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Advanced WorkbookKDL32 Drive

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KDL32 DRIVE

Field Training

KDL32 Drive

KDL32 DRIVE

2 TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

FOR TRAINING PURPOSES ONLY The information in this training package is for training purposes only. Any technical information relative to aproduct is relevant to training only, and must not be used by the recipient holder or passed on to any other personfor use in the design, manufacture, testing, installation, inspection, maintenance, modernisation or repair of theproduct to which it refers. Where technical information is required by any person to carry out their job, that personmust access the authorised copy of the data from the relevant data files held in all regional offices and maintainedin the latest up to date state.

Copyright 2009 KONE Corporation

All rights reserved under International Copyright Conventions. No part of the contents of this manual may becopied, reproduced or transmitted in any form or by any means or translated into another language or format, inwhole or in part, without the written consent of KONE Corporation.

TC05818W43-ENIssue: (A)

Date: 2009-02-27

Produced by: KONE Corporation, Training Center, Hyvink

Target group: Experts, Trainers

TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation 3

KDL32 DRIVE

Contents

Contents1 Introduction ........................................................... 5

1.1 Advanced workbook ....................................... 61.2 Using the book................................................ 8

2 KDL32 drive ........................................................... 92.1 Introduction ................................................... 102.2 KDL32 drive in brief ...................................... 112.3 Drive components......................................... 132.4 Main circuit.................................................... 152.5 KDL32 in detail ............................................. 172.6 Exercises ...................................................... 24

3 Drive control module (DCBM) ........................... 273.1 Introduction ................................................... 283.2 Control module (DCBM) LEDs...................... 323.3 Control module (DCBM) interfaces............... 363.4 Control module (DCBM) functionality ........... 383.5 Exercises ...................................................... 53

4 Drive power module (MCDM) ............................. 554.1 Introduction ................................................... 564.2 Main circuit and driver board (MCDM) ........ 574.3 Power module (MCDM) LEDs ...................... 604.4 Power module (MCDM) interfaces................ 614.5 Power module (MCDM) functionalities ......... 634.6 Capacitor board in DC-link capacitor module

(MCDMC)...................................................... 644.7 Exercises ...................................................... 65

5 Other boards of the drive ................................... 675.1 Introduction ................................................... 685.2 General ......................................................... 695.3 Brake control module (BCM25) ................... 705.4 Landing operation panel adapter ( LOP-ADA) 735.5 Back-up power module (BUP) ..................... 755.6 Exercises ...................................................... 76

6 Drive parameters and diagnostic codes ........... 796.1 Introduction ................................................... 80

KDL32 DRIVE

4 Contents TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

6.2 Drive parameters ..........................................816.3 KDL32 drive diagnostic and fault codes........906.4 Exercises ......................................................91

7 KDL32 drive commissioning ..............................937.1 Introduction ...................................................947.2 KDL32 drive commissioning in brief..............957.3 Prerequisites.................................................967.4 Commissioning for the inspection drive ........977.5 Commissioning for the rated speed ..............987.6 Fine adjustments.........................................1017.7 Safety inspection ........................................1027.8 Exercises ....................................................103

8 References .........................................................1059 Answers to the exercises .................................107Glossary ...................................................................... 113Index ........................................................................... 116


INTRODUCTION

1. Introduction

1. Introduction

INTRODUCTION

6 1.1 Advanced workbook TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

1.1 Advanced workbookThis advanced workbook presents the KDL32 drive. KDL32 is aninverter drive system that controls the hoisting motor according to thespeed and torque references issued by the drive control module(DCBM). The drive control system follows the destination commandsgiven by the elevator controller. The KDL32 drive is an integrateddrive unit including motor control, motion control and brake control.This advanced workbook presents the structure and operation of thedrive more thoroughly. The technology book must be studied beforecontinuing to this advanced workbook. It is also assumed that youunderstand the fundamentals of an inverter drive system.

This advanced workbook is divided into six units. The first unit,KDL32 drive, describes the main components and operation of theKDL32 drive. The second unit, Drive control module (DCBM),presents the elevator motion control board (DCBMCPU) and themotor control board (DCBMMCB).The third unit, Drive power module (MCDM), presents the power partsof the drive.The fourth unit, Other boards of the drive, describes the otherimportant parts of the drive.The last unit, KDL32 drive commissioning, provides an overview ofthe commissioning procedures that relate to the KDL32 drive.

ObjectivesAfter studying this book, you will have basic knowledge of

The components and operation of the KDL32 drive The control module (DCBM), its boards and functions The power module (MCDM), the other modules of the

drive, and their functions KDL32 parameters and fault codes KDL32 drive commissioning

Reference materialThe reference material recommended for each unit is listed in itsintroduction.


INTRODUCTION

1.1 Advanced workbook

INTRODUCTION

8 1.2 Using the book TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

1.2 Using the bookEach unit in the book begins with a short introduction. The introductionpresents the main topics of the unit, describes the learning objectivesand lists any recommended reference material.

Remember these key points.

In addition to the main text and figures, each unit has key points in thesidebar. The key points present important facts of the topic, whichshould be remembered.Each unit contains exercises to help you to focus on the more importantinformation.In addition to the contents, there is a glossary and index at the end ofthe book to help you to find answers to any questions that you mayhave.


KDL32 DRIVE

2. KDL32 drive

2. KDL32 drive

KDL32 DRIVE

10 2.1 Introduction TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

2.1 IntroductionKDL32 is an elevator drive system for controlling the permanent mag-net synchronous hoisting motors with resolver and encoder. The KDLdrive produces a varying voltage, varying frequency waveform todrive the hoisting motor according to the speed and torque referencesit receives from the drive control module (DCBM).This unit presents the following:

Main drive components KDL32 drive main circuit operation

Selected sections of the KDL32 drive circuit diagrams are presented tosupport the discussion.

ObjectivesAfter completing this unit, you will have basic knowledge of

the main components and structure the main circuit operation

Reference material KDL32 drive circuit diagrams


KDL32 DRIVE

2.2 KDL32 drive in brief

2.2 KDL32 drive in briefKDL32 is an inverter drive system designed to operate permanentmagnet synchronous hoisting motors.

KDL32 is replacing old drive modules.

KDL32 is a drive system designed and manufactured by KONE.KDL32 is replacing V3F25-40A, V3F18-38A and V3F25S-40A drivemodules.

There are several KDL32 drive versions.

There are machine-room versions (G01, G02, G04) and versions forelevators without a machine-room (G03,G05).In MonoSpace elevators the KDL32 drive is a separate module,whereas in MiniSpace elevators KDL32 is located in the LCE controlcabinet.

KDL32LCE KDL32

Main switchmodule

KDL32 SEP

SEP

MiniSpace MonoSpace MonoSpace Special

KDL32 DRIVE

12 2.2 KDL32 drive in brief TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

Main parts of KDL32 drive The main parts of the KDL32 drive are: control module (DCBM)

motion control board (DCBMCPU) motor control board (DCBMMCB)

power module (MCDM) main circuit and driver board (MCDM) capacitor board in DC-link capacitor module

(MCDCM) brake control module (BCM25) landing operation panel adapter (LOP-ADA)

Powersupply(L1-L3)

LCECPU

LWD-I

MCDMMain circuit and driver

board

DCBMMCBMotor

control board

BUP(optional)

BCM25Brake control module

DCBMCPUMotion

control board

DC+

Externalbrakingresistor

M

Resolver

Encoder

Thermistor

Brake 1

Brake 2

MA

CH

INER

Y

BR

DCBM ControlModule

MCDMCDC Bus

capacitorboard

MCDM Power ModuleDRIVE

LOP-ADA(optional)

LOPCB(only

MonoSpace)


KDL32 DRIVE

2.3 Drive components

2.3 Drive componentsKDL32 drive versions for MonoSpace and MiniSpace elevators arealike. The only differences are that the MonoSpace elevator drives havea LOP-ADA module and a special soundproofing.The braking resistors are located outside the drive cabinet.

KDL32 drive (MonoSpace)The main components in the MonoSpace KDL32 drive:

Dynamic braking contactor

Power module (MCDM)

Control module (DCBM)

DC-LINK capacitor module(underneath)

Back-up power module (BUP,optional)

LOP-ADA module

RFI filter

Brake control module (BCM25)

Main contactor module

KDL32 DRIVE

14 2.3 Drive components TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

KDL32 drive (MiniSpace)The main components in the MiniSpace KDL32 drive:

Dynamic braking contactor

Power module (MCDM)

Control module (DCBM)

DC-LINK capacitor module(underneath)

Back-up power module (BUP,optional)

RFI filter

Brake control module (BCM25)

Main contactor module


KDL32 DRIVE

2.4 Main circuit

2.4 Main circuitThe drives main circuit converts the main AC supply to a constant DCvoltage and then to suitable variable frequency and variable voltage ACpower to drive the hoisting motor.

