6.1 General
A short run is present, if the floor-to-floor distance is shorter than the sum from acceleration and deceleration distance for rated speed. Rated speed is not reached during such a run. To arrive in the landing, the car will have to move at leveling speed over a longer period of time.
The built-in short-run device recognizes this state and it extends the acceleration phase of the run
automatically. The leveling time into the landing is thus the same as with run at rated speed, i.e. no creep or only short creep (operating delay or rope slip).
The lift data must be set correctly, so that the short-run device will operate correctly. These are :
P13 Gear ratio
P14 Traction sheave diameter P15 Suspension
P19 Jerk P20 Speed P23 Speed V0
P25 Speed VN
The deceleration distance VN will be computed from these parameters and indicated in parameter P111. The
deceleration distance will be measured for each normal run (VN is reached) and displayed in P112. However,
this measured distance will not be considered in the short-run calculation. Short run with "sharper rounding".
This is the case, if the deceleration point is reached during the top rounding of the acceleration phase. If deceleration with the set jerk is performed, the deceleration distance will be too large. The landing will be bypassed. To avoid this, the run will have a "sharper rounding" i.e., a greater jerk.
6.2 Settings
P 38 : Short-run computer (ON/OFF)
There is the option of enabling or disabling the function of short-run computation. Short-run computation only works if VN is switched to V0.
P 39 : Correction of short-run distance
In the event of switching delay times of the control or rope slip, it may become necessary to correct the leveling distance in a short run. If higher figures are entered, the creep distance to the landing will become longer, if lower values are entered, the creep distance will become shorter. Values from –40.0cm to +40.0cm are possible.
The pattern of running characteristic can be checked at measuring points (MP42A or MP43A). For this purpose, parameter P10 or P11 must be set to value (11) – running characteristic status. A diagram will appear at the respective measuring point and this permits the individual phases of the running characteristic to be seen following Figure.
Where : MP42A/43A
2.50 V V = 0 m/s
3.15 V Rounded from constant speed to constant acceleration 3.45 V Constant acceleration
3.75 V Rounded from constant acceleration to constant speed 4.10 V Constant speed
1.90 V With sharper rounding to constant acceleration 1.55 V Constant acceleration extended by short-run device 1.25 V short-run device
7. MODERNIZATION
7.1 General
Frequency inverter CPIK is also designed for use in modernization jobs at elevator installation with third- party motor (no ThyssenKrupp motor). Single speed or pole changing motors may be selected.
A vector control is used here, too. Max. speed of 1.6 m/s is recommended.
The necessary information about modernization jobs is given in the following description. 7.2 Modernization by encoder mounted on motor shaft
The following applies:
• Operation of single-speed or pole-changing motors, frequency inverter and standard motors is possible. • Motors should be of isolation class F; to reduce the wiring stress a frequency inverter output choke is used. • Inertia is to be reduced to max. 1/3 of the original value.
• Devices CPIK 15, 32, 48, 60 and 105 are to be used only.
• The encoder on the motor shaft is to be mounted centrally and stiff against torsion.
• The encoder must send Line drive format signals with 5 V supply voltage (Connection assignment see chapter 2.3.4 Incremental encoder connection)
• Observe min. floor-to-floor distance (see chapter 4.8.3 Diagram for determination of min. permissible floor- to-floor distances) (Area A or B).
7.2.1 Rating
Standard values for rating: Rated motor current
(Name plate) CPIK Line filter Line choke Output choke
~ 24 A CPIK 32 30 A 3 x 0.40 mH, 34 Aeff 3 x 0.15 mH, 43 Aeff ~ 38 A CPIK 48 50 A 3 x 0.29 mH, 50 Aeff 3 x 0.12 mH, 60 Aeff ~ 50 A CPIK 60 50 A 3 x 0.29 mH, 50 Aeff 3 x 0.12 mH, 60 Aeff The braking resistor used depends on the type of installation.
7.2.2 Motor adaptation
To adapt an unknown motor to the frequency inverter proceeds accordingly, by iteration for example. Start with the name plate data. In so doing please note that these data may be incomplete or unequal to the rated working point of the frequency inverter in case of old lift motors as the ratio of maximum current to rated current was limited to special values. This normally results in an excessive no-load current of the frequency inverter. Also see table at the end of this chapter.
