« Torque control » option Technical manual for couple VECTOR V I .O & INCRE V I .O software Edition n 3 - 3 février 1998 0
MB-191
Technical manual
19 janvier 2006 page 3
WARNING
This document is correct, as far as can be known, at the time of publication and may be modified without notice. The information it contains has been scrupulously controlled. However AUTlNOR cannot accept any responsibility for errors or omissions. If you find any inaccuracies or if you have any suggestions you can send your comments written (by mail andlor fax) to :
Société AUTINOR Z.A. Les Marlières
This document is the property of AUTINOR from whom it can be bought (from the above address). It can nonetheless be freely reproduced to convey information to anyone whom it may be justifiably concern. Only its integral reproduction, without addition or omissions is allowed. In the case where this document is quoted, at least :
- AUTINOR, the name of the Company, - Software version,
-
the number and date of the original edition
must be mentioned.
MB-191
Technical manual
19 janvier 2006 page 5
SUMMARY
BEFORE YOU START READING ............................................................................... 7 THE « TORQUE CONTROL » OPTION .................................................................... 9 The aim for this option ....................................................................................II Functional presentation.................................................................................. 1 Limits of use ....................................................................................................15 Minimal car speed ................................................................................ 15 Not adapting to the VF « COMPACT » ................................................. 15 Exclusion of the OND07 board ............................................................. 15 Hole threaded through the motor shaft ................................................. 15 Number of motor poles ......................................................................... 15 ADDING THE « TORQUE CONTROL » OPTION TO AN EXlSTlNG MLIFT ............17 Composition of the modification kit .................................................................19 Preparation of the main OND04 board ...........................................................21 . . . ...................................21 Replacing the quartz crystal .................... Positioning of the J2 connector ............................................................21 23 Replacing the program memory ........................................................... . . . .......................23 Installation of the OND22 board ....................... . Possible modification of the N I 0 main board ..................................................25 Installation of the brake contactor FR (BR) .....................................................27 Connecting the brake coi1 contactor ..................................................... 29 Connecting the contactor "power" contacts ..........................................29 IMPLEMENTATIONOF THE « TORQUE CONTROL » OPTION .................... . .....31 Installation of the incremental encoder ...........................................................33 Preliminary checks ............................................................................. 33 . . .................................................................. 37 Alignment ................... . Coupling assembly .............................................................................. 38 39 Use of longer encoder cables ............................................................... Connecting of « torque control )) option ..........................................................41 Connecting brake contactor............................................................... 41 Connecting incremental encoder .......................................................... 41 Links to the lift controller equipment .....................................................43 lmplementation .................... ..... ................................................................ 45 Checking the incremental encoder wiring .............................................45 « TORQUE CONTROL » OPTION PARAMETERS ..................................................47 LIST OF THE APPLICABLE TEMPORARY MODIFICATION NOTES ...................... 53 APPENDIX A MAINTENANCE HELP ....................................................................... 57 What to do for the fault codes ? ......................................................................59 TO ORDER SPARE PARTS ..................................................................................... 65 APPENDIX B LIST OF FAULT CODES .................................................................... 69 INDEX....................................................................................................................... -75
MB-191
Technical manual
19 janvier 2006 page 6
TABLE OF FIGURES
FIGURE 1 (( TORQUE CONTROL )) ELECTRONIC BOARD IN POSITION ON THE FREQUENCY VARIATION ............ 10 FIGURE 2 (( TORQUE CONTROL )) OPTION SERIAL LINKS ........................................................................... 10 FIGURE 3 (( TORQUE CONTROL )) OPTION INSTALLATION KIT .....................................................................18 FIGURE 4 DISASSEMBLY OF OND04 BOARD .............................................................................................. 20 FIGURE 5 QUARTZ DE-SOLDERING / SOLDERING AND SOLDERING J2 CONNECTOR ONTO THE OND04 BOARD 20 FIGURE 6 REPLACING THE PROGRAM MEMORY ? ....................................................................................... 22 FIGURE 7 REPLACEMENT OF THE MEMORY ON THE OND04 BOARD ........................................................22 FIGURE 8 PLACING OF THE OND22 BOARD ............................................................................................... 22 FIGURE 9 PLACING OF THE OND22 / OND04 LINK BRAID .......................................................................... 23 FIGURE 10 INS AND MAN INPUTS SOLDERING ON NI0 MAIN BOARD ........................................................24 FIGURE 11 PLACING OF THE BRAKE CONTACTOR ON MB191 IN THE CASE OF D l8 OR D25 PRINCIPAL 26 CONTACTORS .................................................................................................................................. FIGURE 12 PLACING OF THE BRAKE CONTACTOR ON iviB191 IN THE CASE OF D l8 OR D25 PRINCIPAL CONTACTORS D40. D65 OR D80 ...............................................................................................26 FIGURE 13 ASSEMBLY OF THE FR (BR) CONTACTOR ONT0 THE SYMMETRICAL OMEGA RAIL ........................27 FIGURE 14 ASSEMBLY OF THE ADAPTER FOR THE ASYMMETRIC RAIL ON CONTACTOR FR (BR) .................... 