The main contactor controls the power supply to the diode bridge.

Power is supplied to the drive module, elevator control electronics andcharging circuit. The main contactor controls the power to the maincircuit of the drive module.

The RFI filters suppress interference.

The RFI filter suppresses radio-frequency interference.

The diode bridge converts AC to DC.

The diode bridge rectifies the AC electrical power into a constant DCvoltage, which is stored in the power capacitors of the intermediatecircuit.

The charging circuit maintains the voltage in the intermediate circuit.

The charging circuit maintains the intermediate circuit voltage whenthe main contactor is open, i.e. when the diode bridge is not feeding theintermediate circuit.

The motor bridge converts DC to varying voltage and varying frequency AC.

When the elevator starts to run, the constant DC voltage of theintermediate circuit is converted by the motor bridge into variablevoltage and variable frequency AC power to drive the hoisting motor.The frequency determines the motors rotating speed while the voltagedetermines the torque.The operation of the motor bridge is controlled by the motor controlboard (DCBMMCB), which receives speed and torque referencesignals from the motion control board (DCBMCPU).Power is fed to the hoisting motor through a dU/dt filter, which limitsthe transition speed of voltage.

KDL32 DRIVE

16 2.4 Main circuit TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

Braking resistorThe braking resistor converts the braking energy to heat.

In certain situations for example, when an empty car moves upwards ora full car moves downwards, the motor functions like a generator andproduces electrical energy. This surplus energy is fed to the brakingresistor, which converts it to heat.

Dynamic brakingIn dynamic braking the motor coils are short-circuited to limit the elevator car speed.

When the mechanical brakes of a synchronous motor are opened,dynamic braking limits rotation speed of the motor. This prevents theelevator car from speeding.


KDL32 DRIVE

2.5 KDL32 in detail

2.5 KDL32 in detailSome KDL32 circuit diagrams are shown on the following pages.Some important parts of them are highlighted and they are explained onthe other side of the double page.At the end of the unit an elevator run timing sequence is shown. Itmakes it easier to understand how the contactors of the drive workwhen the elevator car moves.

KDL32 DRIVE

18 2.5 KDL32 in detail TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation


KDL32 DRIVE

2.5 KDL32 in detail

LCE electronics power supply (*E04 1/2)A.The power for the control equipment in the elevator control cabinet istaken directly from the main 400 VAC power supply in the drivecabinet. The power is fed through the control current transformer (239),which provides 230 VAC and 20 VAC supplies. The 230 VAC supplyis fed through the interface board (LCE230, 379) to the door drives andused in the safety chain. The rectifier board (LCEREC, 723) uses the20VAC supply to produce the 24 VDC supplies for the elevatorcontroller (LCECPU, 375) and shaft and car electrification.Main contactors, dynamic braking and brakesB.The safety chain and LCE software (output from SW main relay K1)control the auxiliary main contactors (201:3, 201:4). C.The diode bridge DBD converts the control voltage into direct currentfor the main contactor (201:1) .D.The diode bridge (MCDM) converts the control voltage into directcurrent for the dynamic braking relay (204). The dynamic braking relaycontact (204/1-2) makes sure that the main contactor (201:1) can not beactivated if dynamic braking is active.E.The auxiliary main contactors (201:3, 201:4) activate the PWM enable(pulse width modulation) input for the motor control board(DCBMMCB).F.The brake control module (BCM25) gets its control voltage when thecontacts of the auxiliary relays (201:3, 201:4) and the main contactor(201:1) close.Control circuit G.The elevator controller (LCECPU, 375) communicates with theinterface board (LCE230, 379) and the motion control board(DCBMCPU, 385:A1).

KDL32 DRIVE



KDL32 DRIVE

2.5 KDL32 in detail

Drive electronics power supply (*E04 2/2)A.The main contactor contacts (201:1) control power supply for the drive.B.The charging circuit (240) feeds the intermediate circuit when the maincontactor is not energized.C.The dynamic braking contactor (204) controls the motor phases (coils)by short-circuiting them when the main contactor is de-energized.Drive electronics power supplyD.The main circuit and driver board (MCDM, 385:A2) receives itspower from the drives control voltage transformer. Power is fed fromit to the motor control board (DCBMMCB, 385:A5). The DCBMMCBboard supplies power to the motion control board (DCBMCPU,385:A1) and the landing operation panel adapter board (LOP-ADA,385:A6) Note! LOP-ADA is used only in MonoSpace elevators).E.The motion control board (DCBMCPU) receives data from thefollowing sensors:

Motor thermistor (PTC or NTC) Load weighing device (LWD, 64) Motor resolver (connected to the DCBMMCB board) Motor encoder (connected to the DCBMMCB board)

KDL32 DRIVE


Elevator run timing sequenceWhen the elevator is not running and the drive is idle:

The main contactor (201:1) is de-energized and the main circuit contacts are open.

The charging circuit contacts (201:1/21-22) are closed and the charging circuit feeds the intermediate circuit capacitors.

The dynamic braking contacts (204/R1-R2, 204/R3-R4) are closed and dynamic braking is active. The coils of the motor are short-circuited.

The phases of the elevator run:Before the elevator starts to run, the LCECPU checks that the startpermit signal is active.

1. The LCECPU and DCBMCPU activate the SW output K1. The safety circuit closes.

2. The auxiliary main contactors (201:3 and 201:4) are energized. The contacts of 201:3 and 201:4 also activate the PWM enable input on the DCBMMCB board enabling the drive to start. The start permit input for the LCE becomes inactive because the contacts of 201:3 and 201:4 open.

3. The dynamic braking relay (204) is energized and it disables the dynamic braking, i.e. the NC contacts (204/R1-R2, 204/R3-R4) open.

Contactor/item Pos. Timing sequence

Torque DCBM/SW

Speed reference curve DCBM/SW

Start permit LCE/SW

Brakes DCBM/SW

SW output K1 LCE/SW

Auxiliary main contactor 201:3/4

PWM enable MCB

Dynamic braking contactor 204

Main contactor 201:1

Brake control module BCM25

Timing phase 1 2 4 7 125 6 1098 11 133


KDL32 DRIVE

2.5 KDL32 in detail

4. The main contactor (201:1) is energized when the dynamic braking contacts (204/1-2) close, and power is fed to the diode bridge (DBD). The main contactor contacts (201:1/13-14) close and then the brake control module (BCM25) gets its control voltage.

5. DCBMCPU controls the motor bridge on i.e. torque to the motor.

6. DCBMCPU controls the brake control module (BCM25) to open the brakes and waits for them to open.

7. DCBMCPU drives the elevator to the desired floor following the speed reference curve until the speed is zero.

8. DCBMCPU controls the brake control module (BCM25) to close the brakes and waits for them to close.

9. DCBMCPU controls the motor bridge off i.e. no torque to the motor.

10. DCBMCPU de-energizes the main contactor (201:1) control and the SW output K1 de-energizes.

11. The auxiliary main contactors (201:3, 201:4) are de-energized. The PWM enable signal is de-energized.

12. The main contactor (201:1) de-energizes , its contacts (201:1/13-14) open and the brake control module (BCM25) is de-energized.

13. The dynamic braking contactor (204) is de-energized with a delay. The drive part of the start permit signal is activated.

KDL32 DRIVE

24 2.6 Exercises TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

2.6 Exercises

Exercise 1. What is the primary function of the diode bridge?

Exercise 2. Why is the charging circuit needed?

Exercise 3. What is the primary function of the motor bridge?

Exercise 4. What is dynamic braking?


KDL32 DRIVE

2.6 Exercises

Exercise 5. Why is a braking resistor used?

KDL32 DRIVE



DRIVE CONTROL MODULE (DCBM)

3. Drive control module (DCBM)

3. Drive control module (DCBM)



3.1 IntroductionThis unit describes the drive control module (DCBM), which is a partof the drive. It is controls the drive and consists of the DCBMCPUboard and the DCBMMCB board.The main functions of the drive control module are presented, as are itsmain functions, supervisions, interfaces, LEDs, parameters, diagnosticand fault codes.

ObjectivesAfter completing this unit your are:

Able to name the drive boards and describe their locations.

Able to describe the primary purpose and main functions of the drive control module (DCBM).

Able to describe the utilised interfaces, and the input and output signals of the drive control module (DCBM).

