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INSTALLATION
MANUAL
Version: 1.2
There are mainly three different systems for encoder implementation in AC series. They are:
1. Place and fix two holders to the guide rails, one at the bottom (HB) and the other at the top
(HT) of the shaft as shown in the Figure 1 as M1. Be sure that the place of holders HB and
HT are outside of the travel range, namely the car will never reach these holders during
operation.
2. Connect one end of the wire/belt to the holder at top (HT) directly, as shown in Figure 1 as
M2.
3. Belt or wire is tensioned by the spring. Connect the other end of the wire/belt at the bottom
to the holder HB with the spring as shown in Figure 1 as M3. Adjust the spring tension to
100 cm length. Be sure that belt/wire never touches to car body along the shaft during
operation.
4. Fix the encoder stand ES on top of the car.
5. Place the belt/wire through the rotating wheels system as shown in Figure 1 as M4.
6. In order to make the electrical connections, first switch off the controller and then connect
the encoder cables as shown in Table 1. Please note that the color codes in the table are
valid for NEMICON brand encoder. Cable colors may change depending on the encoder
type.
7. After finishing the electrical connections, go directly to section B for setup of the encoder
system.
Most of the inverters employed in closed loop applications generate incremental encoder pulse
outputs. When these signals are connected to the inputs of the ENI interface board, then AC lift
controller can use these to calculate car position. This method is very easy to implement
because of no additional hardware is required. For this application, floor selector parameter
[A05] must be 3 or 6. In this case all motion control system depends on encoder pulses. The
magnets at floor levels are only for learning and calibrating purposes.
1) Place KSR1 (817) shalter at the bottom of the shaft just a few centimeters below the point
where the car must switch high speed to the slow speed in downwards motion.
2) Place KSR2(818) shalter at the top of the shaft just a few centimeters above the point where
the car must switch high speed to the slow speed in upwards motion.
4) Move the car in inspection mode to each floor except top and
bottom floors. Bring the car at exact level position. Then put a
short strip magnet (8 cm recommended) on the rail (or any other
holding system) in front of the MK shalter. Locate the strip
magnet in a way that the magnet shalter MK will stay just at the
middle of the strip magnet when the lift is at floor level position.
Carry on this process for each floor besides top and bottom
ones. The controller will take the middle point of the strip magnet
as the floor level reference point for the related floor.
5) Move the car in inspection mode to the top floor. Bring the car to
the exact level position. Then put a long strip magnet (30 cm
recommended) on the rail (or any other holding system) in front
of the MK shalter. Locate the strip magnet in a way that the
lower length of the strip from MK will be half of the short
magnets placed at between floors when the car stays at the
bottom floor level position. The controller will take the point at a
distance of half-length of the short magnet from the lower end of
the strip magnet as the floor level reference point for the related floor.
6) Move the car in inspection mode to the bottom floor. Bring the
car to the exact level position. Then put a long strip magnet (30
cm recommended) on the rail (or any other holding system) in
front of the MK shalter. Locate the strip magnet in a way that the
upper length of the strip from MK will be half of the short
magnets placed at between floors when the car stays at the
bottom floor level position. The controller will take the point at a
distance of half-length of the short magnet from the upper end
of the strip magnet as the floor level reference point for the related floor.
8) Encoder data signals are transmitted to control panel via flexible cable. Encoder lines on
flexible cable must be selected away from high voltage line such as cabin lamp, door supply
and safety circuit. And its shield must be earthed.
In order to use encoder as car position detecting device, the parameter specifying floor selector
must be changed as follows:
P1:MAIN PARAMETERS>
a) [A05]=03 INC.ENCODER
Standard incremental encoder selection. All motion control system depends on encoder pulses.
The magnets at floor levels are only for learning and calibrating purposes.
b) [A05]=06 INC.ENC.+SHALTER
Slow down paths are calculated and activated by using encoder pulses as above ([A05]=03) but
stopping at floor and relevelling processes read strip magnets instead of encoder pulses.
Inverter simulation output section described above has one drawback. When there is no motion
command to the inverter then the mechanical brake is on and the motor shaft cannot rotate. The
source of simulation output of the inverter is the encoder connected to the motor to measure the
speed. In case of any position change of the car during stopping state while the brake is on this
position change will not be converted by the inverter to encoder signals, namely no pulses are
generated. As a result the lift controller will not detect the motion. Therefore in lift applications
where relevelling is requested, this method can be used if the relevelling process is controlled
completely besides the encoder signals. This is also supported in AC series controllers when
floor selector parameter is set to 6 ([A05]=06 INC.ENC.+SHALTER). In this case, slow down
paths are calculated and activated by using encoder pulses as above ([A05]=03) but stopping at
floor and relevelling processes determined by reading strip magnets instead of encoder pulses.