Release below parameters by selecting “third-party motor” in P 40.
a) Automatic current controller optimization (auto-tuning P 80) to be effected.
b) The values of P 65 (“rotor time constant Tr“) and P 66 (“no-load current Id“) are calculated from parameters P 60 (“rated frequency of motor“), P 61 (“rated voltage of motor“), P 62 (“rated speed of motor“), P 63 (“rated current of motor“) and P 64 (“motor cos(phi)“). As a rule, the values of P 65 are between 40 ms and 400 ms, and the values of P 66 between 6 A and 30 A (dependent on motor output).
Parameter No. Setting range As delivered
Rated motor frequency P 60 30 ~ 70 Hz 50 Hz
Rated motor voltage P 61 300 ~ 500 V 360 V
Rated motor speed P 62 500 ~ 2000 min-1 1345 min-1
Rated motor current P 63 10.0 ~ 42.5 A 17.5 A
Motor cos (phi) P 64 0.5 ~ 1.0 0.79
Setting for motor adaptation
Note: Improved computation of rotor time constant (Tr) and no-load current (Id) is available from program version V 15.4. This means that the fine adjustment described below is not necessary in most cases. Fine adjustment (must do c, d, e) for Asynchronous motor
c) Enter computed value of P 65 in P 67 and computed value of P 66 in P 68.
An approximate value for motor adaptation will be determined. These are the values to be used by the controller. If negative values are used for P67 or P68, the computed values of P65 and P66 will continuously be adopted. These are default values.
Parameter No. Setting range As delivered
Rotor time constant (Tr) calculated P 65 ms
Field current (Id) calculated P 66 A
Ref. rotor time constant (Tr) P 67 1 ~ 500 ms -1 ms
Ref. no-load current (Id) P 68 0.1 ~ 38.0 A -0.1 A
Setting for motor adaptation d) These presetting permit an approximate basic setting of the motor.
Load compensation is required to ensure that no-load current is present only (load current < 5% of max. current) if the lift runs at constant speed (electric recall operation, for example). Now initiate run at rated speed. A band error may arise during acceleration; disconnect the band monitoring, if necessary, or set slower acceleration value. Now observe the actual motor voltage in parameter P 76. This value should be between 270 and 300 V with the lift running at rated speed. Decrease motor voltage through P 68 (no-load current Id) (the arising motor voltage based on the no-load current from the name plate data is too high, normally). The motor voltage in P 76 should be approx. between 270 to 300 V both for UP and DOWN direction. Increase or decrease the rotor time constant (Tr) in P 67 if the torque required for acceleration phase is insufficient. This value can be changed step by step by 25 %.
e) Now move the lift with empty car;
This means that motor-driven run under no load shall be performed in DOWN direction and a brake test during run in UP direction. The motor voltage shall increase by the value of the motor slip with the lift running in DOWN direction, i.e. approx. 30 V to 50 V; decrease of the motor voltage shall be less in UP direction (approx. 10 V to 30 V). If this is not the case, change the value of the rotor time constant in P 67 step by step by 25% each. Perform setting when the motor runs at operating temperature (and not with extremely cold or hot motor).
f) Check setting of speed controller once again.
Set I-gain of controller to 0 ms and increase P-gain until the motor vibrates or hums. Now reduce P-gain to half value. Select I-gain approx. between 10 ms and 100 ms depending on overshooting of running characteristic. Pre-controlling of the speed controller through acceleration precontrol (P 21 und P 22) improves running performance. Check running performance with the car running at no-load, half load and full load.
Use below table indicating standard data for values to be entered provided that : • Data on the name plate of the motor are incomplete or
• The rated point indicated is not standard (indicated deliberately in case of single-speed, Pole-changing motors to comply with IA / Irated < 2.5).
Motor type Cos (pi) Rated speed
[U/min] Rotor time constant(Tr) No-load current (Id) Single speed,
pole-changing motor 0.75 ~ 0.85 1320 ~ 1400 40 ~ 150 ms 0.5 ~ 0.7 x Irat Frequency inverter motor 0.85 ~ 0.90 1460 250 ~ 400 ms 0.4 x Irat
Standard motor 0.8 1450 200 ~ 400 ms 0.5 x Irat
Values to be entered 7.2.3 Settings for synchronous motors
Parameter P62 (rated motor speed) and P97 (number of pole pairs) to be entered for synchronous motor. Current controller is easy to adapt to motor through P 80~83 (auto-tuning)
7.2.4 Setting into operation
8. ANNEX
8.2 Parameter setting
The parameters available for the respective operating modes are marked with S for synchronous or A for asynchronous versions. Operating mode exists, i.e. parameters marked F, only valid if "third-party" motor is selected.