Aware of the drive-specific parameters and fault codes.

Reference material KDL32 Parameter List (948570D01) KDL32 Diagnostic Codes (948570D02) KDL32 Parameter Guide (948570D03)



3.1 Introduction

Drive control module (DCBM)

The DCBM is comprised of the DCBMCPU and DCBMMCB boards.

The KDL32 drive has two main control boards: the DCBMCPU(385:A1) and DCBMMCB (385:A5). The control module (DCBM) iscomprised of these two boards. The boards have a 34-pin connectionbetween them where various signals are transferred. The DCBMCPUboard contains one microprosessor, which is responsible for elevatormotion control and driving sequence timing i.e. activating maincontactor, opening brake etc. Also user parameters and diagnostics arehandled by the DCBMCPU. The DCBMMCB board contains also onemicroprosessor and is responsible for power stage control, supervision

Powersupply(L1-L3)

LCECPU

LWD-I


board


DC+


M

Resolver

Encoder

Thermistor

Brake 1

Brake 2M

AC

HIN

ERY

BR

MCDMCDC Bus

capacitorboard


LOP-ADA(optional)

BUP(optional)

DCBMMCBMotor

control board

DCBMCPUMotion

control board

DCBM ControlModule

LOPCB(only

MonoSpace)



and diagnostics. For example the NTS (Normal Terminal Stopping)function is built-in in DCBMMCBs software

The LCECPU sends destination commands to the DCBM.

During elevator setup drive the elevator automatically moves from thelowest level to the highest level, while the distance travelled is read intoDCBM. The exact floor levels and position switch distances are storedin the DCBM memory. Once the setup drive is completed the elevatoris ready for normal drive. In normal drive the LCECPU board sendstarget floor commands to the drive control module. Based on thesecommands, the drive control module controls the drive.

DCBM controls the speed and torque references of the drive.

The DCBM calculates a speed and torque reference for the drive. Italso controls the two mechanical brakes through the brake moduleBCM25.The DCBM uses information from the motor encoder, motor resolver,floor position signals and the shaft image to monitor the location andspeed of the car in the shaft.

Power supply for DCBM control module The DCBM receives its power from the power supply transformer.

The main circuit and driver board MCDM (385:A2) receives its powerfrom the drives control voltage transformer. Power is fed from it to themotor control board (DCBMMCB, 385:A5). The DCBMMCB boardsupplies power further to the motion control board (DCBMCPU,



3.1 Introduction

385:A1) and the landing operation panel adapter board (LOP-ADA,385:A6).

The drive is powered for approximately 10 seconds after a power cutby the back up power module (optional). The elevator stops duringthis period and important parameters, such as car position information,are stored. Because of the power-off delay, when the main switch iscycled for any reason, it should be kept in the off position until theLEDs turn off. Cycling the main switch too quickly can cause a sys-tem malfunction.


32 3.2 Control module (DCBM) LEDs TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

3.2 Control module (DCBM) LEDs

LEDs on DCBMCPU and DCBMMCB boardsThe DCBMCPU and DCBMMCB boards have some status LEDs butthey are difficult to access. However, they can be used whentroubleshooting very difficult faults.

ELED1 (Fault)LED2 (Motor bridge control on)LED3 (MCB deceleration ramp active)

E E

A B C D

TxD (Serial data from LCE to CPU) REDVOL (Reduced brake voltage) POWER (12V power ok) TPOL (Tacho polarity)

RxD (Serial data from CPU to LCE) BRAKE1 (open command) SPARE (Spare) FAULT (Drive fault)LBRE (Line bridge ready) BRAKE2 (open command) MCSTA(Main contactor status) TEST (Test)LBEN (Line bridge enable) MBE (Motor bridge enable) RESET (Reset)

CPU OK (CPU ok)




LEDs on DCBMCPU board

Group

Name Color ON OFF NOTES

A TXD Yellow Serial data from LCE elevator controller to DCBMCPU.

No serial data from LCE to DCBMCPU.

RXD Yellow Serial data from DCBMCPU to LCE.

No serial data from DCBMCPU to LCE.

LBRE (Line bridge ready)

Green Line bridge module is ready.

Line bridge module is not ready.

Notassembled in G01

LBEN (Line bridge enable)

Yellow Line bridge PWM modulation is allowed.

Line bridge PWM is not allowed.

Notassembled in G01

Main contactor enable

Yellow The main contactor is enabled. The MC closing is also controlled by LCE and the safety circuit.

The main contactor is not enabled.

Notassembled in G01

B REDVOL(Reduced brake voltage)

Yellow Reduced brake voltage command.

RBV is not on.

Brake 1 Yellow Brake 1 output has the open command.

Brake 1 output has not the open command.

Brake 2 Yellow Brake 2 output has the open command.

Brake 2 output has not the open command.

MBE (Motor bridge enable)

Yellow The motor bridge PWM modulation is allowed.

The motor bridge PWM modulation is not allowed.

CPU OK (CPU ok) Green The processor is not reset (optional).

The processor is reset. Not assembled in G01


34 3.2 Control module (DCBM) LEDs TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

C POWER (12 V power OK)

Green There is at least a 20 V difference between the 12 V inputs.

Less than 20 Vbetween the 12 V inputs.

SPARE (Spare input)

Yellow The optional spare input is active.

The spare input is not active.

Not assembled in G01

MCSTA (Main contactor status)

Yellow The main contactor is closed.

The main contactor is open.

D TPOL (Tacho polarity)

Green When the motor encoder indicates that the car is moving upwards. The LED may also be lit when the car is stationary.

The car is moving downwards.

FAULT (Drive fault)

Red A fault in the system. The exact fault code can be read with the LCE User Interface.

No fault in the drive.

TEST (Test) Yellow controlled by SW.

RESET (Reset) Red About 0.5 seconds during power-up. Constantly lit, if the processor software is not running.

The processor software is running.

Group





LEDs on DCBMMCB board

Group


E Led 1 Red A fault. No fault.

Led 2 Yellow Motor bridge control is on. Motor bridge control is off.

Led 3 Yellow DCBMMCB boards deceleration ramp is active.

DCBMMCBboards deceleration ramp is not active


36 3.3 Control module (DCBM) interfaces TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

3.3 Control module (DCBM) interfacesDCBM produces the speed and torque references of the drive

The drive control module (DCBM) is connected to severalcomponents. It receives instructions from the LCECPU board. TheDCBM controls the speed and torque references of the drive. It receivesload and data from the car, as well as speed and position informationfrom the motor. It also controls the motor brakes.

DCBMMCB board:Programming PC Motor encoder Resolver LOD-ADA, only MonoSpaceXPR5 XMEN5 XR1 XEN5

E E

LCE connection Programming PC Motor thermistor LWD input XD1 XPR2 XT1 XW1DCBMCPU board:



3.3 Control module (DCBM) interfaces

XLG

6XP

6

XEN

A6

XE

NB

6

LCECPU

LWD-I

MCDMMain circuit and

driver board

DCBMMCBMotor

control board

BUP(optional)

BCM25Brake control

module

DCBMCPUMotion

control board

DC+


M

Resolver

Encoder

Thermistor

Brake 1

Fan

MA

CH

INER

Y

BR

DCBM ControlModule

MCDMCDC Bus

capacitorboard


LOP-ADA(optional)

XR1

XMEN

5XE

N5

XW

1XD

1

XT1

XB

R1

XBR

2

L1L2L3

389 201:1

PE1

PE1

PE

XLD

5

219controller

XFB

5

Brake 2XEB11 XEB12

XBA4

/XBB

4

J4

XBA1/XBB1

XD2

XBP4X

PB2

XBR

2

XT1

XDC2

XL2

XM

21/

XM

22

DC+-

LOPCB(only

MonoSpace)


38 3.4 Control module (DCBM) functionality TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

3.4 Control module (DCBM) functionalityThe DCBM performs several important functions in the elevatorsystem. The most important functions of the DCBM are listed below.

Primary functions

Car positionThe DCBM receives pulse data from the motor encoder, motor resolverand floor level (61U/61N) data on the car. With this information, itconstantly calculates the position of the car in the shaft.

Speed and torque referencesBased on the destination command from the LCECPU board and otherdata (e.g. LWD data), the DCBM uses a mathematical model tocalculate and provide the correct speed and torque reference to thedrive.

Brake controlThe DCBM controls the mechanical brakes with the brake moduleBCM25.

The DCBM monitors current to the brakes.

The DCBM monitors the operation of the brakes. The DCBMconstantly checks that the brakes are operational by monitoring thecurrent of the brakes. If the brake fault occurs a defined number oftimes, the elevator is powered down.

