GALaxy III Traction Elevator Controller V3.3.15
User Manual: GALaxy III Traction Elevator ControllerV3.3.15
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Traction Elevator Controller Manual GAL Manufacturing Corp. 50 East 153rd Street Bronx, NY 10451 Technical Support: 1‐877‐425‐7778 Foreword G.A.L. has developed this manual with usability and safety in mind. General and specific safety notices and precautions are defined in the manual. However, G.A.L. cannot be responsible for any injury to persons or damage to property (including the elevator equipment) resulting from negligence, misuse of the equipment, misinterpretation of instructions included in this manual, or due to any other cause beyond the control of G.A.L. All drawings, illustrations and information herein are the property of G.A.L. and must not be made public or reproduced by any individual or entity other than the purchaser hereof without the express written permission of G.A.L. Rev 3.3.15 September 16th, 2017 Table of Contents Introduction .................................................................................................................................................. 1 1.1 Physical Layout of the Controller ........................................................................................................ 2 1.2 Typical Physical Layout........................................................................................................................ 2 Figure 1.0: Typical Physical Layout........................................................................................................ 3 1.3 Selector System ................................................................................................................................... 4 1.4 Tape Selector System .......................................................................................................................... 4 Figure 1.1: Tape Selector ...................................................................................................................... 4 Figure 1.2: Tapeless System – Absolute Encoder.................................................................................. 5 Figure 1.2A: Tapeless System – CAN Open Encoder ............................................................................. 6 1.5 Tapeless System .................................................................................................................................. 7 1.6 Secondary Speed Feedback ................................................................................................................ 7 1.7 Modes of Operation ............................................................................................................................ 7 1.8 Operating Sequence............................................................................................................................ 7 1.9 Reset Mode ......................................................................................................................................... 8 1.10 Safety String Open Mode .................................................................................................................. 9 1.11 Controller Inspection Mode .............................................................................................................. 9 1.12 Car Top Inspection Mode .................................................................................................................. 9 1.13 Access Mode ................................................................................................................................... 10 1.14 Independent Service Mode............................................................................................................. 10 1.15 Load Weighing Bypass Mode .......................................................................................................... 10 1.16 Attendant Service Mode ................................................................................................................. 11 1.17 Code Blue Hospital Service Mode ................................................................................................... 11 1.18 Fire Service Phase I Mode ............................................................................................................... 12 1.19 Fire Service Phase I Alternate Return Mode ................................................................................... 12 1.20 Fire Service Phase II Mode .............................................................................................................. 13 1.21 Emergency Power ........................................................................................................................... 13 1.22 Earthquake Mode ........................................................................................................................... 13 1.23 Stalled Mode ................................................................................................................................... 14 1.24 Automatic Mode ............................................................................................................................. 14 Section 2 ‐ Product Description .................................................................................................................. 15 2.1 General Information ......................................................................................................................... 15 2.2 Site Selection ..................................................................................................................................... 15 P a g e | iii 2.3 Environmental Considerations.......................................................................................................... 15 2.4 Wiring Guidelines and Instructions ................................................................................................... 15 2.5 The Wiring Prints............................................................................................................................... 15 2.6 Ground Wiring................................................................................................................................... 16 2.7 Hoistway Wiring ................................................................................................................................ 16 2.8 Elevator Car Wiring ........................................................................................................................... 16 2.9 Machine Room Wiring ...................................................................................................................... 16 2.10 Wiring to Top of Car Selector .......................................................................................................... 16 2.11 Slowdown Limits ............................................................................................................................. 16 Table 1: Slowdown Distances from Terminal Landings ...................................................................... 17 2.12 Normal and Final Limit Switches ..................................................................................................... 18 2.13 Tape Selector Installation ............................................................................................................... 18 Figure 2.0: Typical Tape Mounting & Magnet Placement .................................................................. 20 Figure 2.1: Typical Mounting of Selector ............................................................................................ 23 Figure 2.2: Selector Board GALX-1011BN ........................................................................................... 24 Figures 2.3 & 2.4: Selector Tape Layout & Magnet Placement .......................................................... 25 2.14 Tapeless Selector Installation ......................................................................................................... 26 Figure 2.5: Tapeless Selector Mounted on Crosshead........................................................................ 26 Figure 2.5a: Tapeless Selector Magnet Placement ............................................................................. 27 Figure 2.6: Door Zone Template Used to Set Selector Distance ......................................................... 27 Figures 2.7: Sensor Orientation and Wiring ........................................................................................ 28 Figure 2.8: Sensor Orientation Upside Down ..................................................................................... 29 Figures 2.9 & 2.10: Door Zone Template ............................................................................................ 30 Figure 2.11: Tapeless Selector - Sensor Adjustment........................................................................... 31 Figure 2.12: Tapeless Selector – Close-up of Notch & Sensor ............................................................ 32 2.15 Tapeless Selector Assembly Installation ......................................................................................... 33 Figure 2.13 Selector, Door zone and Normal Terminal Slowdown Limit Mounting. .......................... 34 Figure 2.14 Placement of Sensor Labels on Selector Box ................................................................... 35 Figure 2.15 Typical Selector Box Installation ...................................................................................... 35 Figure 2.16 Typical Slowdown Bracket Installation ............................................................................ 