The controller which can be supported in CPIK is only TAC50K, TCM and TIC but CPIK cannot support LS2, LS3 and DCP function.
Parameters present for operating modes CAN interface Parallel
interface Para.
No.
Short description or text displayed on panel
TAC50K TCM TIC
Default value
P0 Reference start deceleration SA SA 500ms
P1 Brake application time SA SA SA 700ms
P2 Full scale motor speed SA S:100, A:1500rpm
P3 Direction of rotation SA SA SA Inverted/ Not inverted
P4 Control direction A A A Inverted/ Not inverted
P5 P gain (speed controller) SA SA SA 10.0
P6 I gain (speed controller) SA SA SA 20 ms
P7 Language selection SA SA SA English
P8 Communication SA SA SA (0)
P10 Analog output MP42A SA SA SA (0)
P11 Analog output MP43A SA SA SA (0)
P13 Gear ratio SA SA SA 35.0
P14 Traction sheave diameter SA SA SA 450 mm
P15 Suspension SA SA SA 1
P16 Run speed V_max SA 1.00 m/ s
P17 N rat. computed SA SA 105.0 1/ min
P18 Operating point for N=0 speed SA SA SA 10.0 1/ min
P19 Jerk SA 0.80 m/ s3
P20 Acceleration SA 0.70 m/ s2
P21 Acceleration pre-control SA SA Off / On
P22 Acceleration pre-control value SA SA +100%
P23 Leveling speed V0 SA 0.03m/ s P24 Inspection speed Vi SA 0.30m/ s P25 Rated speed VN SA 1.0m/ s P26 Intermediate speed V2 SA 0.30m/ s P27 Intermediate speed VN2 SA 0.30m/ s P37 Operating point V < 0.3m/ s SA 0.30m/ s
P38 Short-run device SA Off / On
P39 Correction short-run distance SA ± 0.0 cm
P40 Motor type SA SA SA <0> DTE(DKE)
Parameters present for operating modes CAN interface Parallel
interface Para.
No.
Short description or text displayed on panel
TAC50K TCM TIC
Default value
P44 Speed threshold PROGOUT SA V < 0.0
P45 Output PROGOUT SA <5> V < P44
P46 Output PROGOUT1 SA <6> motor overtemp.
P47 Output V < 0.3 [ m/ s] SA <4> V < 0.3 [ m/ s]
P48 Input PROGANA SA <2> emergency 220V
P49 Input PROGIN SA <1> load weighing FM
P50 Load pre-setting SA SA SA Off / On
P51 Actual load measuring value SA SA SA + 0%
P53 Adopt load current SA SA SA 000.0A
P54 Load specification gain SA SA SA +65.0%
P55 Gain position controller S S S +65.0%
P60 Rated motor frequency AF AF AF Modernization
P61 Rated motor voltage AF AF AF Modernization
P62 Rated motor speed SAF SAF SAF Modernization
P63 Rated motor current AF AF AF Modernization
P64 Motor cos (phi) AF AF AF Modernization
P65 Rotor time constant computed AF AF AF Modernization
P66 No-load current computed AF AF AF Modernization
P67 Reference rotor time constant AF AF AF Modernization
P68 Reference no-load current AF AF AF Modernization
P76 Actual motor voltage AF AF AF Modernization
P80 Auto- tuning SAF SAF SAF Modernization
P81 Comp. values from auto- tuning SAF SAF SAF Modernization P82 Manual change current controller SAF SAF SAF Modernization P83 Manual change current controller SAF SAF SAF Modernization
P86 Adjusting encoder S S S
P92 DC link voltage SA SA SA 0.0 V
P96 Encoder pulse number SA SA SA <0> 1024
P97 motor pole pairs SAF SAF SAF
P98 Id reduced AF AF AF
P124 Speed ref. avg. filter SA
P150 brake on/ off for test SA SA SA
P160 Max. current SA SA SA 100 %
P205 P gain (load compensation) SA hidden
8.3 Monitoring Parameter
Parameters present for operating modes CAN interface Parallel
interface Para.
No.
