Motion Control Engineering Motion 4000 User manual

Motion Control Engineering, Inc.

11380 White Rock Road

Rancho Cordova, CA 95742

voice 916 463 9200

fax 916 463 9201

www.mceinc.com

Motion 4000 Traction Elevator Controller

V8.xx software

Manual # 42-02-2P24, Rev B7, May 2013

This document may not be reproduced, electronically or mechanically, in whole or in part, without

written permission from Motion Control Engineering.

Trademarks

All trademarks or registered product names appearing in this document are the exclusive property

of the respective owners.

Warning and Disclaimer

Although every effort has been made to make this document as complete and accurate as possible,

Motion Control Engineering and the document authors, publishers, distributors, and

representatives have neither liability nor responsibility for any loss or damage arising from

information contained in this document or from informational errors or omissions. Information

contained in this document shall not be deemed to constitute a commitment to provide service,

equipment, or software by Motion Control Engineering or the document authors, publishers,

distributors, or representatives.

Limited Warranty

Motion Control Engineering (manufacturer) warrants its products for a period of 15 months from

the date of shipment from its factory to be free from defects in workmanship and materials. Any

defect appearing more than 15 months from the date of shipment from the factory shall be

deemed to be due to ordinary wear and tear. Manufacturer, however, assumes no risk or liability for

results of the use of the products purchased from it, including, but without limiting the generality

of the forgoing: (1) The use in combination with any electrical or electronic components, circuits,

systems, assemblies or any other material or equipment (2) Unsuitability of this product for use in

any circuit, assembly or environment. Purchasers’ rights under this warranty shall consist solely of

requiring the manufacturer to repair, or in manufacturer's sole discretion, replace free of charge,

F.O.B. factory, any defective items received at said factory within the said 15 months and

determined by manufacturer to be defective. The giving of or failure to give any advice or

recommendation by manufacturer shall not constitute any warranty by or impose any liability upon

the manufacturer. This warranty constitutes the sole and exclusive remedy of the purchaser and

the exclusive liability of the manufacturer, AND IN LIEU OF ANY AND ALL OTHER WARRANTIES,

EXPRESSED, IMPLIED, OR STATUTORY AS TO MERCHANTABILITY, FITNESS, FOR PURPOSE SOLD,

DESCRIPTION, QUALITY PRODUCTIVENESS OR ANY OTHER MATTER. In no event will the

manufacturer be liable for special or consequential damages or for delay in performance of this

warranty.

Products that are not manufactured by MCE (such as drives, CRTs, modems, printers, etc.) are not

covered under the above warranty terms. MCE, however, extends the same warranty terms that

the original manufacturer of such equipment provide with their product (refer to the warranty

terms for such products in their respective manual).

End User License Agreement

This End User License Agreement (“Agreement”) grants you the right to use the software con-

tained in this product (the “Software”) subject to the following restrictions: You may not: (i) copy

the Software, except for archive purposes consistent with your standard archive procedures; (ii)

transfer the Software to a third party apart from the entire product; (iii) modify, decompile, disas-

semble, reverse engineer or otherwise attempt to derive the source code of the Software; (iv)

export the Software or underlying technology in contravention of applicable U.S. and foreign

export laws and regulations; and (v) use the Software other than in connection with operation of

the product.

“LICENSOR'S SUPPLIERS DO NOT MAKE OR PASS ON TO END USER OR ANY OTHER THIRD PARTY,

ANY EXPRESS, IMPLIED OR STATUTORY WARRANTY OR REPRESENTATION ON BEHALF OF SUCH

SUPPLIERS, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF NON-INFRINGE-

MENT, TITLE, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.”

Important Precautions and Useful Information

This preface contains information that will help you understand and safely maintain MCE

equipment. We strongly recommend you review this preface and read this manual before

installing, adjusting, or maintaining Motion Control Engineering equipment. This preface dis-

cusses:

• Safety and Other Symbol Meanings

• Safety Precautions

• Environmental Considerations

•InThisGuide

Safety and Other Symbol Meanings

Danger

This manual symbol is used to alert you to procedures, instructions, or situations which, if not done

properly, might result in personal injury or substantial equipment damage.