An automatic brake test is carried out at about 11- hour intervals

The DCBM carries out an automatic brake test approximately every 11hours when the elevator has been vacant for a predefined time. Theautomatic brake test can be disabled with a drive parameter. The brakesare tested one at a time. The automatic brake test uses the motorresolver and the floor position signals. If the brake test fails too manytimes, the DCBM sets an alarm. The brakes can be tested alsomanually.



3.4 Control module (DCBM) functionality

LWD arrangementAn inductive sensor or a strain-gauge sensor can be used with KDL32.

Two kinds of load weighing sensors can be used with the KDL32 drive: An inductive load weighing sensor (used when the car

has a separate sling) A strain-gauge sensor (used when the sensor is installed

on the rope fixing)LWD for MiniSpace elevators and MonoSpace Special elevatorswith AMD carIn MiniSpace elevators the inductive LWD is mounted between theelevator car and the sling. The inductive LWD has an integratedamplifier and there is no need for a separate amplifier. The load signalcan therefore be used directly by the elevator control system.

806:E/806 DCBMCPU

LWD sensorCar cross

connection board

Travelling cable

CONTROLROOM

CAR

KDL32



LWD setup (adjustment with LCE User Interface)The LWD is adjusted by giving the system three weight references.

In the MiniSpace elevators the LWD is adjusted by using three weightreference points; 0%, 4060% and 90% of the rated load. Theadjustment is performed through the LCE User Interface (parameter6_74).LWD setup procedure

Remove all loads from the car. Check that the air gap of the LWD is 5 mm (only with

an inductive LWD) Clear the "LWD setup" value by writing the value "-1"

(minus one) to the parameter 6_74. Write the value "0" (zero) to the parameter 6_74. (This

is the first reference point) Put about half nominal load (40% - 60%) to the car. Write the numeric value of the load in per cents to 6_74.

(This is the second reference point) Put more than 90% of the nominal load to the car. Write the numeric value of the load in per cents to 6_74.

(This is the third reference point) To guarantee a good ride comfort, all the three reference

points should be defined.




LWD for MonoSpace elevators (strain-gauge sensor)An amplifier board (LCEVTC) is needed with a strain-gauge sensor

In MonoSpace elevators the strain-gauge sensor and an amplifier(LCEVTC board) are installed on the rope fixing. The DCBMCPUboard inside the KDL32 drive receives the load signal from theLCEVTC board and transmits it to the the MAP panel.

MAP

Rope fixing

KDL32

LWDsensor

LCEVTCboard

DCBMCPU

LOPCBboard



Adjusting the OFFSET and GAIN potentiometers and jumpers on LCEVTC board

Setting the jumpersJumpers X1 and X2 are used to adjust the amplification level of theLWD setup curve i.e. the jumpers move the curve up or downdepending on the car weight. If the needed values (mA) cannot bereached, re-set the jumper positions according to the table below.

GAIN potentiometer (for gradient)OFFSET potentiometer (for zero point)

Jumpers X1, X2 (for curve level)

Settings Description Car weight

Low amplification level Heavy car

Medium amplification level Medium weight car

High amplification level Light car




Adjusting the LWD with a strain-gauge sensorTwo reference points are enough with a strain-gauge

A strain-gauge sensor is more linear than an inductive sensor andtherefore two reference points are enough.There are two setup ways to adjust the LWD with a strain-gauge sensor

A fixed scaling (adjustment with the LCEVTC board, parameter 6_74 = -2)

An adjustment with LCE UI

LWD setup for MonoSpace

Fixed scaling - Parameter 6_74=-2 - Adjustment with potentiometers on LCEVTC board ( 0% and 50% load )

Setup phase 2: Final setting - Entering two reference points through LCE UI ( 0% and 50% load )

LWD setup ready

Fixed scaling Adjustment withLCE UI

Setup phase 1:Preliminary setting of LCEVTC board - Adjustment with potentiometers on LCEVTC board ( 0% and 50% load )



LWD setup with fixed scaling (adjustment with LCEVTC board)

In fixed scaling a predefined loading curve is used

In the fixed scaling the LWD is adjusted by using two weight referencepoints; 0% (4 mA) and 50% (10 mA) of the rated load. The adjustmentis performed through the LCE User Interface (parameter 6_74).The LWD setup is done by adjusting the potentiometers of the VTCboard.LWD setup procedure:

Enter value -2 (minus 2) to LWD set-up parameter 6_74 to enable the fixed scaling.

Remove all loads from the car (zero load). Select RealTimeDisplay monitor selection (6_75) to

65 (LWD input value). Adjust the Offset potentiometer on the LCEVTC board

until the LCE UI display shows 4 (4 mA means a 0% load).

Put 50% of the nominal load to the car. Adjust the Gain potentiometer on the LCEVTC board

until the LCE UI display shows 10 (10 mA means a 50 % load).

Note! If the needed values (mA) cannot be reached, re-set thejumpers on LCEVTC board as shown earlier and perform theLWD setup again.

Load / kg

Current / mA

4mA

50 % 100%0%

10mA

16mA

1

2




LWD setup with LCE UI for MonoSpaceWhen this way is used, there are two setup phases:

Setup phase 1: Preliminary setting for the LCEVTCboard with a 0 % and 50 % load

Setup phase 2: Final setting by entering the two reference points; 0 % point and load point (50 %) through the LCE User Interface (parameter 6_74).

Setup Phase 1: Preliminary setting for the LCEVTC board with a0 % and 50 % load

The LCEVTC board must be preset before the LCE UI adjustment is used

The LCEVTC board is preset with a 0 % load and 50 % load to makesure that the board is able to produce proper output for the whole loadscale (0..100 % of the nominal weight).Adjust the Gain and Offset potentiometers on the LCEVTC board untilit gives with a 0 % load 4..6 mA and with a 50 % load 10..15 mA.Note! If the needed values (mA) cannot be reached, re-set the

jumpers on LCEVTC board as shown earlier and perform theLWD setup again.

Load / kg

Current / mA

4mA

50 % 100%0%

10mA

16mA

6mA

15mA



Setup phase 2: Final setting by entering the two reference pointsthrough the LCE User InterfaceThe two reference points; a 0 % point and a load point (50 %) areentered through the LCE User Interface (parameter 6_74).LWD setup procedure:

Remove all loads from the car. Clear the "LWD setup" value by writing the value "-1"

(minus one) to the parameter 6_74. Write the value "0" (zero) to the parameter 6_74. (This

is the first reference point) Put about half nominal load (40% - 60%) to the car. Write the numeric value of the load in per cents to 6_74.

(This is the second reference point)

Load / kg

Voltage/V

1V

40 - 60 % 90%0%

1

2

3




SupervisionsSome of the elevator options that KDL32 supports are listed below.BFC Brake Fault CounterThe DCBM monitors the operation of the brakes by measuring thebrake current. If the mechanical brakes do not open at elevator start, thestart is cancelled. If the brake fault occurs a defined number of times,the elevator is powered down.

DTC Dual Speed SupervisionThe DCBM monitors the speed of the elevator from two sources: motorresolver and motor encoder. If the speed indicated by these two sourcesdiffers by over 0.22 m/s, the elevator is stopped with the mechanicalbrakes.

MOP-T Motor Protection - ThermistorsThe motor protection feature protects the hoisting motor againstoverheating. If triggered, the elevator car stops at a landing so that thepassengers can exit. The feature resets automatically when the motorhas cooled sufficiently.Note! The thermistor can be an NTC (Negative TemperatureCoefficient) or a PTC (Positive Temperature Coefficient) and they areconnected in a different way. An NTC gives a value in degreescentigrade, whereas a PTC gives only one of the two: OK/Too hot. NTCs are used in newer motors, PTCs in older ones.MOP-NA Motor Protection - North-AmericaThis feature monitors the current of the hoisting motor duringacceleration and normal run. If triggered, the elevator car stops. Thecurrent limits must be entered to the drive.TFC Speed Supervision ControlThis feature monitors the operation of speed supervision. TFC has acounter that makes a fault log each time there is a considerabledifference between the speed indicated by the motor encoders and thespeed reference value. After a predetermined number of faults in speedsupervision, the elevator is stopped with the mechanical brakes andpowered down. The default value is three.



Other functionality

Up to 126 floorsThe DCBM control module allows defining up to 126 floors in total.This value includes normal served floors as well as dummy and virtualfloors. There can be up to 40 virtual floors put together.