36 2.16 Transfer Relay Diagram ................................................................................................................... 37 Figure 2.13 – All Controllers Off .......................................................................................................... 37 Figure 2.14 – Leftmost Controller Off ................................................................................................. 37 Section 3 ‐ Adjustment of the GALaxy controller DSD 412 Drive ............................................................... 38 3.1 General Information ......................................................................................................................... 38 3.2 Check Main Line Voltage ................................................................................................................... 38 3.3 SCR Drive Motor Field Current .......................................................................................................... 38 3.4 Set Toggle Switches........................................................................................................................... 39 3.5 Make Sure the Car Is Safe ................................................................................................................. 39 3.6 Check Controller Voltage .................................................................................................................. 39 3.7 Verify the Main CPU is Operating ..................................................................................................... 39 3.8 Preset Adjustable Variables on Safety Processor Board and Main CPU ........................................... 39 3.9 1066 LCD interface "Adj Var" Menu ................................................................................................. 40 3.10 1021/1101/1005 LCD interface "Adjustable Variables -> Car Motion" Submenu .......................... 40 3.11 Place Stop Switch in Run Position ................................................................................................... 41 3.12 Hoist Motor Data ............................................................................................................................ 41 3.13 SCR Drive Self Tune ......................................................................................................................... 42 3.14 Pre‐set the Digital Speed Clamps .................................................................................................... 42 3.15 Ready to Run On Inspection............................................................................................................ 43 Figure 3.1: Inspection String ............................................................................................................... 44 3.16 Adjust the Brake Voltage ................................................................................................................ 44 3.17 Check the Run Direction ................................................................................................................. 45 3.18 Car Runs in the Wrong Direction .................................................................................................... 45 3.19 Drive Trips Immediately .................................................................................................................. 45 3.20 Check Inspection Speed .................................................................................................................. 46 3.21 Verify Controller Encoder Direction ................................................................................................ 46 3.22 Verify Selector and Slowdown Inputs ............................................................................................. 47 3.23 Verify Car Speed on Safety Processor Board .................................................................................. 47 3.24 Correct Car Speed When Using a Tape Installed in Hoistway......................................................... 47 3.25 Correct Car Speed When Using 485 Tapeless System .................................................................... 47 3.26 Correct Car Speed When Using CAN Open Tapeless System .......................................................... 48 3.27 Learn the Hoistway ......................................................................................................................... 48 3.28 Automatic Run ................................................................................................................................ 49 3.29 Fine Tune the Ride Quality .............................................................................................................. 49 3.30 Adjust the Stop................................................................................................................................ 49 Figure 3.2: S-Curve Parameters .......................................................................................................... 50 Page |v 3.31 Adjust the Start ............................................................................................................................... 50 3.32 Verify Top Speed ............................................................................................................................. 51 3.33 Adjust Safety Processor Board Speed Clamps ................................................................................ 51 3.34 Adjust Digital Slowdown Speed Clamps.......................................................................................... 52 Table 3.1: Slowdown Clamps .............................................................................................................. 52 3.35 Verify Inspection Velocity Clamp On Safety Processor Board ........................................................ 52 3.36 Analog Load Weigher Setup ............................................................................................................ 53 3.37 Empty Car Setup.............................................................................................................................. 53 3.38 Full Car Setup .................................................................................................................................. 53 3.39 Load Weighing Calibration Sequence ............................................................................................. 54 3.40 Adjust the Motor Pre‐torque .......................................................................................................... 54 3.41 Verify the Doors Are Safe ................................................................................................................ 55 3.42 Fine Tune the Ride Quality .............................................................................................................. 55 Section 4 ‐ Adjustment of the GALaxy controller HPV‐600/900 (Induction Motor- Geared Machine) ...... 57 4.1 General Setup ................................................................................................................................... 57 4.2 Check Main Line Voltage ................................................................................................................... 57 4.3 Set Toggle Switches........................................................................................................................... 57 4.4 Make Sure the Car Is Safe ................................................................................................................. 58 4.5 Check Controller Voltage .................................................................................................................. 58 4.6 Verify the Main CPU is Operating ..................................................................................................... 58 4.7 Preset Adjustable Variables on Safety Processor Board And Main CPU........................................... 58 4.8 1066 LCD interface "Adj Var" Menu ................................................................................................. 58 4.9 1021/1101/1005 LCD interface "Adjustable Variables -> Car Motion" Submenu ............................ 59 4.10 Place Stop Switch in Run Position ................................................................................................... 59 4.11 Hoist Motor Data ............................................................................................................................ 60 4.12 Pre‐set the Digital Speed Clamps .................................................................................................... 61 4.13 Ready to Run On Inspection............................................................................................................ 61 Figure 4.1: Inspection String ............................................................................................................... 63 4.14 Adjust the Brake Voltage ................................................................................................................ 63 4.15 Check the Run Direction ................................................................................................................. 64 4.16 Car Runs the Wrong Direction ........................................................................................................ 64 4.17 Drive Trips Immediately .................................................................................................................. 65 4.18 Car Runs Extremely Slow ................................................................................................................ 