27 FIGURE 15 CONNECT-UP DIAGRAM FOR THE BRAKE CONTACTOR ..........................................................28 FIGURE 16 CONNECTING THE FR (BR) BRAKE CONTACTOR COIL .............................................................29 FIGURE 17 COMPOSITION OF THE (( INCREMENTAL ENCODER KIT )) .........................................................32 FIGURE 18 ASSEMBLY DIMENSIONS OF THE INCREMENTAL ENCODER .......................................................32 FIGURE 19 STANDARDISED MOTOR SHAFTS THREAD HOLE (STANDARD DlN 332) ........................................34 FIGURE 20 ~NSTALLATIONOF THE INCREMENTAL ENCODER ......................................................................36 FIGURE 21 CONNECTING-UP THE (( TORQUE CONTROL )) OPTION WITH VARIABLE FREQUENCY .....................40 FIGURE 22 CONNECTION OF THE OND22 BOARD .................................................................................42 FIGURE 23 CONNECTION OF THE MULTI-VOLTAGE INPUTS VINS AND VISO .................................................44 FIGURE 24 SIGNALS DELIVERED BY THE INCREMENTAL ENCODER ...........................................................45 FIGURE 25 FAULT 70 : REPLACING OF THE OND22 / OND04 LlNK BRAlD ................................................... 60
TABLE TABLE 1 DIMENSION OF THE MOTOR SHAFTS THREAD HOLE .......................................................................34 TABLE 2 MECHANICAL CHARACTERISTICS OF THE INCREMENTAL ENCODER ..............................................38
MB-191
Technical manual
19 janvier 2006 page 7
BEFORE YOU START READING
This guide is a summary of the "Series 191 Bible" technical manual, which contains al1 the information on al1 the different equipment in this series (the electrically driven -A1 91 & B191-, and the frequency drive -MB 191 (ML1FT)-). It has been written especially for the engineers who install MLIFT + B191 equipment. The aim was to make a manual essentially practical and concise ; al1 the information which you only need in certain cases has .thus been eliminated. If need be, you can refer to the complete technical manual. The essential goal of the documentation is to ease your job. A certain number of techniques have been put into operation to achieve this, in particular :
-
Information pertinent to a given subject has been included each time you may need it ; this could mean re-reading but avoids referencing to others parts of the document, The documentation has an index which has been constructed in the style of an analogical dictionary to allow you to quickly find information. It provides crossed references on al1 the information which figures in the summary. So, the index avoids the irritation of being sent to other sections... which do not always contain the information you may be looking for (for Incremental encoder connecting : see Incremental encoder - Encoder connecting or Connecting - of Incremental encoder !page 41).
USE THE INDEX ! If the desired goal is not seem reached, if the documentation does not meet your expectations or if you run into difficulties in your search, send your criticisms andlor observations to the address indicated on the page 1; they will be gratefully welcomed and will allow us to improve future editions.
YOU WlLL HELP EVERYONE ! The documentation is peppered with numerous references to standards; their numbers are in direct relation to the instruction number to which the lift installations are subjected. (you will find the list of these standards in the appendix). These references are not intended to flaunt basically useless knowledge, but, on the contrary, to give you the reason for certain directives and to make readily available the elements which will allow you, if necessary, to reply to the questions which certain customers or safety bodies may pose.
MB-191
Technical manual
19 janvier 2006 page 9
THE « TORQUE CONTROL D OPTION
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Technical manual
19 janvier 2006 page 10
Figure 1 « Torque control » Electronic Board in position on the frequency variation.
* 4
Inter-board line Direction of transmission
OND22 Board
A
The OND22 board's Measure transfer
Figure 2 « Torque control » option serial links
Main board Variable Frequency
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Technical manual
19 janvier 2006 page 11
The aim for this option
The « torque control » option, also called "semi-vectorial regulationJ1,is an addition to the frequency variations for AUTINOR lift motors.. Its main objective is to ensure a real car speed servo-control which allows a better following of the commands given. It additionally allows us : to delay lifting of the brake when starting, to allow motor torque to be established, to allow lower approach speeds from the level than the standard regulation (motor supply voltage frequency of 1 Hz instead of 3 to 4 Hz), to totallv stabilise the motor on arriva1 at a level to eliminate al1 rollback immediately when the brake is dropped. Functional presentation
The option is presented in the form of an electronic board to be fixed ont0 the main frequency variation board, an incremental encoder to be fixed ont0 the motor shaft and a brake contactor. The incremental encoder is substituted with the counter tape to deliver the speed data, but the counter band continues to assure the counting function to determine the car altitude. During its rotation, the incremental encoder delivers 2 signals in the form of 2 series of 500 square symetrical impulses per rotation, in quadrature:
Diagram of the signals obtained with the encoder turning clockwise when viewed from the axis side in accordance with
Channel
Channel
This arrangement allows us to get 2 000 items of data per revolution as the signal composition of A and B gives 4 states (see above), which lets us obtain data on the speed every 10 msl (with a precision of 1/16 Hz on the frequency), although the
For the "mathema.ticians" : As the encoder delivers 2 000 items of data per turn, this means that it is possible to know the position of the motor rotor with a precision of 360°12 000 or approximately 11' (hardly more than 116").
MB-191
Technical manual
19 janvier 2006 page 12
standard regulation does only allow us to get .this data every 200 ms (with a precision of 1 Hz on the frequency), or an increase by a factor of 20. The electronic torque control » OND22 board is substituted, if so desired, with the OND07 extension board from existing eqmipment ; these 2 boards are mutually exclusive. Attention : the OND22 board does not guarantee al1 the OND07 board's functions, in particular :
it does not have the necessary output relays for the selection emulation, it does not have the relay which beats every time the MLlFT detects an overload. The table below gives the electrical equivalence between the OND022 and OND07 inputs 1 outputs (the J I connector is common to the 2 boards).