Real-time displayThe real-time display function enables certain system signals to beviewed in real-time. These signals include speed and position data,drive control signals, temperature readings and supervisory data. Thereal-time display function can be selected with parameter 6_75. Seedocument KDL Parameter List (948570D01) for a list of the availablesignals.

DCBM also supports EBD, EPD and RESEBD (Emergency Battery Drive) moves the car to the nearest floor inthe light direction at slow speed if it has stopped between floorsbecause of a power failure. The Emergency Power Drive (EPD) system controls the elevators in agroup when standby power becomes available after a power failure.EPD runs the elevators in a preselected order to a designated returnfloor with the doors closed. After the cars are recalled, predefinedoperation (e.g. one elevator is in service) begins.The LCE moves the car at reduced speed (RES) always when neededfor example to save the generators in an EPD situation.Express zones and virtual floorsThe DCBM supports the definition of express zones and virtual floors.Express zones are typically used in high-rise buildings to bypass floors.The bypassed floors form the express zone. An express zone requires adummy plate at each end of the zone and is defined using parameter6_76.




Virtual floors are used to update the floor number (on the COP display)for building floors that are not served. Virtual floors are also used inconjunction with express zones.

Example of defining an express zone with virtual floors:1. Set 6_76 to 5.02 (last served floor before express zone

and number of floors to dummy floor). Skip if there are no virtual floors.

2. Set 6_76 to 6.06 (floor index of lower dummy floor and number of floors to upper dummy floor). If there are no virtual floors, set to 6.00.

3. Set 6_76 to 7.02 (floor index of upper dummy floor and number of floors to first served floor after express zone). Skip if there are no virtual floors.

Refer to AM-11.65.023-API, chapter 9.11 Express zone (EZO) andvirtual floor setup.



Normal terminal stopping (NTS)

NTS function is a built-in feature and therefore always in use.

The NTS is a function that decelerates the elevator car in terminalfloors so that the car will stop to floor and not pass the terminal floorand collide to the shaft end. In KDL32 the NTS function is a built-infeature and therefore always in use. NTS is built-in in the DCBMMCBboards software. NTS is used as an additional function to decelerateto terminal floor. The primary system for deceleration to terminal andother floors is KDL32s motion control. NTS is activated only if theelevator does not follow the speed curve determined by set parame-ters.




NTS operating principle NTS operating principle

If the measured speed exceeds the calculated speed limit an NTSslowdown sequence is initiated. The following actions will take place:

1. Speed reference from DCBMCPU board is ignored and replaced by reference from the NTS function. This new reference is a direct deceleration ramp with slight rounding to prevent excessive torque steps to motor.

2. Speed reference from NTS will stay at 0.25m/s after ramping. This constant speed is kept until the floor is encountered i.e. the 61UN signal becomes active.

3. Speed reference from NTS will ramp down to very slow speed.

4. Speed reference from NTS will stay at 0.02m/s after ramping. This constant speed is kept until the exact floor is encountered i.e. both 61U and 61N signals become active.

5. Speed reference from NTS will ramp down to zero speed.

6. When the measured speed is zero, NTS will de-energize its brake control causing the mechanical brake to close. After 500ms the NTS function will de-energize its main contactor control causing the main contactor to open.

Speed

0DistanceNormal

decelerationpoint

NTSactivates

NTSslowdown

NTSslow speed

NTSstopping

Fullspeed

NTS slowdownNormal slowdown

Terminallanding 1060027.wmf

NTSvery slowspeed

0,25m/s0,02m/s



The NTS function uses 77U1...U4 and 77N1...N4 switches forpositioning. The system contains always 77U and 77N switches anddepending on the elevator speed a number of NTS exclusive switches.Locations of the NTS positioning switches depend on the speed of theelevator.The NTS positioning switches and their locations in the elevator shaftare shown in the following picture.

Switch Name Speed (m/s) L1 (mm)77:N Normal terminal stopping 0.5 75077:U Normal terminal stopping 1.0 1200

1.6 27001.75 30002.0 37002.5 5500



3.5 Exercises

3.5 Exercises

Exercise 6. What are the boards of the KDL32 drive.

Exercise 7. What are the primary functions of the DCBM?

Exercise 8. Which signals does DCBM use to monitor the speed of the car?

Exercise 9. What is an express zone?



Exercise 10. What is a virtual floor?


DRIVE POWER MODULE (MCDM)

4. Drive power module (MCDM)

4. Drive power module (MCDM)



4.1 IntroductionThis unit describes the drive power module (MCDM). It consists of themain circuit and the driver board (MCDM) and the capacitor board inDC-link capacitor module (MCDMC).The main functions of the drive power module are presented, as are itsmain functions, supervisions, interfaces, LEDs, parameters, diagnosticand fault codes.


Able to name the boards of the power module and describe their locations.

Able to describe the purpose and main functions of the drive power module (MCDM).

Able to describe the utilised interfaces, and the input and output signals of the drive power module (MCDM).

Reference material To go through this workbook you do not need any

reference material.



4.2 Main circuit and driver board (MCDM)


Powersupply(L1-L3)

LCECPU

LWD-I


board


DC+


M

Resolver

Encoder

Thermistor

Brake 1

Brake 2

MA

CH

INER

Y

BR

MCDMCDC Bus

capacitorboard


LOP-ADA(optional)

BUP(optional)

DCBMMCBMotor

control board

DCBMCPUMotion

control board

DCBM ControlModule

LOPCB(only

MonoSpace)


58 4.2 Main circuit and driver board (MCDM) TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

The MCDM is comprised of the drive power stage and control and supervision for it.

The MCDM (Main circuit driver mid i.e. Main circuit and driver board)board provides the power stage of the drive and the control andsupervision for the drive power stage. This includes the rectifying ofthe supply AC-voltage with a diode bridge, a braking chopper and 3-phase AC-voltage outputs with IGBT type transistors. The board alsoincludes needed measurements for motor control and supervisions toprotect power components. All the main components are integrated into a PCB (printed circuitboard), which effectively limits the output current. The specifiedthermal current is 32A and the maximum current 80A. The integrationalso means that the MCDM is designed to be replaced totally as onemodule in the field in case of a failure. The DC-voltage storingcapacitors are placed on a separate PCB board (MCDMC).The MCDM board includes also a connection to the dynamic brakingcontactor, fan control (for drive and for GMX2 motor) outputs and a21VAC input for an auxiliary power supply with an optional backuppower input. All auxiliary power supplies of the KDL32 drive areproduced on the MCDM board.

Capacitor board in DC-link capacitor module (MCDMC)

Main circuit and driver board (MCDM)




MCDM signals and symbolsSignal or symbol Description

IGBT Isolated gate bipolar transistor.MCDM Main Circuit Driver Mid.201:1 Main contactor.204 Dynamic braking contactor.MBE Motor Bridge Enable.OC Over Current.DCOV DC link Over Voltage.BRS Brake Resistor Supervision.IGBT FAULT Fault Feedback Signal from IGBT Driver.15V FAULT +/- 15V Power Supply Fault.17V FAULT IGBT Driver Power Supply FAULT.DCM Analog DC link Voltage Feedback Signal.FAN CONTROL Fan PWM Control Signal.BTC Braking Transistor Control signal.FU, FV, FW Motor Phase Voltage signal.CP Central Point of DC link.


60 4.3 Power module (MCDM) LEDs TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

4.3 Power module (MCDM) LEDs

LEDs on MCDM board

E

Power Fault


Power Green Power on. Power off. +/-15Vdc within limits

Fault Red Fault on. Fault off.

DC-link voltage present

Yellow DC-link voltagepresent.

DC-link voltage not present.

Notassembled in G01



4.4 Power module (MCDM) interfaces

4.4 Power module (MCDM) interfacesThe drive power module (MCDM) is connected to several components.

XL2 XDC2Line supply. DC link voltage or MLB

bridge output.

XBRE2 External braking resistor.

XDF2 Drive fan output.

XMF2 Motor fan output.

J1-J4 DC link screw terminals.

XTH2 Thermistor connector.

XD2 DCBMMCB connector.

XP2 21VAC power input.

XPB2 +24VDC backup power.

XM21/XM22 XRD2MOTOR output and dynamic braking

Dynamic braking contactor control.