Short description or text displayed on panel
TAC50K TCM TIC Default value P100 Motor speed SA SA SA P101 Actual speed SA SA SA P102 Motor frequency SA SA P103 Binary inputs SA P104 Binary outputs SA
P105 Encoder pulse number SA SA SA
P106 Reference value SA SA SA
P107 Load current SA SA SA
P110 Switching sequence index SA SA SA
P111 SV computed SA
P112 SV measured SA
P113 Distance covered SA
P116 DC link voltage SA SA SA
P117 PWM operating frequency SA SA SA
P118 Absolute encoder position S S S
P120 System information SA SA SA
P122 CAN- Inputs SA
8.4 Error description
LCD display Description Extra info Causes, remedy or notes React
Control voltage ON Inverter switched on for the first time R
Watchdog error Time error in program sequence of C167
processor Number of errors Exchange TMI2 board, EEPRO R SMR to TCM (only with
TCM control) Collective fault message to TCM Varying error causes R No SMR present No collective fault message present Error deleted message R
No power part
recognized Undefined value at AD-channel 14 and 15
CPIK type is displayed
Electronics does not recognized connected power part of inverter.
Check ribbon cable X934 for correct fastening. Exchange complete device. H and DC link EEPROM error 1) Wrong EEPROM cross sum
2) Error in EPROM data set
= 0; EPROM <>0; EEPROM
Load default values; set installation dependent parameters; exchange TMI2
board, if unsuccessful. R
Over-temperature
heat sink Module temperature over 90 °C
Actual motor current
at error tripping Check connections to sensor at heat sink
H and DC link delayed Over-temperature motor Motor PTC thermistor tripped Actual motor current
at error tripping
1) Check connections to sensor at motor 2) Measure using ohmmeter
CAN: R TIC: H and DC link delayed
Error stack deleted Error stack was deleted None
Earth Fault
1) Motor current sum not zero
2) Time error in program sequence of F240 3) Encoder of synchronous machine is defective
Actual motor current at error tripping
1) Perform isolation test at motor windings 2) Exchange TMI2 board
3) Exchange synchronous encoder
1) H
2) Reset F240
DC link under-voltage DC link voltage less than 410 V Actual motor current at error tripping
1) Check 3-phase power input
2) Compare DC link voltage displayed at PEP and measuring 3) Exchange device
H and DC link
DC link over-voltage DC link voltage is greater than 760 V Actual motor current at error tripping
1) Check chopper resistor
2) Compare DC link voltage displayed at PEP and measuring 3) Exchange device
H and DC link
Power Drive Protection (event message)
PDPINT
PDPINT tripped by following errors: 1) Over-current
2) Monitoring saturation voltage of power device
3) Over-voltage DC link 4) Supply voltage error
1) see error “over-current”
2) Power module in CPIK device defective; exchange 3) see error “DC link over-voltage”
4) see error “±15V under-voltage”
H for 10sec after 5 x PDPINT DSP reset
Overcurrent Hardware suppressor circuit recognized overcurrent
Does error occur in operating phase, “driving” with “empty car up” or “fully loaded car down” or in both case?
Measure motor current: check offset load: car clamped in rails?
H and DC link DSP reset DSP timeout Time error in program sequence of F240 1) Sin/cos encoder (EnDat) not connected
2) Error message for defective components
H DSP reset DSP current controller F240 stopped operation of “current controller”
program
Actual motor speed
at error tripping Program does not work properly: EMC failures
H DSP reset DSP reset
(event message)
F240 performed reset caused by 1) command given by C167 processor
128 = Power ON
(software reset) 2) F240 automatically reset (program failure in F240) 4 = Software reset 2 = Watchdog ±15V undervoltage or
DC link > 850V Power supply error or DC link voltage error
Actual motor speed at error tripping
1) Measure supply voltage at TMI2 board; 15V, 5V, 24V 2) Check reference module MAX675CSA808
3) Chopper module, check braking resistor
4) Compare DC link voltage displayed at P116 and actual value using voltmeter
H and DC link DSP reset Vist unequal Vsoll ±10%
(not monitored for CPIK with CAN bus)
Monitoring reference-actual speed values, (“hose error”)
Actual motor speed
at error tripping Error output with CPIK devices not connected to CAN bus only H
CAN-error
a) Control does not respond to handshake telegram
b) Control does not transmit reference value telegrams (CPIK with CAN only)
= 0 (case a)) = 1 (case b))
1) Check wiring of CAN bus connection
2) load "default values" in CPIK device H Encoder failure
(with synchronous machines only)
Pulse encoder “EnDat” 1) Check motor connection lines
2) Adjust pulse encoder (with “hidden P86”) H Flag set (with CPIK with
CAN bus only)
Marking initiated from TCM control through CAN telegram
Flag No. from error
stack of TCM control Flag from TCM control R Chopper with pulses
disabled
Degree of DC link voltage increase causes chopper connection
DC LINK voltage at
error tripping DC link protection against temporary over-voltage; chopper disconnected again R
Device size changed Changed coding resistance recognized with device ON
Extra info important for software development only
Loose contact, 5V reference voltage faulty, A/D conversion faulty. Check ribbon cable X934 for correct fastening. Device out of service until device size recognized during switching on, is recognized again. Perform reset: switching ON/OFF Error recognized in standstill phase only. Standby supply operation active
Standby supply operation is activated. (No further entry in error stack when standby supply operation is ended.)