Caution

This manual symbol is used to alert you to procedures, instructions, or situations which, if not done

properly, might result in equipment damage.

Note

This manual symbol is used to alert you to instructions or other immediately helpful information.

Safety Precautions

Danger

This equipment is designed to comply with ASME A17.1, National Electrical Code, CE, and CAN/

CSA-B44.1/ASME-A17.5 and must be installed by a qualified contractor. It is the responsibility of the

contractor to make sure that the final installation complies with all local codes and is installed in a

safe manner.

This equipment is suitable for use on a circuit capable of delivering not more than 10,000 rms sym-

metrical amperes, 600 volts maximum. The three-phase AC power supply to the Drive Isolation

Transformer used with this equipment must originate from a fused disconnect switch or circuit

breaker sized in conformance to all applicable national, state, and local electrical codes in order to

provide the necessary motor branch circuit protection for the Drive Unit and motor. Incorrect motor

branch circuit protection will void the warranty and may create a hazardous condition.

Proper grounding is vitally important to safe and successful operation. Bring your ground wire to the

system subplate. You must choose the proper conductor size and minimize the resistance to ground

by using the shortest possible routing. See National Electrical Code Article 250 or the applicable local

electrical code.

Before applying power to the controller, physically check all the power resistors and other compo-

nents located in the resistor cabinet and inside the controller. Components loosened during ship-

ment may cause damage.

For proper operation of the AC Drive Unit in your controller, you must make sure that: 1) A direct

solid ground is provided in the machine room to properly ground the controller and motor. Indirect

grounds such as the building structure or a water pipe may not provide proper grounding and could

act as an antenna to radiate RFI noise, thus disturbing sensitive equipment in the building. Improper

grounding may also render any RFI filter ineffective. 2) The incoming power to the controller and the

outgoing power wires to the motor are in their respective, separate, grounded conduits.

This equipment may contain voltages as high as 1000 volts. Use extreme caution. Do not touch any

components, resistors, circuit boards, power devices, or electrical connections without ensuring that

high voltage is not present.

Environmental Considerations

• Keep the machine room clean.

•Controllersaregenerally in NEMA 1 enclosures.

• Do not install the controller in a dusty area.

• Do not install the controller in a carpeted area.

• Keep room temperature between 32 and 104 degrees F (0 to 40 degrees C).

• Prevent condensation on the equipment.

• Do not install the controller in a hazardous location or where excessive amounts of

vapors or chemical fumes may be present.

• Make certain that power line fluctuations are within plus or minus 10% of proper value.

Air Conditioned Equipment Cabinets

If your control or group enclosure is equipped with an air conditioning unit, it is very important

to observe the following precautions. (Failure to do so can result in moisture damage to electri-

cal components.)

• Maintain the integrity of the cabinet by using sealed knockouts and sealing any holes

made during installation.

• Do not run the air conditioning while the cabinet doors are open.

• If you turn the air conditioner off while it is running, wait at least five minutes before

restarting it. Otherwise, the compressor may be damaged.

• Observe the recommended thermostat setting (75 degrees) and follow recommended

maintenance schedules.

• Make certain that the air conditioning drain tube remains clear to avoid water accumula-

tion in the unit.

In This Manual:

This manual is the installation, adjustment, and troubleshooting guide for the Motion 4000

traction controller. When viewed online as a pdf file, hyperlinks (buttons or blue text) link to

related topics and informational websites. The manual includes:

•Contents: Table of Contents. When viewed online as a pdf file, hyperlinks in the Contents

link to the associated topic in the body of the manual.

•Section 1. General Information: System description; operating modes

•Section 2. Installation

•Section 3. Final Adjustments

•Section 4. User Interface

•Section 5. Troubleshooting

•Appendix

•Index: Alphabetical index to help you find information in the manual. When viewed

online as a pdf file, index entry page references are hyperlinks to the associated informa-

tion in the body of the manual.