62 4.4 Power module (MCDM) interfaces TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

LCECPU

LWD-I


driver board

DCBMMCBMotor

control board

BUP(optional)

BCM25Brake control

module

DCBMCPUMotion

control board

DC+


M

Resolver

Encoder

Thermistor

Brake 1

Fan

MA

CH

INER

Y

BR

DCBM ControlModule

MCDMCDC Bus

capacitorboard


XR

1XM

EN

5XE

N5

XW

1X

D1

XT1

XB

R1

XB

R2

L1L2L3

389 201:1

PE1

PE1

PE

XLD

5

219controller

XFB

5

Brake 2XEB11 XEB12

XB

A4/

XB

B4

J4

XBA1/XBB1

XD2

XBP4XP

B2

XBR

2

XT1

XDC2

XL2

XM

21/

XM

22

DC+-

LOPCB(only

MonoSpace)

XLG

6X

P6

XE

NA

6X

EN

B6

LOP-ADA(optional)

XLG

6X

P6

XE

NB

6X

EN

A6



4.5 Power module (MCDM) functionalities

4.5 Power module (MCDM) functionalities

FusesThe fuses are Multifuses which reset automatically when overcurrentcondition has been removed.

SupervisionsThere is an 8-bit fault memory on the MCDM board, which is readableserially by the motor control system. The purpose of this system is toprovide more detailed diagnostic information to help troubleshooting. Note! Only the first fault will be taken into accountSome of the options that MCDM supports are listed below.

Pos. Description Current Voltage Fuse type Size

F1 +24V supply 1,85A 60VDC Multifuse 5,08

F2 +24V supply 3A 30VDC Multifuse 5,08

F3 +24V drive fan 0,75A 30VDC Multifuse

F4 +24V motor fan 0,75A 30VDC Multifuse

MCDM supervisionsName Description

DC overvoltage The DC overvoltage supervision detects overvoltage to protect the power components. If supervision trips, MCDM is faulted immediately. DC link voltage is measured differentially and attenuated by factor 1:100 to DCM signal.

Shortcircuitovervoltage

Motor shortcircuit supervision ( _OC) detects overcurrent very fast (react in microseconds) to protect power components. If supervision trips MCDM is faulted immediately. There is a slower software overcurrent supervision in motor control system, which protects drive and connected motor of excess current.Motor shortcircuit supervision measures current from two phases U (IU) and W(IW).

Brakingsupervision

Braking supervision detects if braking resistor is not connected or brak-ing transistor is conducting too long (about 1 second). If supervision trips MCDM makes fault immediately.


64 4.6 Capacitor board in DC-link capacitor module (MCDMC) TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

4.6 Capacitor board in DC-link capacitor module (MCDMC)

The capacitors maintain the voltage in the intermediate circuit.

The capacitors of the charging circuit maintain the intermediate circuitvoltage when the main contactor is open, i.e. when the diode bridge isnot feeding the intermediate circuit.The life time for the capacitors is about five years.



4.7 Exercises

4.7 Exercises

Exercise 11. What are the functions of the MCDM?

Exercise 12. What is a Multifuse and how does it work?


OTHER BOARDS OF THE DRIVE

5. Other boards of the drive

5. Other boards of the drive



5.1 IntroductionThis unit describes the other control boards of the drive:

Brake control board (BCM25) Landing operation panel adapter board (LOP-ADA) Power back-up module (BUP)

The main functions of the boards are presented, as are their mainfunctions, supervisions, interfaces and LEDs.


Able to describe the purposes and main functions of these boards.

Able to describe the utilised interfaces, and the input and output signals of the boards.

Reference material To go through this workbook you do not need any

reference material.



5.2 General

5.2 General

This unit describes the other control boards of the drive and theirinterfaces:

Brake control board (BCM25) Landing operation panel adapter board (LOP-ADA) Power back-up module (BUP)

XLG

6XP

6

XEN

A6

XEN

B6

LCECPU

LWD-I


driver board

DCBMMCBMotor

control board

BUP(optional)

BCM25Brake control

module

DCBMCPUMotion

control board

DC+


M

Resolver

Encoder

Thermistor

Brake 1

Fan

MA

CH

INER

Y

BR

DCBM ControlModule

MCDMCDC Bus

capacitorboard


LOP-ADA(optional)

XR

1XM

EN

5X

EN

5

XW

1XD

1

XT1

XB

R1

XB

R2

L1L2L3

389 201:1

PE1

PE1

PE

XLD

5

219controller

XFB5

Brake 2XEB11 XEB12

XBA

4/XB

B4

J4

XBA1/XBB1

XD2

XBP4

XPB2

XBR

2

XT1

XDC2

XL2

XM21

/XM

22

DC+-

LOPCB(only

MonoSpace)

XLG

6XP

6

XEN

B6X

ENA6


70 5.3 Brake control module (BCM25) TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

5.3 Brake control module (BCM25)

The brake control module (BCM25) controls the two mechanical brakes separately.

The motion control board (DCBMCPU) opens and closes the twoseparate electrical brakes by using relays K1 and K2 on the brakecontrol module (BCM25).The BCM25 module also gives feedback of electrical brake current.The DC-side relay coil voltage is also a feedback. The BCM25 modulegives mechanical support (and heat dissipation if needed) to the BCB25board.

BCM25 uses a reduced voltage after opening the brakes.

The supply voltage for the brakes is 200 VDC or 100 VDC (reducedvoltage). 200 VDC is applied for two seconds to open the brake andafter that the reduced voltage 100 VDC is used.

K3 and K4 relays are for voltage reduction.

Normally the brake supply voltage is a full wave rectified DC voltage(200 VDC). In case of voltage reduction a half wave rectification (100VDC) is used. The K3 and K4 relays are used for voltage reduction.



5.3 Brake control module (BCM25)

K5 and K6 relays are for emergency brake closing.

The relays K5 and K6 are located after the DC diode bridges. In anemergency situation the relays K5 and K6 are energized and the brakesclose quicker than in normal drive. That is why the brakes are noisierin an emergency situation. This quick brake closing is also called a DCbrake closing.

The normal brake closing is slower than the emergency brake closing.

In normal drive only the relays K1 and K2 are used. The relays K5 andK6 are not energized and the brakes close more slowly. The normalbrake closing is also called an AC brake closing.The typical brake closing times are:

50-100 milliseconds in emergency 200-300 milliseconds in normal drive

Brake 2 open command Coil 1 feedback

Brake 1 open commandReduced voltage control

Current measurementBrake 1

Supply voltage

Brake 2

Coil 2 feedback

K1

XB12XB12:1

XB12:2

XB11XB11:1

XB11:2

XB4

XB4:4

XB4:5

XB4:2

XB4:3

XB4:1

XB4:7

XB4:6

XBR1

XBR1:1

XBR1:3

J4

J4:1

J4:3

K2

K3K5

K1

K3

+

_

K6

K4

K2

+

_

XB13XB13:2

XB13:1

XEB12XEB12:1

XEB12:2

XBR2

XBR2:4

XBR2:6

J4:4

J4:6

230V

N/230

N/230

230V

XEB11XEB11:1

XEB11:2

BCM25


72 5.3 Brake control module (BCM25) TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

BCM25 module interfaces

XBA4/XBB4 Control interface

XBR2 Connection for brake 2

XB11 Brake coil feedback

XBR1 Connection for brake 1



5.4 Landing operation panel adapter ( LOP-ADA)

5.4 Landing operation panel adapter ( LOP-ADA)

The LOP-ADA module is used in MonoSpace elevators.

In MonoSpace elevators there are three speed leds (>0.02, >0.3 and>0.6 m/s) for both directions. The leds are located on the LOPCB boardin the maintenance access panel (MAP). The LOP-ADA boardconverts encoder pulses into a DC voltage, which is needed to light upthe maintenance drive speed information LEDs. The encoder pulses areconverted from +-15 VDC into 0 to 5 VDC. The encoder pulsefrequency varies from 0 Hz to 52 kHz. The frequency transformation isdone using a microcontroller.The LOP-ADA board has a 4-position DIP-switch, which is needed toselect an appropriate encoder/rope combination. There are 16 differentcombinations available.

XENB6 Connection to DCBM control module (optional)

XP6 XENA6 XLG6Power supply from LOPCB (MAP).

Connection to DCBM control module.

Tachometer to LOPCB (optional).


74 5.4 Landing operation panel adapter ( LOP-ADA) TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

LOP-ADA board functionalitiesFuses

Pos. Description Current Voltage Speed Fusetype Size

F1 +12V controller 0,2A 30VDC Fast PTC 1210



5.5 Back-up power module (BUP)

5.5 Back-up power module (BUP)

The BUP module is optional and used during a power break to maintain supply voltages.

The BUP board is optional and used with the MCDM board. TheMCDM board supplies the BUP board with a nominal 24Vdc voltagerectified from a 21Vac transformer secondary voltage. The purpose ofthe BUP board is to maintain the 24Vdc (min.14,6Vdc) and +/-15Vdcsupply voltages for the MCDM and DCBMCPU up to 10 secondsduring a power break. The elevator stops during this period andimportant parameters, such as car position information, are stored.