So the lift controller can detect any slip of the car when the mechanical brake is ON, namely
when there is no motion.
Please note that if the travel distance is different than 1m then the division must be done by the
travel distance in mm.
AC series lift controllers can work as distance based. This facility is especially useful in high
speed and short floor applications. Distance based operation also allows directly pass to slow
speed function and omits the necessity of intermediate speeds. (Distance based operation
works only when floor selector is selected as encoder)
4) GENERAL PULSES
User should specify path lengths for every deceleration, stopping and relevelling type. These
paths are general for all floors. If they are adjusted and tested in one floor then these
adjustments are valid for all floors. As a result, if one path needs to be changed due to any
change in speed or comfort request, then changing the pulses of the related path in general
pulses will apply for all floors. These general pulses should be tested and confirmed before use
the lift. To edit general pulse data, follow:
All data in this table are in pulses. Please note that the corresponding distance for one encoder
pulse depends on pulse per revolution of the encoder (ppr) and the wheel diameter of the
encoder.
The items in general pulse section are as follows:
In electric lifts, if [A10]=0 (1 Stopper) then MKD is active for both upwards and downwards, and
MKU is not used. In hydraulic lift or in electric lifts with [A10]=1 (2 Stoppers) both MKD and
MKU are used. Please note that if [A05]=06, [A10] is always 0.
d) Door Zone: The region in which the door is allowed to be opened. Outside this zone car is
accepted between floors and cabin door is always closed. (If ML1/ML2 not used)
e) Level Start: The limits of relevelling zone from floor level. If the car exceeds the limits of this
zone while waiting in landing, then relevelling will start. (Passive if [A05]=6)
g) MK Length Up: The distance between lower end of the MK magnet and floor level. This
value is automatically calculated and written during autolearning procedure. Usually there is no
need to change this value. However in some cases there may be some disorder in magnetic
fields of the strip magnets or no uniform detection of the magnet shalter. In such a situation
either MK LENGTH UP or MK LENGTH DOWN can be changed (decreased or increased)
mutually or alone to create an offset to overcome unwanted magnetic field effect. The effect of
magnetic field of floor magnet in stopping is explained in detail in section B2. If the car exceeds
or lags floor level in both directions nearly by the same distance then you should correct this
situation by changing MKU STOPPER and MKD STOPPER parameters not MK LENGTH UP
and DOWN.
h) MK Length Down: The distance between upper end of the MK magnet and floor level. The
same arguments in MK LENGTH UP are also valid for this data.
* The data in this table are calculated as 1 pulse corresponds to 1 mm approximately. In case a
different pulse/distance ratio is selected than take the recommended values in the table as mm
unit.
** The data in this table are only a sample. The distances can be selected differently according
to the application.
This parameter is used only in distance based operation. The data in this parameter specifies
the length of the deceleration path from 3rd speed to slow speed in pulses.
This parameter is used only in distance based operation. The data in this parameter specifies
the length of the deceleration path from 4th speed to slow speed in pulses.
k) Minimum Way 3rd Speed (Minimum Pulses for Start with 3rd Speed)
This parameter is used only in distance based operation. When the controller receives a new
call then it compares the distance to the target with the saved pulses in this parameter. If the
target distance is greater than the value in this parameter then the travel will be in 3rd speed
otherwise in 2nd speed.
l) Minimum Way 4th Speed (Minimum Pulses for Start with 4th Speed)
This parameter is used only in distance based operation. When the controller receives a new
call then it compares the distance to the target with the saved pulses in this parameter. If the
target distance is greater than the value in this parameter then the travel will be in 4th speed
otherwise in 3rd speed.
When the parameters discussed in section B1 and general pulses in section B2 has been
adjusted then the lift is ready to run in normal operation provided that the FLOOR PULSES are
correct. Therefore the last step in encoder installation is entering the floor pulses to the AC
controller.
Each floor has a floor pulse indicating its distance from the base floor. Base floor, floor 0, has
always floor pulse 1000. In order to get the floor pulse of the next floor above 0, floor1, the car
must be moved upwards to the next floor level. The encoder data on the main screen is the floor
pulse of the floor 1. Similarly floor pulses of all floors above can be learned by travelling the
floors upwards one by one.