There are also other limits of use (cf. the Limits of use chapter, page 15). The OND22 board ensures the interface between the incremental encoder and the OND04 board to supply this last bit of data on the motor rotation speed ; this data is substituted for the car speed data deduced from the counter tape in the standard equipment. The OND22 board supplies this data to the OND04 board by a unidirectional link (Figure 2 page 10 : inter-board links) ; strictly speaking, there is no dialogue between the boards. The OND22 board is also "crossed" by the OND04 board microprocessor series output ; this output is used when the factory tests are done to transmit the speed, instruction and other curves to a micro-computer. ATTENTION !!
The +24V, OV, RD and TD connections from the OND22 board K36 connector are reserved for the R&D, Service Qualitv and After-Sales Service departments. Do not connect anything !!
The signals delivered by the RD and TD points do not have the necessary levels to be directly connected to the serial port of a micro-computer and you risk destrovina the OND22 and OND04
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Technical manual
19 janvier 2006 page 13
board micro- roce essors in doinq so. The brake contactor allows the OND22 board to delay the opening of the brake, as long as the electromagnetic flux in the motor is not proven. These "power" contacts are inserted between the output of the +RDF / -RDF D.C voltage, delivered by the lift control equipment, and the usual brake control circuit, made up of one contact from each of the contactors L and S.
MB-191
Technical manual
19 janvier 2006 page 14
Counter speed and tape
To fix these ideas, consider an installation using : A 4 pole motor, which turns at 1500 t/mn when it is fed with a voltage of frequency 50 Hz, A 1/50 reducer, A traction pulley of 0.6 m (600mm) diameter. The car speed Vcabiwhich equals the pulley periphery speed, is linked to the rotation speed V,, from the latter by the relationship : Vcab in mls Vcab= Vrpx x D V,, in t/s D in m The pulley rotation speed is itself linked to the motor rotation speed by the motor reducer p : V,, in t/s Vrp = Vmot X P Vmot in t/s from where : Vcab in mls Vcab= Vmotx p x x D Vmot in t/s D in m When the motor is fed from voltage frequency 50 Hz, it turns at 1500 t/mn, or 1 --500 - 25 Us. This drives, with the values used in the example, at a car speed of : 60 1 Vcab (50 HZ) 0995 m/s Vcab(50Hz) = 25 x x 3,1416 x 0,6 a
50
The motor rotation speed is directly related to the frequency voltage ; a motor fed from a voltage frequency of 1 Hz will turn 50 times more slowly than if it was fed from a voltage frequency of 50 Hz, which will lead therefore to a car speed 50 times less, or V HZ - 0,95 Vcab (1 Hz) = =3 Vcab (1 Hz) 0 ~ 0 2m/s
'
50
As a counter tape "notch" corresponds to travel of approximately 2 mm, we therefore need approximately 1/10 s (100 ms) for the software to get data on the car speed.
Remember from school : «The circumference is equal to 2nR, The circle area is equal to n ~ ~ , ) )
MB-191
Technical manual
19 janvier 2006 page 15
f use
Minimal car speed
Although it can be applied in al1 cases, the « torque control » option is only useful for apparatus operating at speed >1 mls.
Not adapting to the VF « COMPACT D
The « torque control » option does not apply to the COMPACT frequency variations, i.e. models 1 and 2 which use the VF07 main board.. Exclusion of the OND07 board
The « torque control » option uses an OND22 interface and processing board, which can be substituted with an OND07 board. .
The OND27 board does not auarantee al1 of the OND07 board functions, in particular :
it does not have the output relays necessary for the selection emulation and,, it does not have the relays which pulse when the MB detects an overload. Hole threaded throucah the motor shaft
The motor shaft must have a threaded hole such that it is possible to couple up the incremental rotary encoder to it necessary for the functioning of this option.
Number of motor poles
The VECTOR V1.O software deduces the motor car speed from the incremental encoder fixed ont0 the motor shaft. For a given command frequency, the motor rotation speed depends on the number of pairs of motor poles.
The INCRE Vi.0 software can only be used with 4 pole motors (2 pairs of poles) whose nominal rotation speed is 1 500 tlmn !
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Technical manual
19 janvier 2006 page 17
ADDING THE TORQUE CONTROL » OPTION TO AN EXISTING MLIFT
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Technical manual
19 janvier 2006 page 18
lncremental enc
coupling device
Nylon spacer
14 pt connector
OND22 board
I
1 N400x diodes +cabling wiring
Quartz flange (Bare metal wire) 14.7456 MHz
Ne Double sided adhesive
1
rake contactor ~lectroluminescent diodes
Figure 3 « Torque control » option installation Kit
MB-191
Technical manual
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m
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19 janvier 2006 page 19
.
Composition of the modification kit
If you add the « torque control » option to an existing set-up, check that the modification kit you have received has al1 ,the following parts :
O
The "Encoder kit", made up of the following elements : An incremental encoder (R158-0/500), 3 encoder fixing screws (M 3 x 5) The incremental encoder fixing plate, The special tapping screw to be screwed into the thread hole at the end of motor shaft, The coupling device training screw 1 encoder.