66 4.19 Check Inspection Speed .................................................................................................................. 66 4.20 Verify Controller Encoder Direction ................................................................................................ 67 4.21 Verify Car Speed on Safety Processor Board .................................................................................. 67 4.22 Correct Car Speed When Using a Tape ........................................................................................... 68 4.23 Correct Car Speed When Using 485 Tapeless System .................................................................... 68 4.24 Correct Car Speed When Using CAN Open Tapeless System .......................................................... 68 4.25 Learn the Hoistway ......................................................................................................................... 69 4.26 Automatic Run ................................................................................................................................ 70 4.27 Drive Adaptive Tune........................................................................................................................ 70 4.28 Fine Tune the Ride Quality .............................................................................................................. 70 4.29 Adjust the Stop................................................................................................................................ 71 Figure 4.2: S‐Curve Parameter ............................................................................................................ 72 4.30 Adjust the Start ............................................................................................................................... 72 4.31 Verify Top Speed ............................................................................................................................. 72 4.32 Adjust Safety Processor Board Speed Clamps ................................................................................ 72 4.33 Adjust Digital Slowdown Speed Clamps.......................................................................................... 73 Table 4.1: Slowdown Clamps .............................................................................................................. 74 4.34 Verify Inspection Velocity Clamp on Safety Processor Board ......................................................... 74 4.35 Analog Load Weigher Setup ............................................................................................................ 74 4.36 Empty Car Setup.............................................................................................................................. 75 4.37 Full Car Setup .................................................................................................................................. 75 4.38 Load Weighing Calibration Sequence ............................................................................................. 76 4.39 Adjust the Motor Pre‐torque .......................................................................................................... 76 4.40 Verify the Doors Are Safe ................................................................................................................ 77 4.41 Fine Tune the Ride Quality .............................................................................................................. 77 Section 5 ‐ Adjustment of the GALaxy Non‐ Distance Feedback controller ‐ HPV‐600/900 ....................... 79 5.1 General Setup ................................................................................................................................... 79 5.2 Check Main‐line Voltage ................................................................................................................... 79 5.3 Set Toggle Switches........................................................................................................................... 79 5.4 Make Sure the Car Is Safe ................................................................................................................. 80 5.5 Check Controller Voltage .................................................................................................................. 80 5.6 Verify the Main CPU is Operating ..................................................................................................... 80 5.7 Preset Adjustable Variables on Safety Processor Board And Main CPU .......................................... 80 P a g e | vii 5.8 1066 LCD interface "Adj Var" Menu .................................................................................................. 80 5.9 1021/1101/1005 LCD interface "Adjustable Variables -> Car Motion" Submenu ............................ 81 5.10 Place Stop Switch in Run Position ................................................................................................... 81 5.11 Hoist Motor Data ............................................................................................................................ 81 5.12 HPV 900/600 Drive .......................................................................................................................... 81 5.13 GPD 515 Drive ................................................................................................................................. 84 5.14 Ready to Run On Inspection............................................................................................................ 85 Figure 5.1: Inspection String Circuit .................................................................................................... 86 5.15 Adjust the Brake Voltage ................................................................................................................ 87 5.16 Check Run Direction ........................................................................................................................ 87 5.17 Car Runs Wrong Direction............................................................................................................... 88 5.18 Verify Encoder Connection ............................................................................................................. 88 5.19 Check Inspection Speed .................................................................................................................. 89 5.20 Check Selector Inputs...................................................................................................................... 89 5.21 Verify Slowdown Limits ................................................................................................................... 89 5.22 Verify Car Speed on Safety Processor Board .................................................................................... 90 5.23 Correct Car Speed When Using a Tape ........................................................................................... 90 Figure 5.2: Selector Magnet Placement .............................................................................................. 90 5.24 Automatic Run ................................................................................................................................ 91 5.25 Adjust the Drive Speed Profile ........................................................................................................ 91 5.26 Drive Adaptive Tune (HPV 900 /600 Only) ...................................................................................... 92 5.27 Adjust the Stop................................................................................................................................ 92 5.28 Adjust the Start ............................................................................................................................... 93 5.29 Adjust Safety Processor Board Speed Clamps ................................................................................ 93 Table 5.1: Slowdown Clamps .............................................................................................................. 94 5.30 Verify Inspection Velocity Clamp on Safety Processor Board ......................................................... 95 5.31 Analog Load Weigher Setup............................................................................................................ 95 5.32 Empty Car Setup.............................................................................................................................. 95 5.33 Full Car Setup .................................................................................................................................. 96 5.34 Load Weighing Calibration Sequence ............................................................................................. 97 5.35 Check the Doors .............................................................................................................................. 97 5.36 Fine Tune Ride and Stops ................................................................................................................ 97 Section 6 ‐ Adjustment of the GALaxy Controller DC Quattro Drive........................................................... 98 6.1 General Information ......................................................................................................................... 98 6.2 Check Main Line Voltage ................................................................................................................... 98 6.3 Set Toggle Switches........................................................................................................................... 