Since this method is hard and time consuming AC series offers an automatic learning function
of the shaft as described in section B4.
Be sure that all necessary adjustments in section B1 and B2 has been completed before
starting normal operation or autolearning process.
Autolearning process is an operation which moves the car along the shaft to get floor level
positions to calculate and save floor parameters automatically. Since the car travel is managed
only by the controller during this operation, the limits of the shaft must be clearly defined. In
autolearning process top and bottom references are 817 (KSR1 input) and 818 (KSR2 input).
817 must be OPEN just below the starting point of the slowdown motion when approaching to
the base floor (floor 0) in fast speed (2nd speed) and it must be CLOSE everywhere in the shaft
above this point. Consequently 818 must be OPEN just above the starting point of the
slowdown motion when approaching to the top floor in fast speed (2nd speed) and it must be
CLOSE everywhere in the shaft below this point. These shalter must be adjusted correctly
before autolearning otherwise the car may over travel the shaft limits.
After completing all installation, connection and parameters settings, start auto-learning
process. In normal mode enter M2-PARAMETERS> P9-UTILITIES > RA>ENCODER SETUP
menu. Press ENTER button to start auto-learning.
1) The car comes to the bottom floor and stops. Then it travels upwards in fast speed till 818 is
OPEN and MK is CLOSE. During this travel floor pulses of all floors are saved.
2) Then it returns to bottom floor, stops and moves again one floor up. Be sure that the lift slows
down before reaching this floor (floor 1). The purpose of this travel is to measure the length of
the strip magnet at each floor. Read section B5 to get information on these topics.
When the car comes to the first floor after up travel the autolearning process is finished. An
approval message is shown on LCD screen for information. By pushing ENT button, all values
are stored in permanent memory. By pushing ENT again, lift gets a call for bottom floor and
moves there.
Auto-learning process assigns K6-FLOOR PULSES and K7-GENERAL PULSE >MK LENGTH
UP and DOWN parameters automatically. Bottom floor pulse value is assigned as 1000. All
pulse values can be changed manually for fine tuning.
The main purpose of the presence of these parameters is to overcome any asymmetry in
magnets. This can happen easily by non-uniform shapes of strip magnets or different detection
sensitivities of the shalter in up and down sides. In this case adjust the data of MK LENGTHs. If
the the car does not reach the floor in one direction but stops at level in the other direction then
increase the data in this direction. For example if the car stays 1cm below floor level when
reaching from down then you should increase MK LENGTH UP by 10 (if 1mm=1pulse).
Similarly, if the car exceeds floor level 0,5 cm when approaching the level from up then you
should decrease MK LENGTH DOWN by 5 (if 1mm=1pulse).
Be aware of that these correction described in this section are only for the case where
asymmetrical results in stopping is detected which cannot be adjusted by general pulse
parameters except MK LENGTHs. Otherwise do not change these parameters. If the car
exceeds or lags floor level in both directions nearly by the same distance (pulse), then
you should correct this by changing MKU STOPPER and MKD STOPPER parameters not
MK LENGTHs.
After completing auto-learning procedure, register calls for all floors form cabin inside and check
all floor levels from up and down. Take notes about differences. There may be same amount of
difference for all floors only in one direction. This difference can be fixed by shifting strip magnet
of that floor. If there are differences for some floors, it can be adjusted by setting FLOOR
PULSE value for that floor. If there is leveling/relevelling function in your system, set
LEVELLING START and LEVELLING STOP parameters too.
Problem: Car stops at floor levels in one direction. But in other direction it always passes floor
levels about 8-10 mm.
Comment: Decrease 8-10 pulse K7-GENERAL PULSE >MK LENGTH with faulty direction.
Problem: Car stops at floor levels at all floors. But at top floor it stops 15 mm before.
Comment: Shift strip magnet of top floor up to 15 mm.
E
H A H
C H A B FLOOR LEVEL
D
F
G G
E
A
FLOOR C H
LEVEL C H A B
M1
M2
D
F F
E E
M1 M2
FLOOR LEVEL
SLOW
FAST
CONNECTION WITH OPEN COLLECTOR, PUSH PULL AND TOTEM POLE ENCODER OUTPUTS
100 100
24V DC
1000 1000
H H
(OPTIONAL)
150
100
1000
CSI
10AC
CNT
N/Mp
L1/R
L2/S
S41
L3/T
S44
CAN-1
CL
120
CH
ENCODER
130
(5-30V DC)
140
ACT&ACS&ACH supply (+) 5-30V DC
151 ground (-)
A- 0V (GND)
signal A
ENI A+ A
signal B
LCD (24V) B+ B
B- Z
G G
I
O
NORM
24V
(-) (+)
POWER Line
SUPPLY Load
(OPTIONAL)
CSI
10AC
CNT
N/Mp
L2/S
L1/R
S41
L3/T
S44
CAN-1
120 CL 5V
CH ENCODER
130 (5V DC)
supply (+)
E +V (5V DC) E
140 ground (-)
0V (GND)
151 ACT&ACS&ACH A-
signal A'
signal A
A
ENI A+ A
signal B B
(5V) B+
signal B'
B- B
LCD
HXKL
REV/ INSP.