ATTENTION !!! Take account of the variety of gear and chassis, the "encoder kit" does not contain the linking piece between encoder fixing plate and the gear chassis! It is therefore up to you to make the adaptor specific to your requirements.
@
The "Electronic kit" is made up of the following elements : An OND22 electronic processing and interface board, 4 nylon spacers which allow us to fix the OND22 board ont0 the main frequency variation board, The link braid between the OND22 board and the main board OND04, A 14 point male connector to connect the braid to the OND04 board, 2 1 N400x (1N4004 or 1 N4007) diodes soldered at the end of a connection wire, to connect-up the VINS input (see page 43 the Links to the /if? controller equipment chapter).
@
The "VF modification kit" is made up of the following elements : A 14.7456 Mhz HC18U quartz, A rectangular piece of doubled-sided adhesive tape which sticks the quartz ont0 the main frequency variation board, A bare metal wire which helps the quartz fixing wire, A program memory carrying the reference VECTOR V1.0,
@
The "Electromechanical kit" is made up of the following elements : A brake contactor labelled FR (BR), equipped with its RC anti-interference network (the contactor is identical whatever the traction motor power), 2 contactor coi1 supply wires (pre-cabled ont0 the contactor), 2 brake supply wires (pre-cabled ont0 the contactor).
@
The "Equipment modification kit" made up of a network of 5 10 kR resistors and 2 x 3 mm diameter red electroluminescent diodes (DEL).
MB-191
Technical manual
19 janvier 2006 page 21
Preparation of the main ONDO4 board
Before any installation it is necessary to modify the main frequency variation board in 3 areas : Replace the 12 Mhz quartz on the OND06 board, with a 14.7456 Mhz quartz. This replacement allows us to : s accelerate the execution of the program (because te work load is bigger than that of the standard MLlFT program), =synchronise the communication speed between the OND06 board and the OND22 board (the 2 boards communicate through a serial link, cf. Figure 2, page IO), 3 a l l o w the frequency variation connection to a micro-computer serial communication port for regulation purposes. Change the memory which holds the frequency variation program such that the latter can interact with the OND22 board, lnsert the OND22 board fixing spacers ont0 the OND04 board. You can use this opportunity, when making modifications, to put into operation any possible Temporary Modification Notes on to the OND04 board board which may be applicable. Before everything else, SWITCH OFF the power to al1 of the equipment Replacinq the quartz crystal
To replace the quartz crystal : Unplug al1 the OND06 board connectors from their connectors, Remove the 6 spacers which keeps it on the metal equipment socket (see Figure 4, page 20, Disassembly of OND06 board), Carefully unsolder (see Figure 5, page 20, Quartz de-soldering / soldering and soldering J2 connector ont0 the OND06 board) : 3 the XT2 quartz fixing strap (2 solder points), s the XT2 itself (2 solder points). Replace the double-sided adhesive rectangle which sticks the quartz ont0 the board by the one which is included in the modification kit, Solder the modification kit quartz and its strap, Re-assemble the OND04 or OND06 board ont0 its spacers. Positioninq of the 52 connector
The J2 connector, which allows us to connect the linking braid to the OND22 board, may be absent on certain OND04 boards. In this case, solder the connector supplied with the modification kit.
Attention ! The connector has a device which prevents incorrect insertion, this is a little notch in the connector case ; this device must be directed towards the left when the OND04 board is in position.
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Technical manual
19 janvier 2006 page 23
Replacina the program memory
To replace ,the frequency variation program memory :
O
Put the jumper SWf in the upper position (figure 7 page22), because the new program memory is a 64 K memory (the older may be a 32 K or a 64 K) Locate program memory (figure 7 page22), Extract the old memory (MLIFT Vxx) with a « small screwdriver », slide under the program memory and extraxt it, be carreful not to damage memory legs (figure 6 page 22). lnsert the new program memory VECTOR V I .O
@ @
Ensure program memory legs are correctly inserted
Installation of the OND22 board The OND22 board is fixed ont0 the OND06 board by 4 spacers (included in .the modifica.tion kit). The link between the 2 boards is guaranteed by the 14 point flat braid supplied with the kit.
Advice
When the OND22 board is clicked into ifs spacers, the access to the J2 contactor of the OND06 board is difficult; it is therefore recommended that the installation is carried out by following the procedure shown below, in the order shown. The linking braid between the OND22 and OND06 supplied with the modification kit is symmetrical and the order in which you assemble if does not matter (Figure 9-a). If, for some reason or other, you are happen to use the braid non-symmetrically, respect the assembly method shown below (Figure 9-b ) in order to avoid the risk of rubbing the braid against the OND22 board solderings, which can cause short-circuits and lead malfunctions. /Braid delivered with the modification Kit
Figure 9 Placing of the OND22 / OND06 link braid
To install the board :
Q
Q
Click the modification kit spacers into the holes drilled into the OND06 board, ensuring they go in the right way as shown in Figure 7, lnsert braid connector O (see the advice above) into the OND06 board J2 connector, ATTENTION ! The OND06 board has 2 identical connectors side-by-side ; the J2 connector is the Jowerconnector when the OND06 board is in position.
@ @
Click the OND22 board ont0 the spacers, lnsert braid connector O into the OND22 board connector.