Extra info relevant for software
development only
PWM frequency switched to 4kHz. Lower threshold for DC LINK undervoltage. Energy regeneration unit remains switched off.
Overspeed 120% rated speed exceeded Actual motor speed at error tripping
P106: check reference value,
P101: check actual speed H
DC LINK > 200V not reached
During DC link charge UDC LINK repeatedly not increased above 200V within 200 ms.
Actual DC LINK voltage at error tripping
Short circuit DC link, charging resistor defective; power voltage missing?
Speed Monitor
Unintended movement a) EnDat encoder miss aliened b) moving without speed command
Speed in RPM a) Re-alien EnDat encoder
b) Check controller and brake H
Abbreviations in “response” part (resp.):
CAN: CAN Bus operation TIC: Operation with TIC board R: Registration only H: Stop
8.5 Extra information Power Drive Protection (PDPINT)
The extra information displayed must be split up in binary. The meaning of each bit is defined individually. Example: extra info = 402
Conversion Decimal
number 2^8 2^7 2^6 2^5 2^4 2^3 2^2 2^1 2^0 Binary number
402 256 128 0 0 16 0 0 2 0 110010010
402-256-128-16-2=0. This means that bits 2^8, 2^7, 2^4, 2^1 are set.
The software monitoring recognized over-voltage DC link and F240 properly responded that “pulse enable” is “initiated".
Furthermore it is clear that this happened with current controller and PWM active. PDPINT cause:
Bit number Binary code Error description
Bit 2^0= 1 00 0000 0001 SC (from power module) Bit 2^1= 2 00 0000 0010 F240 signals PDPINT
Bit 2^2= 4 00 0000 0100 Error with supply voltage (24V,-15V or +15V) Bit 2^3= 8 00 0000 1000 Error with supply voltage +15V
Bit 2^4= 16 00 0001 0000 DC link over-voltage is recognizes by Software Bit 2^5= 32 00 0010 0000 DC link over-voltage is recognizes by Hardware Bit 2^6= 64 00 0100 0000 KS over-current (hardware recognition)
Further information:
Bit number Binary code Error description
Bit 2^7=128 00 1000 0000 PDPINT occurred with PWM Off (red LED H99 Off) It is available EPROM version under V17.x and V7.x Bit 2^7=128 00 1000 0000 PDPINT occurred with PWM On (red LED H99 On)
It is available EPROM version over V18.x and V8.x Bit 2^8=256 01 0000 0000 PDPINT occurred with current controller ON
Bit 2^9=512 10 0000 0000 F240 refuses PWM (LED H99 remains OFF despite pulse enable) It is available EPROM version over V18.x and V8.x
8.6 Extra info for “run contactor problems”
Regenerative devices have odd and the remaining devices even error numbers. - Prior to switching on, the contactor contacts are checked for sticking. No. Input (connector) possible cause
2 X91/2 (RK1) K06 does not go off 3 X91/2 (RK1) K01 does not go off 4 X91/3 (RK2) K06.1 does not go off
5 X91/3 (RK2) K01.1 and K06 does not go off ---almost impossible! (and K06.1 as a result of K01.1)
6 RK1 and RK2 K06.1 and K06 do not go off
7 RK1 and RK2 K01.1, K01, K06.1 and K06 do not go off
Non-recurring error entry for error numbers 2...7; new disconnection attempts after 1s
- Relay K1 or K2 switched on, wait for acknowledge RK1: No. Input (connector) possible cause
10 K06 does not go on. Safety circuit (X517) interrupted? 11 K01 does not go on. Safety circuit (X517) interrupted?
14 RK2 K06.1 instead of K06 ON.
15 RK2 K01.1 instead of K01 ON
6 RK1 and RK2 K06.1 and K06 ON; K06 expected only
7 RK1 and RK2 K01.1, K01, K06.1 and K06 ON; K06 expected only