98 6.4 Make Sure the Car Is Safe ................................................................................................................. 99 6.5 Check Controller Voltage .................................................................................................................. 99 6.6 Verify the Main CPU is Operating ..................................................................................................... 99 6.7 Preset Adjustable Variables on Safety Processor Board and Main CPU .......................................... 99 6.8 1066 LCD interface "Adj Var" Menu.................................................................................................. 99 6.9 1021/1101/1005 LCD interface "Adjustable Variables ->Car Motion" Submenu .......................... 100 6.10 Place Stop Switch in Run Position ................................................................................................. 100 6.11 Hoist Motor Data .......................................................................................................................... 101 6.12 Quattro Drive Self‐Tune ................................................................................................................ 101 6.13 Pre‐set the Digital Speed Clamps .................................................................................................. 102 6.14 Ready to Run On Inspection.......................................................................................................... 103 Figure 6.1: Inspection String Circuit .................................................................................................. 104 6.15 Adjust the Brake Voltage .............................................................................................................. 105 6.16 Check the Run Direction ............................................................................................................... 105 6.17 Car Runs in The Wrong Direction .................................................................................................. 105 6.18 Drive Trips Immediately ................................................................................................................ 106 6.19 Check Inspection Speed ................................................................................................................ 106 6.20 Verify Controller Encoder Direction .............................................................................................. 107 6.21 Verify Selector and Slowdown Inputs ........................................................................................... 107 6.22 Verify Car Speed on Safety Processor Board .................................................................................. 107 6.23 Correct Car Speed When Using A Tape Installed In Hoistway ...................................................... 108 6.24 Correct Car Speed When Using 485 Tapeless System .................................................................. 108 6.25 Correct Car Speed When Using CAN Open Tapeless System ........................................................ 108 6.26 Learn the Hoistway ....................................................................................................................... 109 6.27 Automatic Run .............................................................................................................................. 110 6.28 Fine Tune the Ride Quality ............................................................................................................ 110 Figure 6.2: S‐Curve Parameters......................................................................................................... 110 6.29 Adjust the Stop.............................................................................................................................. 111 6.30 Adjust the Start ............................................................................................................................. 112 6.31 Verify Top Speed ........................................................................................................................... 112 P a g e | ix 6.32 Adjust Safety Processor Board Speed Clamps .............................................................................. 112 6.33 Adjust Digital Slowdown Speed Clamps ........................................................................................ 113 Table 6.1: Slowdown Clamps ............................................................................................................ 114 6.34 Verify Inspection Velocity Clamp On Safety Processor Board ....................................................... 114 6.35 Analog Load Weigher Setup.......................................................................................................... 114 6.36 Empty Car Setup............................................................................................................................ 115 6.37 Full Car Setup ................................................................................................................................ 115 6.38 Load Weighing Calibration Sequence ........................................................................................... 116 6.39 Adjust the Motor Pre‐torque ........................................................................................................ 116 6.40 Verify the Doors Are Safe .............................................................................................................. 117 6.41 Fine Tune the Ride Quality ............................................................................................................ 117 Section 7 ‐ Adjustment of the GALaxy Combivert F5 AC Drive ................................................................. 119 7.1 General Setup ................................................................................................................................. 119 7.2 Check Main Line Voltage ................................................................................................................. 119 7.3 Set Toggle Switches......................................................................................................................... 119 7.4 Make Sure the Car Is Safe ............................................................................................................... 120 7.5 Check Controller Voltage ................................................................................................................ 120 7.6 Verify the Main CPU is Operating ................................................................................................... 120 7.7 Preset Adjustable Variables On Safety Processor Board And Main CPU ........................................ 120 7.8 1066 LCD interface "Adj Var" Menu ................................................................................................ 120 7.9 1021/1101/1005 LCD interface "Adjustable Variables -> Car Motion" Submenu ......................... 121 7.10 Place Stop Switch in Run Position ................................................................................................. 121 7.11 Hoist Motor Data .......................................................................................................................... 122 7.12 Pre‐set the Digital Speed Clamps .................................................................................................. 123 7.13 Adjust the Brake Voltage .............................................................................................................. 124 7.14 Motor Learn Procedure ................................................................................................................ 124 7.15 Encoder Learn Procedure, v1.62 (Unroped machine) .................................................................. 125 7.16 Encoder Learn Procedure, v1.72 (Unroped or Roped machine) .................................................. 125 7.17 Check Inspection Speed ................................................................................................................ 126 7.18 Verify Controller Encoder Direction .............................................................................................. 127 7.19 Run The Car On Inspection With The Ropes On The Sheave Of The Motor ................................. 127 7.20 Ready to Run On Inspection.......................................................................................................... 127 Figure 7.1: Inspection String Circuit ...................................................................................................... 129 7.21 Verify Selector and Slowdown Inputs ........................................................................................... 129 7.22 Verify Car Speed on Safety Processor Board .................................................................................. 130 7.23 Correct Car Speed When Using a Tape......................................................................................... 130 7.24 Correct Car Speed When Using 485 Tapeless System .................................................................. 130 7.25 Correct Car Speed When Using CAN Open Tapeless System ....................................................... 131 7.26 Learn the Hoistway ....................................................................................................................... 131 7.27 Automatic Run .............................................................................................................................. 132 7.28 Fine Tune the Ride Quality ............................................................................................................ 