MB-191
Technical manual
19 janvier 2006 page 25
.. .
Possible modification of the N I 0 main board
When this is fed by D.C. voltage, the OND22 board VINS input must be polarised ; normally this polarisa,tion is assured by the N I 0 board INS and MAN inputs LED (connector KC23). The LEDS are sometimes omitted on request. In this case it is essential to cable them by using the 10 kS2 resistor network and the 2 electroluminscent diodes supplied with the modification kit.
ATTENTION ! Resistor network cabling direction. The network is marked in the form of a coloured dot which is locatéd towards the toi, (see Figure 10, page 24), Polarity of the INS and MAN inputs 2 electroluminescent diodes. The 2 diodes must be polarized cathode to the riaht. This cathode is shown by the shortest (see Figure 10, page 24). Be careful, once the leads are cut you will have no means of knowing the polarity direction !
19 janvier 2006 page 26
Figure 12 Placing of the brake contactor on MB191 in the case of D l 8 or D25 principal contactors D40, D65 or D80
Technical manual
Figure 11 Placing of the brake contactor on MB191 in the case of Dl8 or D25 principal contactors
MB-191
MB-191
Technical manual
19 janvier 2006 page 27
Installation of the brake contactor FR (BR) The brake conductor is identical whatever the traction motor power may be (it depends only on the brake coi1 current) but its position in the kit varies, depending on the size of the main contactors with which the frequency variation is equipped with it is here that it must be installed. The Figure 11 and Figure 12, page 26, illustrate the brake contactor position in accordance with the size of ,the main contactors, but you may well have to take account of your own equipment's contactors or extra options. For the main D l 8 or D25 size contactors, the FR (BR) contactor can, in principal, be assembled on the same plate as these ; the contactor is fixed ont0 a symmetrical omega rail, as shown in Figure 13 below :
Figure 13 Assembly of the FR (BR) contactor ont0 the symmetrical omega rail
For the D40, D65 or D80 size contactors, the FR (BR) contactor is assembled ont0 the left end of the asymmetrical rail which supports the frequency variation terminal block. In this case you must assemble the adaptor delivered with the electromechanical kit under the contactor, as shown in Figure 14 below :
O O
Turn over the contactor and click the adaptor as shown on Figure 14, Click the contactor ont0 the asymmetric rail.
Figure 14 Assembly of the adapter for the asymmetric rail on contactor FR (BR)
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Technical manual
19 janvier 2006 page 29
Connectinn the brake coi1 contactor
The brake contactor FR (BR) is controlled by the OND22 board and the coi1 contactor must be connected-up between the FRT (brake work)(OND22 board K34 connector) and 10 terminals (connected to the end of the safety chain) from the terminal block (Figure 15, page 28). The coi1 supply voltage (terminal CV from the tef-l-ninal block) and must be connected to the OND22 board K34 connector FRC terminal (brake common).. OND22 board option "Torque control"
FRC
FRT
Figure 16 Connecting the FR (BR) brake contactor coi1
FR
Connecting the contactor "power" contacts
The connection must allow the OND22 board to operate the brake control, independent of the commands given out by the OND04 board to the L and S ; the FR (BR) power contacts must therefore be inserted between the brake supply voltage (FR (B-) and +FR (B+) provided by the equipment, and the L and S contactors contacts which control the brake in the standard controller (shaded area on (Figure 15, page 28).
O
Disconnect the wire which arrives at terminal 7 from the L contactor and connect it ont0 the FR (BR) contactor terminal 1,
@
Disconnect the wire which arrives at terminal 5 from the S contactor and connect it ont0 the FR (BR) contactor terminal 3. Connect the free end of the pre-cabled wire on the FR (BR) contactor terminal 2 to the terminal 7 of L contactor,
@
Connect the free end of the pre-cabled wire on the FR (BR) contactor terminal 4 to the terminal 3 of S contactor
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IMPLEMENTATION OF THE « TORQUE CONTROL » OPTION
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Technical manual
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( lncremental encoder
) Encoder fixing screws
Screw 1 encoder coupling device
\ Tapping screw Figure 17 Composition of the « incremental encoder kit ))
58,s
Figure 18 Assembly dimensions of the incremental encoder
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Technical manual
19 janvier 2006 page 33
installation of the incremental encoder Preliminarv checks
The « torque control » option uses an incremental encoder to be assembled at the end of the traction motor shaft. The "incremental kit encoder", delivered in a box contains the following parts (Figure 17, page 32) : An incremental encoder (R158-0/500), 3 encoder fixing screws (M 3 x 5) The incremental encoder fixing plate, The special tapping screw to be screwed into the thread hole at the end of motor shaft, The coupling device training screw 1 encoder.
ATTENTION !!! Take account of the variety of gear and chassis, the "encoder kit" does not contain the linking piece between encoder fixing plate and the gear chassis! It is therefore up to you to make the adaptor specific to your requirements. The Figure 18 gives the assembly dimensions for the incremental encoder. The present documentation presumes that the incremental encoder is fixed at the end of the traction motor shaft, from the wheel side to allow manual operation ; this ought always be possible with new installations which must respect paragraph 6.3.2.1 b) of the standard EN 81-1 : 6.3 Construction and equipment of machine rooms .. , 6.3.2 Dimensions 6.3.2.1 The dimensions of machine rooms shall be sufficient to permit easy and safe access for servicing personnel to al1 the components, especially the electrical equipment.
