be separated at least 30 cm from other channels. Assemble sot that conductors or cables that carry different classes of signal cross each other at right angles, particularly in the case of sensitive and noisy signals Unidrive SP Lift Speed Control System 56/83

57 PROBLEM SOLVING Free or unused conductors in a cable should be systematically connected to ground (chassis, channelling, cabinet, etc. ) at each end CABLING LAYOUT DIAGRAMS M M33 optimized: and M33 original and extended: Gearless Ziehl-Abegg: , and Gearless Leroy-Somer: , and M322: With machine room: Having started the installation, we can make an indirect measurement that tells us if the installation has been correctly performed. We should verify, using the Maintenance Terminal, for the near total absence of error messages in the bus after various car travels EXAMPLES OF POOR CABLING LAYOUT BRAKING RESISTANCE CABLE- SET WHAT S WRONG WITH IT? It isn t shielded. It s long. The cable is looped (power emission). It runs parallel to the filter cable. WHAT S WRONG WITH IT? The encoder cable and motor power supply cable run together, they should be separated by at least 300 mm if they run parallel. The cable, on arrival at the panel, forms a long loop before passing through the ferrite. Cables should be a short as possible and not have loops Unidrive SP Lift Speed Control System 57/83

58 PROBLEM SOLVING EXAMPLES OF GOOD CABLING LAYOUT WHY IS THIS OK? Metallic clip fixes shielding to chassis (ground). Covering > 180º. WHAT S WRONG WITH IT? This capacitor is incompatible with the external filter. It must be removed. WHAT S WRONG WITH IT? The filter ground cable should be connected to the drive s ground terminal Unidrive SP Lift Speed Control System 58/83

59 PROBLEM SOLVING The following image displays an example of how to layout cabling in an M33 Optimized lift, separating power, short-circuits and encoder cables as much as possible: Short resistance Encoder cable-set separated connection from power cable Short-circuit cable-set separated from rest of cables Shielding to ground Cables cross 90º ELECTROMAGNETIC COMPATIBILITY REGULATIONS By following the advice above, the installations should give no problems at all. It has been demonstrated in accredited labs: That, emissions levels from ORONA installations are within the levels set by Standard EN That, immunity levels from ORONA installations are within the levels set by Standard EN Compliance with the standard is an important guarantee. However, there may be installations, where due to their special characteristics there is a problem with: Poor ground connections. Motor connections separated from rest of cables Shielding to ground Cables cross 90º Very sensitive radio/audio equipment installed near the lift. There are particularly sensitive radio frequencies. In such cases, special intervention from the Technical Support Service can be sought Unidrive SP Lift Speed Control System 59/83