133 7.29 Adjust the Stop.............................................................................................................................. 133 7.30 Adjust the Start ............................................................................................................................. 134 Figure 7.2: Speed clamps .................................................................................................................. 136 7.31 Adjust Safety Processor Board Speed Clamps .............................................................................. 136 7.32 Adjust Digital Slowdown Speed Clamps ....................................................................................... 137 Table 7.1: Slowdown Clamps ............................................................................................................ 137 7.33 Verify Inspection Velocity Clamp on Safety Processor Board ....................................................... 138 7.34 Analog Load Weigher Setup .......................................................................................................... 138 7.35 Empty Car Setup............................................................................................................................ 138 7.36 Full Car Setup ................................................................................................................................ 139 7.37 Load Weighing Calibration Sequence ........................................................................................... 140 7.38 Adjust the Motor Pre‐torque ........................................................................................................ 140 7.39 Verify the Doors Are Safe .............................................................................................................. 141 7.40 Fine Tune the Ride Quality ............................................................................................................ 141 Section 8 ‐ Adjustment of the GALaxy ‐ HPV‐ 900 Permanent Magnet AC Gearless Motor ....................... 143 8.1 General Setup ................................................................................................................................. 143 8.2 Check Main Line Voltage ................................................................................................................. 143 8.3 Set Toggle Switches......................................................................................................................... 143 8.4 Make Sure the Car Is Safe ............................................................................................................... 143 8.5 Check Controller Voltage ................................................................................................................ 144 8.6 Verify the Main CPU is Operating ................................................................................................... 144 8.7 Preset Adjustable Variables on Safety Processor Board And Main CPU ........................................ 144 8.8 1066 LCD interface "Adj Var" Menu ................................................................................................ 144 8.9 1021/1101/1005 LCD interface "Adjustable Variables -> Motion" Submenu ................................ 145 8.10 Place Stop Switch in Run Position ................................................................................................. 145 P a g e | xi 8.11 Hoist Motor Data .......................................................................................................................... 145 8.12 Pre‐set the Digital Speed Clamps .................................................................................................. 147 8.13 PM Start‐Up Procedure ................................................................................................................. 148 8.14 Adjust the Brake Voltage .............................................................................................................. 148 8.15 Encoder Learn Procedure and Motor Auto Tune Procedure ........................................................ 148 8.16 Check Inspection Speed ................................................................................................................ 149 8.17 Verify Controller Encoder Direction .............................................................................................. 149 8.18 Ready to Run On Inspection.......................................................................................................... 150 Figure 8.1: Inspection String Circuit .................................................................................................. 151 8.19 Verify Selector and Slowdown Inputs ........................................................................................... 151 8.20 Verify Car Speed on Safety Processor Board .................................................................................. 152 8.21 Correct Car Speed When Using a Tape ........................................................................................ 152 8.22 Correct Car Speed When Using 485 Tapeless System .................................................................. 152 8.23 Correct Car Speed When Using CAN Open Tapeless System ........................................................ 153 8.24 Learn the Hoistway ....................................................................................................................... 153 8.25 Automatic Run .............................................................................................................................. 154 8.26 Fine Tune the Ride Quality ............................................................................................................ 154 Figure 8.2: S‐Curve Parameters......................................................................................................... 155 8.27 Adjust the Stop.............................................................................................................................. 155 8.28 Adjust the Start ............................................................................................................................. 156 8.29 Verify Top Speed ........................................................................................................................... 156 8.30 Adjust Safety Processor Board Speed Clamps .............................................................................. 157 8.31 Adjust Digital Slowdown Speed Clamps ....................................................................................... 157 Table 8.1: Slowdown Clamps ............................................................................................................ 158 8.32 Verify Inspection Velocity Clamp On Safety Processor Board ....................................................... 158 8.33 Analog Load Weigher Setup.......................................................................................................... 158 8.34 Empty Car Setup............................................................................................................................ 159 8.35 Full Car Setup ................................................................................................................................ 159 8.36 Load Weighing Calibration Sequence ........................................................................................... 160 8.37 Adjust the Motor Pre‐torque ........................................................................................................ 160 8.38 Verify the Doors Are Safe .............................................................................................................. 161 8.39 Fine Tune the Ride Quality ............................................................................................................ 161 Section 9 ‐ Troubleshooting ...................................................................................................................... 163 9.1 General Information........................................................................................................................ 163 9.2 Microprocessor CPU........................................................................................................................ 163 9.3 Input/Output Boards....................................................................................................................... 163 Figure 9.0 - High Voltage & Low Voltage .......................................................................................... 164 Figure 9.1 Run Sequence................................................................................................................... 165 Figure 9.2 – Safety Processor Board.................................................................................................. 166 9.4 System Faults .................................................................................................................................. 167 Section 10 – 1021/1101/1005 LCD Interface ............................................................................................ 168 10.1 Operating the 1021/1101/1005 LCD Interface ............................................................................. 168 10.2 1021/1101/1005 LCD Interface Main Menu ................................................................................. 169 10.3 Elevator Status .............................................................................................................................. 