In particular there shall be provided , .. .
b) c)
a clear horizontal area of at least 0.5 m x 0.6 m for servicing and inspection of moving parts at points where this is necessary and, if need be, manual emergency operation (12.5.1) ; access ways to these clear spaces which shall have a width of at least 0.5 m. This value may be reduced to 0.4 m in areas where there are no moving parts.
If the installation configuration does not allow you to fix the encoder at the end of the motor shaft (especially when renovating the installation) contact AUTINOR, who will look into the coupling required with you (cardan system, angular reflexion or other). If this is the case, do not forget to supply a plan with the dimensions of the chassis 1 motor assembly, its position in relation to the machine room walls and al1 obstacles hindering assembly at the end of the shaft.
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Technical manual
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BEFORE BEGlNNlNG THE INCREMENTAL ENCODER ASSEMBLY, ENSURE THAT THE DIAMETER AND SCREW TAPPING THREAD CORRESPOND TO THE DIAMETER AND THE THREAD OF THE MOTOR SHAFT HOLE! Athough in principal, the dimensions of the holes and the threads should be standardised (Standard DIN 332 for centring points and ISO for the threads), there are a large variety of diameters and threads depending on the motor shaft. The table below gives the dimensions for motors delivered by IWNOR. These dimensions are identical whatever the motor fixing method may be (B3 or B9).
Figure 19 Standardised motor shafts thread hole (Standard DIN 332)
Table 1 Dimension of the motor shafts thread hole
Figure 20 Installation of the incremental encoder
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Technical manual
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The alignment of the motor shaft and incremental encoder axis is the only operation which proves to be a little delicate in the implementation of the « Torque control » option. THIS ALIGNMENT HAS AN INFLUENCE ON THE LlFE LENGTH OF THE TAPPING SCREW ENCODER COUPLING AND ON THE ENCODER ITSELF!
In a fixed shaft installation such as the encoder on the motor shaft, The alignments are : The axis not being parallel, called a radialfault, An angular fault.
fault I
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Technical manual
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The incremental encoder has the following mechanical constraints :
Table 2 Mechanical characteristics of the incremental encoder
Absolute maximum radial load 160 N
Absolute maximum axial load 107 N
->
Couplinci assembly Tapping screw
l Motor shaft
1
lncremental encoder
in
11 L
lncremental encoder fixing plate
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Technical manual
19 janvier 2006 page 39
Use of loncier encoder cables The encoder is delivered with a 6 conductor screened cable, 6 m long encoder cable. If necessary, you can lengthen this cable using a 4 conductor screened cable and screening (2 of the wires are not used by the « torque control » option).
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Technical manual
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Connectina of « torque control » option
All of the necessary connections for the « torque control » are summarised on Figure 22, page 42. As you know, these connections are few. On the Figure 21, general electrical diagram on page 40, the specific connections for the « torque control » option are shown by the grey areas.
Connectinci brake contactor
If the « torque control » option has been installed in the factory, the brake contactor is already cabled. If, by contrast, you add the option to on-site equipment, proceed as indicated on page 29, in the Installation of the brake contactor FR (BR), Connecting the brake coi1 contactor and Connecting the contactor "power" contacts paragraphs.
Connectinci incremental encoder
The incremental encoder is delivered with a 6 conductor screened cable, 6 m in length, connected to the encoder body. 4 of these wires are to be connected to the OND22 board K38 connector : Black wire on the OV terminal, Red wire on the +24V terminal, White wire on the CA terminal, Green wire on the CB terminal.
The 2 others are not used by the « torque control » option ; these are the Yellow wires (Channel C) and BlacWellow wires (Fault). Carefully insulate the unused wires !
The cable screen is connected at the encoder box and not to the O V The cable screen must be connected to the CV terminal (yellowlgreen) on the electromechanical terminal block and not to the K38 connector OV or anything else. The connecting of OV to earth does not however present the risk of encoder deterioration, e x c e ~in t the event of an earth fault. You will be able to check the encoder connections when performing the operations preliminary to implementation (Checking the incremental encoder wiring paragraph page 45).
MB-191
Technical manual
19 janvier 2006 page 43
Links to the lift controller equipment The EN 81-1 Standard fixes the speed limits when levelling and re-levelling with doors open (§ 14.2.1.2 b) and (§ 14.2.1.4.6) and 14.2.1.2
Levelling and re-levelling with doors open
... b)
c)
The speed of levelling does not exceed 0.8 mls. On lifts with manually controlled landing doors, there should be a check that , 1) for machines whose maximum speed of rotation is determined by the fixed frequency of the supply, that the control circuit for the low speed movement orily has been energised, 2) for other machines, the speed at the moment the unlocking zone is reached does not exceed 0.8 mls; The speed of re-levelling does not exceed 0.3 mls , It should be checked : 1) for machines whose maximum speed of rotation is determined by the fixed frequency of the supply, that the control circuit for the low speed movement only has been energised, 2) for machines supplied from static converters, that re-levelling does not exceed 0.3 mls.
14.2.1.3 Inspection operation ... d) The car speed shall not exceed 0.63 mls ;
14.2.1.4 ... 14.2.1.4.6
Emergency electrical operation
The car speed shall not exceed 0.63 mls.