XBP4 +24VDC backup power connector to MCDM



5.6 Exercises

Exercise 13. How does the drive test the brakes?

Exercise 14. Why are the brakes louder in emergency situations?

Exercise 15. What is a reduced voltage concerning the BCM25?

Exercise 16. What is the purpose of the LOP-ADA board?



5.6 Exercises

Exercise 17. What is purpose of the BUP board?


DRIVE PARAMETERS AND DIAGNOSTIC CODES

6. Drive parameters and diagnostic codes

6. Drive parameters and diagnostic codes



6.1 IntroductionThis unit describes the parameters of the KDL32 drive. They affect theoperation of the drive. The KDL32 parameter guide is also presented,which describes the drive parameters more thoroughly.The diagnostic codes of the KDL32 drive are also presented. Theyindicate the operational faults of the drive.


Aware of the KDL32 drive-specific parameters. Aware of the KDL32 drive-specific diagnostic codes.

Reference material KDL32 Parameter List (948570D01) KDL32 Diagnostic Codes (948570D02) KDL32 Parameter Guide (948570D03)



6.2 Drive parameters

6.2 Drive parametersThe drive parameters are accessed through the LCE User Interface.

There are parameters that affect the operation of the KDL32 drive.They control, for example, how the DCBM forms the speed and torquereference signals. There are also parameters for controlling otherfunctions of the DCBM module, such as supervisions. Most of theseparameters are set during commissioning and fine tuning. The availableDCBM parameters are accessed through menu 6 of the LCE UserInterface.The list of available DCBM parameters is presented in documentKDL32 Parameter List (948570D01). This document provides thename, number, unit, value range and factory default value of eachparameter. It also indicates the parameters that require the PC-basedinterface, which is intended only for factory use.KDL32 Parameter Guide (948570D03) describes the driveparameters more thoroughly and explains how changing aparticular parameter affects the elevator car movement.Note! Before modifying any parameters, ensure that you have the

correct version of the parameter list.

Note! The commissioning instructions indicate which parametershave to be checked and modified and in which order thechanges have to be made. Record the new value of anymodified parameters on the parameter list for laterreference.


82 6.2 Drive parameters TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

Basic elevator parameters (6_1 to 6_39)

The first two groups of parameters in the parameter list are Elevatorparameters (6_1 to 6_9) and Additional elevator parameters (6_20 to6_39). These parameters are set during commissioning and fine tuning.The groups include parameters for setting the nominal and inspectionspeeds, controlling the acceleration and jerks, as well as adjusting otherperformance characteristics.




The basic elevator parameters can be divided into three groups: Predetermined elevator parameters

These parameters are predetermined by the mechanical and electrical characteristics, as well as the performance specifications of the elevator. These parameters are set at the factory and are not adjusted in the field.

Torque control and fine tuning parametersThese parameters are used to tune elevator performance and ride comfort.

Other elevator parametersThese parameters are used to control other operational aspects of the elevator, such as supervisions and elevator control features.

Special parameters (6_40 to 6_53)

The special parameters are also available through the LCE UserInterface.

Machinery parameters (6_60 and 6_69)

These parameters are used to read and adjust for example the motortype, the resolver angle offset and the resolver type, the encoder pulsesper round and encoder type. When defining the resolver speed (6_63) and polarity:

1 = resolver is installed on the motor shaft 2 = resolver is installed on the brake wheel



+ or - (sign for 1 or 2) = resolver angle (must be set so that the value increases when the motor rotates in the up direction and the value decreases when the motor rotates down). The resolver angle value can be monitored by selecting Real TimeDisplay monitor selection (6_75)to 134.

When defining the encoder type (6_65) and polarity: 1 = encoder is installed on the motor shaft 2 = encoder is installed on the brake wheel + or - (sign for 1 or 2) = elevator speed (must be set so

that the value is positive when the motor rotates in the up direction and negative when the motor rotates down). The elevator speed value can be monitored by selecting Real TimeDisplay monitor selection (6_75) to 1.

In MX14 machine the resolver and the encoder are located in one unitthat is installed on the motor shaft. Thus both the resolver speed (6_63)and the encoder type (6_65) must be set 1.

Commissioning and testing parameters (6_70 to 6_76)

These parameters are used to commission and test the elevator. Forexample, the drive commissioning is performed with parameter 6_70,the drive tests are performed with parameter 6_72, the LWD is adjustedwith parameter 6_74 and express zones and virtual floors are definedwith parameter 6_76. The real-time display function can be accessedthrough parameter 6_75. The signals accessible with the real-timedisplay function are presented in document KDL32 Parameter List(948570D01).




When setting up the LWD (6_74): -2 = enables fixed scaling for LWD input, where 4 mA

corresponds to 0% load and 16 mA 100 %. -1 = clear, setup is cleared. 0 = zero point, adjust with empty car. LWD is set to 0%. 1..120 = load point, adjust with loaded car. LWD is set

to given percentageNote! After changing setup, save results with "99 Save" parameter.Note! It is possible to adjust the exixting setup point by point.

Motor data parameters (6_80 to 6_84)

These important parameters are used to enter the data of the hoistingmotor into the system. The drive needs these parameters to control themotor. The parameters are read from the data plate of the hoistingmotor.



Motor data plate

It is a good idea to write down the highlighted motor values (when stilleasily accessible), because they will be needed later during thecommissioning.

Rs

WEIGHT Kg

GEARLESS ELEVATOR MACHINE

TYPE

-Serial Number-

3~MOTOR

kW

S1240 s/h

r/min Hz

IP 21

V A

INS.CLASS F

DC BRAKE

-Elevator Number-

LIFT OFF xxx V / yyy A

RES.AT 20 C

HOLD ON xxx V / yyy A

E V

Nm/A

MACHINERY

cos o

ELEVATOR

SN

SH. DIA

7288

43 H

05

1

2

54 6 7

8 9

10

B1

B2

B3

B4

11

3

(KTC)

Machinery data Brake dataPos Name Pos Name1 Machinery type B1 Brake unit type2 Motor nominal rotation speed (rpm) B2 Brake pull voltage/current3 Motor nominal stator frequency B3 Brake hold voltage/current4 Motor nominal output power B4 Brake coil resistance5 Motor nominal voltage6 Motor nominal current7 Motor power factor (cos phi)8 Motor source voltage (Er)9 Stator resistance, 1 phase10 Stator reactance, 1 phase11 Traction sheave diameter12 KTC factor




Storage parameters (6_95 to 6_99)

Parameter 6_95 is the parameter lock. Parameter 6_97 displays thesoftware versions of the DCBMCPU board and the DCBMMCB board.Parameter 6_98 can be used to restore factory preset parameter valuesfor the DCBMCPU. Parameter 6_99 is used to store modifiedparameter values in DCBMCPU memory.Note! To store LCE parameters (LCE User Interface menus 0-5, 7

and 8), you must cycle the main power to the LCE.



Main speed and torque reference parametersThe figure shows the most important speed and torque referenceparameters and how they affect the operation of the elevator.

Main speed and torque reference parametersPos Name

6_2 Acceleration Acceleration and deceleration in normal operation.6_3 Nominal speed

Maximum speed of elevator in normal operation.

6_10 Balancing 0 = No counterweight, 30.00..65.00 = Balancing percentage. Thismust be correctly set so that motion control can calculate elevator torque.




6_23 Start torque scaling

For tuning torque feed forward. Increasing value gives more torque at start. With correct value speed controller output stays near zero and elevator does not move when brake is opened.

6_25 KTW/Q factor

For tuning torque feed forward. Proportion of total moving masses and nominal load. Torque feed forward value during acceleration and deceleration can be adjusted with this parameter. With correct value speed controlled output is near zero during acceleration and decelera-tion. Value can be searched by using KTW/Q-estimator in RealTime-Display.

6_26 Rope weight For tuning torque feed forward. Compensates rope unbalance. Positive values give more torque at top of shaft and less at the bottom.

6_27 Car cable weight

For tuning torque feed forward. Compensates weight of car cable. Increasing value reduces torque at the top of the shaft.

6_28 Final jerk distance

Additional distance used for final jerk. Longer distance gives smoother approach to landing but reduces performance as approach takes more time.

6_33 Start delay Delay between brake open command and start of speed reference. Too small values cause bouncy starts because elevators starts against brake.

6_52 Full speed jerk

Maximum acceleration change rate during speed reference phases 3 and 5. Lower values provide smoother operation but performance is decreased because more time is needed for jerks. This parameter is automatically recalculated when parameter "2 Acceleration" is altered.