169 10.4 Elevator Service............................................................................................................................. 170 10.5 Fault Status ................................................................................................................................... 170 10.6 Elevator Status .............................................................................................................................. 173 10.7 Door Status.................................................................................................................................... 173 10.8 Rear Door Status ........................................................................................................................... 174 10.9 Set Calls and Lockouts ................................................................................................................... 175 10.10 Car Call Test................................................................................................................................. 175 10.10a CAN Encoder Comm Status Submenu....................................................................................... 176 10.10b UPS Comm Status Submenu ..................................................................................................... 176 10.11 Lockouts Front Car Calls .............................................................................................................. 176 10.12 Car/Group Inputs & Outputs....................................................................................................... 176 10.13 Job Statistics – Clear Job Statistics .............................................................................................. 176 10.14 Adjustable Variables ................................................................................................................... 177 10.15 Car Timers ................................................................................................................................... 177 10.16 Date and Time ............................................................................................................................. 177 10.17 Diagnostics .................................................................................................................................. 177 10.18 View System Status ..................................................................................................................... 177 10.19 Group Comm Status .................................................................................................................... 177 10.20 Car Comm Status......................................................................................................................... 178 10.21 Drive Comm Status ..................................................................................................................... 178 10.22 Software Utilities......................................................................................................................... 178 10.23 LCD Interface - SD Card Read - Write Data Submenu ................................................................. 178 P a g e | xiii 10.24 LCD Interface - Power-Up Mode ................................................................................................. 178 10.25 LCD Interface - Update - Verify Program Submenu .................................................................... 178 10.26 Select Video Display .................................................................................................................... 178 10.27 Display Hoistway Table ............................................................................................................... 179 10.28 Auto/Inspection Learn Hoistway ................................................................................................ 179 10.29 DZ & DZ Offset, Sel Cnt ............................................................................................................... 179 10.30 FL & FL Offset Count ................................................................................................................... 179 10.31 Reset Update Count Trig, Pulse Count Update Data................................................................... 179 10.32 Elevator Setup/Speed Clamps..................................................................................................... 180 10.33 Inspection Open – Close Doors ................................................................................................... 180 10.34 Lift Brake on Inspection .............................................................................................................. 180 10.35 Load Weigher Setup .................................................................................................................... 180 10.36 View - Modify Load Weigher Limits ............................................................................................ 180 10.37 Calibrate Load Weigher .............................................................................................................. 180 10.38 Counterweight & Buffer Test ...................................................................................................... 181 10.39 Overspeed Test ........................................................................................................................... 181 10.40 Reset Gripper Menu .................................................................................................................... 181 10.41 Fault Log ...................................................................................................................................... 181 LCD Interface Flowcharts .......................................................................................................................... 182 LCD Interface Main Menu ................................................................................................................. 182 LCD Interface Main Menu - Elevator Status...................................................................................... 183 LCD Interface - Set Calls and Lockouts .............................................................................................. 184 LCD Interface - Car Call Test Submenu.............................................................................................. 185 LCD Interface - Lockout Front Car Calls Submenu ............................................................................ 186 LCD Interface Main Menu - Inputs and Outputs ............................................................................... 187 LCD Interface Main Menu - Job Statistics ......................................................................................... 188 LCD Interface Main Menu - Adjustable Variables ............................................................................. 189 LCD Interface Main Menu - Car Timers Submenu ............................................................................ 190 LCD Interface Main Menu - Date and Time ...................................................................................... 191 LCD Interface Main Menu - Diagnostics............................................................................................ 192 LCD Interface - View System Status Log Submenu ........................................................................... 193 LCD Interface - Group Comm Status Submenu ................................................................................. 194 LCD Interface – Car Comm Status Submenu ..................................................................................... 195 LCD Interface CAN Encoder Comm Status ........................................................................................ 196 LCD Interface – UPS Comm Status Submenu .................................................................................... 197 LCD Interface - Drive Comm Status Submenu .................................................................................. 198 LCD Interface Main Menu - Software Utilities .................................................................................. 199 LCD Interface - SD Card Read - Write Data Submenu ....................................................................... 200 LCD Interface - Power-Up Mode ....................................................................................................... 201 LCD Interface - Update - Verify Program Submenu .......................................................................... 202 LCD Interface Main Menu - Select Video Display ............................................................................. 203 LCD Interface Main Menu - Hoistway Tables – Display - Mod Hoistway Tables Submenu .............. 204 LCD Interface - Hoistway Tables - Learn Hoistway Submenu ........................................................... 205 LCD Interface Main Menu - DZ & DZ Offset, Sel Cnt Submenu......................................................... 206 LCD Interface Main Menu - FL & FL Offset, Sel Cnt Submenu .......................................................... 207 LCD Interface Main Menu - Reset Update Count Trig, Pulse Count Update Data Submenu............ 208 LCD Interface Main Menu - Elevator Setup ...................................................................................... 209 LCD Interface - Open - Close doors ................................................................................................... 210 LCD Interface - Lift Brake On Inspection Submenu ........................................................................... 