The OND22 « torque control » board allows us to stay within these limitss. To do this, the board must of course be kept informed about the car movement ; it is the VlNS and VlSO inputs which petform this function. These inputs are designed so as to be insulated from the electronics of the OND22 board by opto-couplers and accept any voltage, D.C. or A.C. between O and 220 V.
ATTENTION !!! Each of ,the VlNS and VlSO inputs use 3 connection points :
-
1 point marked = (VINS and VISO -) which corresponds to the negative polarity of the input signal when this signal presents itself in the form of D.C. voltage,
+
1 point marked (VINS + and VlSO +) to be used when the input voltage signal is between O and 24 V and which corresponds to the positive polarity of the input signal when this signal presents itself in the form of D.C. voltage,
++
1 point marked (VINS ++ et VlSO ++) to be used when the voltage input signal is between 24 and 220 V and which corresponds to the positive polarity of the input signal when this signal presents itself in the form of D.C. voltage,
Do not forget however to fix the suitable values for the frequency variation Vr and Vp parameters.
19 janvier 2006 page 44
Technical rnanual
MB-191
Note :
The 2 connection points corresponding to the positive polarity are
+
bath marked on the OND22 board markings The point corresponding to the 0-24 V input is the middle point for each connector, the one corresponding to 24-220 V input is the point to the extreme left.
1
~@ @ @~
l@
1
l
I
@
L K - ~ \ 1
VINS++ (24 to 220 V) VINS+ (O to 24 V) VINS-
LVISO+
(O to 24 V)
VISO++ (24 to 220 V)
Figure 23 Connection of the multi-voltage inputs VINS and VISO
MB-191
Technical manual
19 janvier 2006 page 45
lmalementation Checkinci the incremental encoder wiring
When rotating, the incremental encoder delivers 2 signals in the form of 2 sets of 500 impulses symmetrically squared per revolution, in quadrature :
Diagram of the signals obtained with the encoder turning clockwise when viewed from the axis side in accordance with V
-I-
Channel A (White wire)
"O*
90'
-
l
Channel B (Green wire)
Channel N (Yellow wire)
-
n
Figure 24 Signals delivered by the incremental encoder
To control the signals coming from the OND04 board (through the OND22 board) in the right direction :
O
Open the safety chain to prevent the lift from starting,
@
Switch on the power,
@
Place the diagnostic system to address AA,
@
Open the brake by hand and turn the control wheel slowly ; the value shown by the diagnostic system must :
INCREASE
when the car GOES DOWN,
DECREASE
when the car GOES UP
If this is not the case, reverse the Green and White wires connected to the CA and CB OND22 K38 connector terminals.
MB-191
Technical manual
19 janvier 2006 page 47
« TORQUE CONTROL )) OPTION PARAMETERS
MB-191
Technical manual
19 janvier 2006 page 48
ALPHABETICALLY ORDERED LIST OF THE PARAMETER NAMES The table below gives the « Torque Control » option parameters, put into alphabetical order by name. For each parameter, the table also shows : The parameter address in the frequency variation parameter memory, The segment number, if there is one, The page number of the current documentation where the parameter and its advised adjustment values are held. Abbreviation
Signification
Address
Seg.
See detail
COEFIL
Filtering Co-efficient
Ad 13
Page 49
FILTEN
Voltage Regulation Filtering
Ad 17
Page 51
GLISSE GLlSVl
Sliding Sliding Speed
Add 18 Ad 19
Page 51 Page 51
OPTREG
Regulation Options
Ad 16
Page 50
RETMOT
Delay Motor
Ad 12
Page 49
TTMAX TTMlN
Maximum Voltage Table Minimum Voltage Table
Page 50 Page 50
MB-191
Technical manual
19 janvier 2006 page 49
This section contains the Torque Control >> option specific parameters list, put into increasing alphabetical order. These parameters can be visualised and modified from the OND04 frequency variation control board parametering 1 diagnostic system.
Best displayed in figure mode
RETMOT (Delay Motor) This parameter allows us to tell the software the delay with which the motor reacts to a command given by the controller. This delay essentially depends on the selfinduction motor windings, connected to the link between start-up current and the nominal motor current. The value of the parameter is shown in tens and milli-seconds and must be between O and 99. The standard values, result from the experiments are as follows : Id = 2,5 In
12 (=120 ms)
Id = 3 In
13 Ft
7 (=70 ms)
Best displayed in figure mode
COEFIL (FILtering CO-Efficient) This parameter allows us to fix the frequency regulation filtering CO-efficient. The parameter value is shown in tens and milli-seconds and must be between O and 99. The standard value is 10 (= 100 ms). See also :
FILTEN (address 17, page 51)
MB-191
Technical manual
14
19 janvier 2006 page 50
Best displayed in figure mode
TTMAX (Maximum Voltage Table) This parameter allows us to limit the usable voltage tables with the software when the motor pulls the load (resistant load). The parameter value has no unit and must be between O and 7. See also :
.
TTMiN (addressl5, page 50)
15
Best displayed in figure mode
TTMIN (Minimum Voltage Table) This parameter allows us to limit the usable voltage tables with the software when the motor is pulled by the load (overhaulinq load). This parameter allows us to fix the frequency regulation filtering CO-efficient. The parameter value has no unit and must be between O and 7.
.