6_53 Distance advance

Additional deceleration distance. This parameter affects especially short one floor runs. For maximum performance set this as low as pos-sible. Too small values can cause elevator not to make final approach smoothly.

Main speed and torque reference parametersPos Name


90 6.3 KDL32 drive diagnostic and fault codes TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

6.3 KDL32 drive diagnostic and fault codesDCBM relays drive faults to the LCECPU.

All the diagnostic and fault codes are listed in document KDL32Diagnostic Codes (948570D02). The DCBM indicates any driveoperational faults to the LCECPU board, which displays them throughthe LCE User Interface. The diagnostic codes are divided into groupsby a main code and subcodes under it.



6.4 Exercises

6.4 Exercises

Exercise 18. How do you access the KDL32 drive parameters?

Exercise 19. Where can you find a list of the available KDL32 drive parameters?


KDL32 DRIVE COMMISSIONING

7. KDL32 drive commissioning

7. KDL32 drive commissioning

1037870.wmf



7.1 IntroductionThis unit provides an overview of the commissioning procedures forthe KDL32 drive. The unit presents the main phases of commissioningand fine tuning, and comments on the safety inspection. Some topicsare examined in more detail, including ETSL, NTS, LWD and shaftset-ups.

ObjectivesAfter completing this unit, you know the most important phases ofcommissioning and the primary procedures of each phase.

Reference material KONE Monopace with KDL32 Drive Commissioning

and Safety Inspection (AM-11.65.030) Repair instruction for KDL32 drive module (AS-

11.65.031)



7.2 KDL32 drive commissioning in brief

7.2 KDL32 drive commissioning in briefCommissioning is divided into several phases, which are performed atdifferent stages of elevator installation. Note that a considerableamount of time may elapse between the phases.The main phases of commissioning:

1. Commissioning for the inspection driveThis phase is done to take the hoisting motor into use to complete the installation.

2. Commissioning for the rated speedThis phase completes the commissioning procedures and sets up the elevator for driving at its rated speed.

3. Fine adjustmentsFine adjustments enhance the ride comfort and optimise the performance of the elevator.

4. Safety inspectionThe safety inspection must be completed before the elevator can be taken into use.

Note! For more information and detailed commissioningprocedures, refer to document KONE MonoSpace withKDL32 Drive Commissioning and Safety Inspection (AM-11.65.030).


96 7.3 Prerequisites TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

7.3 PrerequisitesThe drive is dried before initial commissioning.

Before the commissioning procedures are started, the drive must bedried to make sure that any accumulated moisture is removed.In addition to the checking of motor cable routes, connections andearthing, the actual initial commissioning procedures includeperforming safety chain overconnections, verifying LCE and KDL32drive parameters, and checking the polarities of the motor encoder andresolver.



7.4 Commissioning for the inspection drive

7.4 Commissioning for the inspection driveThe elevators machinery is taken into use in the first phase of commissioning.

The first phase of commissioning is carried out before the installationof the elevator has been completed, but after roping. The purpose ofthis phase is to start driving the car or temporary working platform withthe elevators machinery. The Tirak hoist, which has been used untilthis stage, can be removed. The elevators installation is completedusing its own machinery. Safety chain checks are performed during thisphase of commissioning.


98 7.5 Commissioning for the rated speed TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

7.5 Commissioning for the rated speedSeveral important systems are set up in the second phase of commissioning.

At this point of the installation, the core components of the elevatorhave been installed. The associated commissioning proceduresconfigure the elevator to operate at its rated speed and the speed ischecked. This is an important phase, as several important systems areconfigured, such as ETSL, the load weighing device and NTS. Thisphase of commissioning also includes creating the shaft image andother procedures, such as downloading software to various systems andsetting up possible express zones and virtual floors.



7.5 Commissioning for the rated speed

ETSL configurationETSL prevents the car from running into a terminal buffer at high speed.

The emergency terminal speed-limiting (ETSL) device is anindependent safety feature, which monitors the speed of the car whenit approaches the top or bottom terminal floor. ETSL prevents the carfrom running into a terminal buffer at a high speed. When ETSLactivates, it breaks the safety chain, which causes the elevator toperform an emergency stop using the mechanical motor brakes.

The speed setting of each board is configured individually.

The ETSL system is configured by checking that the motor encodersignal reaches each ETSL board in the system. The number of ETSLboards depends on the rated speed of the elevator. The configurationcontinues with the manual adjustment of the speed set value on eachETSL board using two rotary switches. To perform the adjustment, theset-up jumper of each ETSL board is moved to the SET position.The LCE User Interface is used to enter the speed set value of eachboard into the system. The ETSL set-up drive is then performed usingthe RDF drive mode. After configuration, the set-up jumper of eachETSL board is returned to the RUN position.

LWD adjustmentLWD data is used by DCBM in forming the torque reference.

Setting up the load weighing device (LWD) is important as theelevator's drive control system (DCBM) utilises LWD data. Loadinformation is used to calculate the required motor torque to give theelevator car a smooth start. The LWD is also used to detect overloadsituations, as well as to allocate elevators in a group and detect peaktraffic situations.

The LWD is adjusted with three weight references.

The LWD adjustment procedure begins with verifying sensoroperation. The LCE User Interface is used to check that the signal fromthe inductive sensor is valid. The actual set-up procedure begins withaccessing the Enable LWD setup parameter via the LCE UserInterface. First, the system is calibrated for an empty car. Then, 40% to60% of the rated load is placed into the car and the value is entered intothe system. Finally, 90% of the rated load is placed into the car and thevalue is entered into the system.After using the weight references and storing the values into thesystem, the LWD is verified to provide the correct load value. Note thatif the LWD is adjusted before the car is completely finished, theadjustment must be redone.

Shaft and NTS set-upThe shaft image is stored on the DCBMCPU board.

The purpose of this commissioning procedure is to store an image ofthe elevator shaft with its landings (61U/61N) in the elevator's drivecontrol system (DCBMCPU). The shaft image is used as a reference


100 7.5 Commissioning for the rated speed TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

when controlling the movement of the car in the shaft. The shaft imageis also used by the Normal Terminal Stopping (NTS) system.During this procedure, the elevator is set to use the inspection speed.The procedure is automatic and is initiated with the Shaft setupparameter via the LCE User Interface. The NTS system is also set upautomatically during the Shaft setup.The elevator car starts the configuration run from slightly below thebottom floor landing and moves at inspection speed to the top terminal.While the car moves, the floor numbers are displayed by the LCE UserInterface as they are registered by the LCE. After the procedure, theLCE User Interface indicates whether the run was successful.

Express zonesExpress zones are typically used in high-rise buildings to bypass floors.

An express zone is an optional control feature, which is marked in theshaft using a dummy floor plate at each end of the zone. The distancebetween the two dummy plates is several metres (e.g. 40 m). Theexpress zone is configured with the EZO and virtual floor setupparameter in the LCE User Interface. This parameter is also used toconfigure virtual floors. Virtual floors are used to update the COPdisplay while the car is travelling in the express zone.After an express zone and virtual floors have been created, a shaft set-up drive must be performed. A shaft set-up drive is not necessary ifonly an express zone and no virtual floors have been created. Note thatthe correction drive speed within an express zone is 2.5 m/s.



7.6 Fine adjustments

7.6 Fine adjustmentsFine adjustments enhance ride comfort and optimise performance.

The purpose of fine adjustments is to enhance the ride comfort andoptimise the performance of the elevator. Note that after the fineadjustment procedures, the elevator must still go through the safetyinspection before it can be taken into use.The fine adjustment procedures include:

1. Checking the balancing of the elevator car and the counterweight.

2. Adjusting the torque angle offset.3. Checking the adjustment of the load weighing device.4. Tuning the torque feedforward parameters.5. Setting the KTW/Q factor.6. Tuning ride comfort by adjusting accelerations, starting

and stopping jerks, and levelling accuracy.

1039636.wmf


102 7.7 Safety inspection TC05818W43-EN / Issue: (A) / Copyright 2009 KONE Corporation

7.7 Safety inspectionThe safety inspection ensures that the elevator conforms to safety standards.

Before the elevator can be taken into use, the mandatory safetyinspection procedures are carried out. The safety inspection proceduresverify that the elevator complies with the EN 81-1 safety standard(Safety rules for the constructio

mono KDL32.pdf

Documents

drive power module mcdm

drive control module

power module mcdm leds

power module mcdm interfaces

control module dcbm

control module dcbm

brake control module

drive components