211 LCD Interface - Load Weigher Setup Submenu ................................................................................. 212 LCD Interface - View - Modify Load Weigher Limits ......................................................................... 213 LCD Interface - Calibrate Load Weigher ............................................................................................ 214 LCD Interface - Car Buffer Test Submenu ......................................................................................... 215 LCD Interface – Overspeed Test Submenu ....................................................................................... 215 LCD Interface - Reset Gripper Fault .................................................................................................. 217 LCD Interface - Fault Log ................................................................................................................... 218 Section 10a - Service Activation Timers .................................................................................................... 219 LCD Interface Main Menu - Service Activation Timer ....................................................................... 221 LCD Interface - Set Month/Day Timers Submenu ............................................................................. 222 LCD Interface - Clear Timer Submenu ............................................................................................... 223 LCD Interface - Copy Day of Week Timers Submenu ........................................................................ 223 LCD Interface – View/Modify Timer Status Submenu ...................................................................... 224 LCD Interface - Set Timer Service Submenu ..................................................................................... 225 LCD Interface - Set Day of Week Timers Submenu ........................................................................... 226 Section 11 Main CPU Faults ...................................................................................................................... 227 Determining “Gripper/EBK Fault” Device ............................................................................................. 296 P a g e | xv 11.1 Detailed Faults .............................................................................................................................. 297 Car Com Device Reset – HC Com Device Reset ..................................................................................... 306 Serial Hall Calls – Secondary Device...................................................................................................... 307 Serial RGB Car Stations – Secondary Device & Specific I/O .................................................................. 307 Section 12 Combined Field Adjustable Variables ......................................................................................... 309 Section 13 ‐ Safety Processor 1066 LCD Interface..................................................................................... 403 Operating the 1066 LCD Interface ........................................................................................................ 403 Safety Processor Functions ................................................................................................................... 405 1066 LCD Interface Main Menu ........................................................................................................ 406 1066 LCD Interface Elevator Service ................................................................................................. 407 Table 1: Safety Processor Elevator Service........................................................................................ 408 1066 LCD Interface Car Speed........................................................................................................... 409 1066 LCD Interface Encoder Comm .................................................................................................. 409 1066 LCD Interface Encoder Status................................................................................................... 410 1066 LCD Interface Pulse Count........................................................................................................ 411 1066 LCD Interface Adjustable Variables .......................................................................................... 412 1066 LCD Interface Inputs & Outputs ............................................................................................... 413 Table 3: Safety Processor Inputs & Outputs ..................................................................................... 414 1066 LCD Interface Limit Velocity ..................................................................................................... 416 1066 LCD Interface Faults ................................................................................................................. 417 Table 2: Safety Processor Faults ....................................................................................................... 418 1066 LCD Interface Clear Faults ........................................................................................................ 421 1066 LCD Interface Reset Fault Latch ............................................................................................... 421 1066 LCD Interface Board Temperature ........................................................................................... 422 1066 LCD Interface External Temperature ....................................................................................... 422 Section 14 - GALX‐0320AN NTSD Board.................................................................................................... 423 Appendix A - Mnemonics .......................................................................................................................... 429 Appendix B - Compliance Testing ............................................................................................................. 436 1.0 Overspeed Test on a DSD-412 ........................................................................................................ 437 2.0 Overspeed Test on a KEB Drive (For AC Geared & PM Gearless) ................................................... 438 3.0 Overspeed Test on a HPV-600/900 W Distance Feedback (Also For Quattro Cube) ...................... 438 4.0 Buffer Test ....................................................................................................................................... 439 5.0 Normal Terminal Slowdown Test .................................................................................................... 440 6.0 Emergency Terminal Limit Test ....................................................................................................... 441 7.0 Reset Gripper Fault or Emergency Brake Fault ............................................................................... 442 Appendix C – GALX-1100 CPU.................................................................................................................... 443 GALX‐1100 CPU (Replacement CPU for TS‐5300board) ............................................................................... 444 GALX‐1100 CPU ...................................................................................................................................... 444 GALX‐1100 CPU Board Replacement‐ Installation ....................................................................................... 444 LCD Display ............................................................................................................................................ 446 Software UtilitiesMenu........................................................................................................................... 448 SD Card Read/Write Data ....................................................................................................................... 450 Detailed Fault Data.................................................................................................................................. 453 P a g e | xvii The label WARNING identifies procedures and practices that may result in personal injury and/or equipment damage if not correctly followed. The label NOTE identifies information intended to be helpful in the described procedure or practice. WARNING: Installation and wiring must be in accordance with the national electrical code, all local codes, and all elevator safety codes and standards. The 3‐phase AC power supply to the equipment must originate from a properly fused disconnect or circuit breaker (not capable of delivering more than 10,000 RMS symmetrical amperes). Improper motor branch circuit protection will void warranty and may create a hazardous condition. WARNING: Wiring to the controller terminals must be installed in a careful, neat manner. Stranded wire conductors must not have strands left out of the terminals. Leaving strands of wire out of the terminals creates potential shorts. All terminals and cable connectors must be seated properly. WARNING: Elevator control products must be installed by elevator personnel who have been trained in the construction, maintenance, repair, inspection, and testing of elevator equipment. The elevator personnel must comply with all applicable safety codes and standards. WARNING: This equipment is an O.E.M. product designed and built to comply with CSA B44.1/ASME A17.5, and the national electrical code, and it must be installed by a qualified contractor. It is the responsibility of the contractor to make sure that the installation