See also :
TTMAX (addressl4, page 50)
16
Best displayed in Segment mode
OPTREG (Regulation Options) This parameter is used by the R & D department during the development phase and
ABSOLUTELY MUST BE SET TO ZERO.
MB-191
Technical manual
19 janvier 2006 page 51
Best displayed in figure mode
FILTEN (voltage Regulation Filtering) This parameter allows us to fix the voltage regulation filtering CO-efficient. The parameter value is shown in tens and milli-seconds and must be between O and 99. The standard value is 10 (= 100 ms). See also :
COEFIL (Ft) (address 13, page 49)
18
Best displayed in figure mode
GLISSE (Sliding) This parameter allows us to fix the allowed frequencv slide when the motor pulls the load (resistant load). The parameter value is shown in tenths of Hertz and must be between O and 99. The standard value is 10 (= 1 Hz). See also :
GLISVl (address 19, page51)
19
Best displayed in figure mode
GLlSVl (Sliding Speed) This parameter allows us to fix the allowed frequencv slide when the motor is pulled by the load (overhauling load). The parameter value is shown in tenths of Hertz and must be between O and 99.
MB-191
Technical manual
19 janvier 2006 page 52
The standard value is equal to 30 (= 3 Hz) This value is higher than that of the GLISSE (SLIDE) parameter because experience has shown that the motor has more torque when the load is overhauling. See also :
GLISSE (sliding) (address 18, page 51)
MB-191
Technical manual
19 janvier 2006 page 53
LIST OF THE APPLICABLE TEMPORARY MODIFICATION NOTES List up to date on the 27th January 1995
MB-191
Technical manual
19 janvier 2006 page 55
MB-191
Technical manual
19 janvier 2006 page 57
APPENDIX A MAINTENANCE HELP
MB-191
Technical manual
19 janvier 2006 page 59
What to do for the fault codes ? Fault I O Reverse of the rotation direction (DETECTION by tape-head) Fault 22 Slip INTEGRATOR. Fault 52 SAFETY CHAIN cutting FAULT Fault 62 Tape-head 0 0 3 FAULT.
MB-191
Technical manual
19 janvier 2006 page 60
/Braid delivered with the modification Kit
Figure 25 Fault 70 : Replacing of the OND22 1 OND06 link braid
' S o l
@Td OND22 board
Main board
MB-191
Technical manual
19 janvier 2006 page 61
Fault 70 Loss of communication o~~o4between the OND22 « Torque Control D board and the OND04 frequency variation control board.
The fault causes an immediate car stop as the controller does not use the motor rotation speed data anymore. The fault disappears automatically 6 seconds after the OND04 board has reported the re-establishment of the link. Why ?
This fault appears when the OND04 board no longer receives data from the OND22 board for more than 50 ms. Note :
in normal working conditions, the OND22 board constantly sends blocks of 6 bytes to the OND04 board ; 4 of these bytes are reserved for the motor speed transmission (in the form of 2 integer numbers (+ or -) 16 bit), 2 are used for interna1 processing. The bytes are transmitted along a serial link at the speed of 9600 bits per second ; as each byte is preceded by a start bit and followed by a stop bit, this means 10 bits to transmit for 8 useful bits (there is no parity control, but the speed transmission viability is assured by the comparison of the 2 whole numbers, which must be identical). At a speed of 9600 bitls, the transmission 1O length of a useful byte is thus equal to 9 0,001 s or, approximately 6 ms for one block. The fault only appears therefore if 8 successive transmissions fail, do not occur or the transmission is spoilt by mistakes. Whatever the OND22 board microprocessor work load, there is little chance that this phenomenon will occur without equipment defects.
What to do ?
1. Begin by making sure that the link braid between the OND22 and OND04 boards is correctly connected ont0 the OND04 board J2 connector and ont0 the OND22 J I connector. 2. Check that the link braid is not damaged, especially if you use a nonsymmetrical braid, which may have been damaged by the OND22 board solder points ; if in doubt change it ! by following the Figure 25, recommendations page 60 (eventually consult the fo order spare parts chapter, page 65). 3. Change the OND22 board.
4. Change the OND04 board (catastrophe!).
MB-191
Technical manual
19 janvier 2006 page 63
Fault 81
Average current MORE than the ALLOWED power. Fault 82
REAL speed MORE than 20% of the PROGRAMMED nominal speed, vn. Fault 83
Inspection speed MORE than 0,63 mls. Fault 84
Re-levelling speed MORE than 0,30 mls. Fault 85
RECOVERY voltage MORE than 650 volts. (Brake circuit FAULT). Fault 86
No voltage when the movement command is given (fuse or non-contact of the contactors). Fault 87
Line contactor has NOT DROPPED OUT. Fault 88
"UP" and "DOWN" command SIMULTANEOUSLY. Fault 89
Radiator TEMPERATURE MORE than 40". Fault 90
MAINS CURRENT IN EXCESS of the maximum transistor current. Fault 91
Top transistor FAULT. Fault 92
Middle transistor FAULT. Fault 93
Middle and top transistors FAULT. Fault 94
Bottom transistor FAULT.
MB-191
Technical manual
Fault 95
Bottom and top transistors FAULT. Fault 96
Middle and bottom transistors FAULT. Fault 97
Bottom, middle and top transistors FAULT. Fault 98
Slope (pt) INCORRECT to Vn. Fault 99
Eerom WRlTlNG FAULT.
19 janvier 2006 page 64