Contents

Section 1. Motion 4000 Traction Elevator Control

In this section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Motion 4000 Traction Elevator Control Overview . . . . . . . . . . . . . . . . . . . . . . .1-2

System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

System Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Controller Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Hand-Held User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Landing and Positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Load Weigher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Cartop Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hoistway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Motion 4000 Specific Traveler Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Operating Mode Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Inspection Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Cartop Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Mode Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

In Car Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Mode Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Hoistway Access Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Mode Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Machine Room Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Mode Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Attendant Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Mode Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Independent Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Mode Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Sabbath Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

Emergency Medical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

Hospital Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Seismic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Mode Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Modifiers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Fire Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

Emergency Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

Generator Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

TAPS Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Car Recall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15

Capture for Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15

Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15

Monitoring and Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

ii Manual # 42-02-2P24 5/20/13

Section 2. Installation

In this Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Equipment Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

EMI/RFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Recommended Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

MCE Wiring Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Drawing Number Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Power Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Controller Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Proper Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Check for Shorts to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Brake Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Power Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Motor, Brake, and Encoder Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Motor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Insulation Breakdown Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Motor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

MRL or Extended Motor Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Brake Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Standard Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Brake Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Brake Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Velocity Encoder Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Encoder Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Emergency Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

Resetting the Rope Gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Initial Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

Often Used Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

How to check Car Speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

How to place the car on Inspection Mode Fault Bypass: . . . . . . . . . . . . . . . . . . . . . . . 2-15

How to place the car on Automatic Mode Fault Bypass:. . . . . . . . . . . . . . . . . . . . . . . . 2-15

How to change TORQMAX F5 Drive parameter settings: . . . . . . . . . . . . . . . . . . . . . . 2-16

How to change Magnetek Drive parameter settings:. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

How to access/set the F7 parameters:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

How to Reset Excessive Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

iii

Auto Tuning and Encoder Data Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Torqmax/Keb F5 Drive Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Keypad Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Clear Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

TorqMax/KEB Drive Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Drive Motor/Encoder Setup Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Check Correct Motor/Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Check Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Learn or Enter Motor or Encoder Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Auto-tuning AC Induction Motors to the F5 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Manual Induction Motor Parameter Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

The Drive Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Loading Data from PM AC Encoder to the F5 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Learning Encoder Data From PM Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Setting the Drive to Run Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Magnetek AC Drive Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Keypad Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Clear Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Magnetek Drive Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Operator (HPV600/600PM/900/900PM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Operator (HPV 900II). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Cover (HPV 900/900PM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

Drive Motor/Encoder Setup Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Auto-tuning AC Motors to the Magnetek Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Tuning Motor No-Load Current (HPV 600/900/900II Only). . . . . . . . . . . . . . . . . . . . . . . .2-27

Tuning Motor Flux Saturation Curve (HPV 600/900/900II Only). . . . . . . . . . . . . . . . . . . .2-27

Tuning Motor Rated RPM (HPV 600/900/900II Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Determining System Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

The Drive Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Set Up for Construction Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Minimal Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Jumper Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Bypassing Faults on Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Resolving Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Speed and Acceleration Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Required Drive Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Torqmax F5 AC Drive Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Magnetek AC Drive Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Required Controller Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Acceleration and Deceleration Rates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Curves Used for Operating Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

The F7 Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Important . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Changing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Next . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Move Back. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Saving Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

iv Manual # 42-02-2P24 5/20/13

Controller Motion Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Using Inspection Stations to Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Encoder Polarity (KEB, TorqMAX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Align Encoder (Magnetek) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

HPV 600/900/900II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

HPV 600PM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

HPV 900PM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

Brake Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Verify Motor Speed, KEB/TorqMAX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Verify Motor Speed, Magnetek. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Temporary Run Box Hookup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

Prepare for Inspection Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

Hoistway Safety String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

Cartop Safety String . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

Hoistway Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

Virtual/Physical/Unused . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52

LS-EDGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Seismic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

Running on Inspection Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

Controller Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Bypassing Faults on Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

Finishing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Landing/Positioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

LS-EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Tape Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Top and Bottom Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Tape Detector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

Tape Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

Tape Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Sensor Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

Door Zone, Terminal, and ETS Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

Top Terminal and ETS Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Bottom Terminal and ETS Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

Permanent Magnet Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

ELGO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

Safety String Connection Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

Tape End Pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70

Hanging Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70

Sensor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

Hoistway Learn, Elgo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

Periodic Maintenance Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

Left to Right Rail Side Reversal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

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