ESC ENT
I
D O D
NORM
C C
(OPTIONAL)
150
100
1000
CSI
10AC
CNT
N/Mp
L2/S
L1/R
S41
L3/T
S44
CAN-1
CL
120
CH
LS (LG) STARVERT
130 iV5 INVERTER
140
GE
151
ACT & ACS A- PAO
ENI A+
GE
B (24V) B+ B
B- PBO
LCD
HXKL
REV/ INSP.
ESC ENT
I
O
NORM
F/7.5.5.02.90
A A
ENI BOARD WITH ENCODER CONNECTIONS
This document is a sample for applications. All information contained in
(ENCODER SUPPLY 5V or 24V DC)
these materials are subject to change by Aybey Elektronik without notice.
SERIES AC DRW. M. AKKUŞ
Aybey Elektronik assumes no responsibility for any damage, liability, or AYBEY
other loss rising from these inaccuracies or errors. PROJ. AC145 APPRV. M. AYBEY
ELEKTRONİK
REV. 00 DATE 12 DEC 13
1 2 3 4
1 2 3 4
TOP LIMIT M?
SWITCH d2 = 6-15 mm
KSR2 818 d1 d2
ML2
ML2
CAR ML1-2
AT TOP ML1
100 ML1 Rail
MK MK
1000
6 Magnet
G G
818 818/KSR2
$
817 817/KSR1
1000
USE MECHANICAL SHALTERS AS
5 817 (KSR1) AND 818(KSR2) LIMIT SWITCHES
HU
HU
HD
SAFE ZONE LIMIT
4 1000
HD
FOR LEVELLING
30cm
'N' POLE OF MAGNET
(30cm strip magnet)
D NO MAGNET D
30cm
C
$ NO MAGNET
C
'S' POLE OF MAGNET 8cm
FOR AUTOMATIC (Strip magnet)
DOOR OPEN 15cm 30cm ML2
ZONE LIMIT
(K7-GENERAL PALS) 15cm
1 ML2
ML1
CAR
AT BOTTOM
100 ML1
MK
KSR1 817
1000 MK
B COMPULSORY B
BOTTOM LIMIT
ML1 and ML2 Floor level sensors that detect the unlocking
SWITCH zone must comply with EN 81-1, EN81-2 article14.1.2.5
4cm
15cm
0 WARNING !!!
30cm If parameter A17-UCM CONTROL : 4 then locate ML1 and ML2
818
817
ML1
HU
HD
relevelling functions are disabled then do not use ML1 and ML2 shalters.
MK
ML1, ML2 AND MK ARE PLACED ON CARTOP FOR HIGHER (PRM A05 = 003)
#
MK
Magnet
G G
UP STOPPER
818 818/KSR2
MAGNET
DOWN STOPPER
MAGNET
4
817 817/KSR1
1000
USE MECHANICAL SWITCHES
$ AS 817 (KSR1) AND 818(KSR2) LIMIT SWITCHES
BLACK SIDE OF MAGNET (NC)
30cm
MAGNET 'N' POLE
SAFE ZONE LIMIT (Strip Magnet)
FOR RELEVELLING 2
NO MAGNET
ML2
$ ML2
ML1
15cm
FOR AUTOMATIC 30cm 10cm 100 ML1
DOOR OPEN
ZONE LIMIT 10cm
1 ML1 and ML2 Floor level sensors that detect the
unlocking zone must comply with EN81-1 and
C EN81-2 article14.1.2.5 C
CONTACT
CAR STATE
10cm
15cm 10cm 0 B
MKD
1000 MKD
HU
HD
ML2
MKD MKU
817
818
ML1
MKU STOPPER
MKD STOPPER
ML2
#
ML1
ML1, ML2, MKU AND MKD ARE PLACED ON CARTOP. (PRM A05 = 006)
UP
DOWN