is performed safely, and that it complies with all applicable codes. WARNING: Proper grounding is vitally important to the safe and successful operation of this system. A separate ground wire should be installed from the building earth ground to the earth ground terminal in each controller. Proper conductor size must be utilized for grounding. In order to minimize resistance to ground, the shortest possible route should be used for the ground conductor. See national electrical code article or related local applicable code. WARNING: Use only the correct rated fusing for controller protection. Use of improperly rated fusing will void the warranty. NOTE: Every precaution, whether or not specifically stated in this document, should be taken when installing, adjusting or servicing any elevator. All safety precautions should be followed to make sure life and limb of the service person and public is not endangered. NOTE: Keep the control room/control space clean. Do not install the controller in a dusty area. Do not install the controller in a carpeted area. Keep control room/control space temperature between 32 F and 110 F. Avoid condensation on the equipment. Do not install the controller in a hazardous location and where excessive amounts of vapors or chemical fumes may be present. Make sure that the power supply feeding the elevator controller does not fluctuate more than +/‐ 10 percent Introduction Introduction The GALaxy traction elevator controller is a computer‐based system that offers superior performance, flexibility and reliability. It has been designed to save time in installation and troubleshooting, but it is still very important that the field personnel familiarize themselves with this manual before attempting to install the equipment. Specifications: Environment: 35° F to 110° F ambient 12,000 feet altitude 95% humidity Standard Features: CSA B44.1 / ASME A17.5 Inspection Operation (car top and controller) Access Operation Independent Service Fire Service Phase I Fire Service Phase I Alternate Return Fire Service Phase II Emergency Power Earthquake Service On Board Diagnostics LEDs On Board LCD Interface Motor Protection Timers Door Motor Protection Timer Field Adjustable Parameters Elevator Duty Rated NEMA Motor Optional Features: Selective Rear Doors Page |1 Attendant Service Code Blue Hospital Service Security Remote Diagnostics Emergency Power 1.1 Physical Layout of the Controller 1.2 Typical Physical Layout Figure 1.0 shows a typical layout of the GALaxy controller in a standard G.A.L. cabinet. Below, is a brief description of each block: 1. Main Control Board: The 1064 main control board contains input and output devices, controller switches, fuses and field wiring terminal connections. 2. Safety Processor Board: The Safety Processor board uses a microprocessor and a PAL device to implement the independent speed and redundancy checks required for A17.1‐2000 compliance. This board has its own LCD interface for parameter adjustment and diagnostics. 3. Main CPU: The TS‐5300 computer board is a single board IBM compatible computer (see Appendix C for GALX-1100 information.). It executes the program and turns on and off the inputs and outputs. 4. LCD Interface: The 1021/1101/1005 LCD Interface board provides a user interface to all controller adjustment and setup parameters. It also shows diagnostic information. 5. Power Supply: The power supply provides power to the computer and its peripheral boards. It is a 5-volt DC regulated power supply rated at 3 amps with overvoltage, and short circuit protection. 6. Dynamic Braking Resistors: Additional space for dynamic braking resistors and brake resistors. 7. Options: This section of the controller can be used for options such as the Hall Call I/O board, job specific I/O expansion and a digital PI display driver. 8. Transformer: The system transformer is located in the lower part of the cabinet. It is usually a 500VA building power to 120VAC transfer. It is used to convert the building power to a lower voltage for the signals and other controller functions. 9. Contactors: These are various contactors used for the brake, brake cooling, and run control. 10. Drive: Magnetek DSD‐412 DC SCR Drive, Magnetek DC Quattro, HPV‐ 600/900/900 PM or KEB Combivert F5. 11. Motor Contactors: DC or AC rated motor contactor sized for each specific job. 12. Ground Terminal: The ground terminal block is where the earth ground is attached. Introduction Figure 1.0: Typical Physical Layout Page |3 1.3 Selector System The selector system for the GALaxy controller can be either a tape system or tapeless one. 1.4 Tape Selector System The tape system uses a perforated steel tape that is hung the length of the Hoistway. A set of magnets are placed on the tape at each floor having one 8” magnet as the door zone magnet and one to five smaller 2” magnets as binary position preset magnets. The selector is mounted on the car and is guided along the tape by nylon guides to keep the tape and magnets the proper distance from the selector sensors. The controller uses the door zone magnet to determine the elevator’s level position relative to the floor. At the dead level position, the binary preset inputs are read in order to verify that the car is at the correct floor. A block diagram of the tape system is shown in Figure 1.1. Figure 1.1: Tape Selector Introduction Figure 1.2: Tapeless System – Absolute Encoder Page |5 Figure 1.2A: Tapeless System – CAN Open Encoder Motor UL, DL UL, DZ, DL Safety Processor & Safety PAL Board Secondary Speed Primary Speed & Position Incremental Encoder Governor CAN Open Encoder CPU & Main I/O Board Tapeless Selector Door Zone Elevator Introduction 1.5 Tapeless System The tapeless system uses an absolute encoder mounted on the governor and a four sensor selector on the car top to read the door zone magnet for each floor. The door zone magnets are placed in the corner of the rail. There are two configurations of the tapeless system; 485 configuration and CAN Open configuration. The 485 configuration uses the governor mounted encoder for secondary speed feedback and for absolute position of the car. The CAN Open configuration uses the governor mounted encoder for the primary speed feedback and position of the car. The encoder is coupled to a rotating shaft on the governor. If the governor on the job does not have a rotating shaft, it must be replaced with one that does The door zone sensors are used for exact floor position on stop and re‐leveling the car. A block diagram of the tapeless selector system using an Absolute Encoder is shown in Figure 1.2. The tapeless selector system using an CAN Open Encoder is shown in Figure 1.2A. 1.6 Secondary Speed Feedback With a tape system, the tape is perforated with 3/8 inch holes every 3/8 of an inch. A sensor is mounted on the selector to provide a secondary speed feedback to the Safety Processor Board. With the 485 tapeless system, the Safety Processor receives position information from the absolute encoder and uses the change in position to calculate velocity. With the CAN open tapeless system, the Safety Processor receives position information from the machine mounted incremental encoder and uses the change in position to calculate velocity. With all three methods, the Safety Processor uses this velocity to verify that the car is traveling at a safe speed when slowdown limits are activated, when the car doors are open and when running on inspection. There are two type of inputs used to verify the car speed at the terminal landing. The “UT & DT” slowdown limits are always used to verify the velocity of the car at the terminal landings. The emergency slowdown limits “UTS & DTS” are used on traction cars greater than 200 fpm, traction cars with reduced stroke buffers and all hydro cars. Traction cars less than 200 fpm read the “UTS & DTS” velocity values but will not shut the car down from the velocity check. For all control systems, the “UT & DT” limits are used to verify the operation of “UTS & DTS” and vice versa. 1.7 Modes of Operation 1.8 Operating Sequence Normal elevator operation, Automatic Mode, is selective‐collective. When the elevator is traveling upwards to answer calls, all up hall calls at floors above the car are answered in the order reached by the car, regardless of the order in which the calls were registered. Upon reaching each landing with a car call or hall call registered, the car and hall doors at that floor are automatically opened. The doors stay opened for a dwell time that is field adjustable. There are three different dwell times depending on whether it is a lobby call, car call, or hall call. The door will close before the set dwell time has elapsed if a passenger presses the door close button. The door will reopen before it is fully closed if the door open button is pressed, if a passenger pushes on the safety edge, if the photo‐eye light beam is Page |7 interrupted, or if a call for that floor in the direction of travel is pushed. The door will close when the door opening condition is eliminated. When the door has fully closed, the calls are answered. When all up hall calls and car calls above the car have been answered, the elevator reverses direction and travels downward to answer car calls and down hall calls placed below the car. The calls are answered as previously described for up calls. When all calls below a down car are answered, the car reverses direction to repeat the cycle. In short, an elevator traveling up will bypass down hall calls, and an elevator traveling down will bypass up hall calls. In buildings with more than one elevator grouped together, the actual time of arrival, “real time”, is used to estimate how long each elevator will take to answer a hall call. The elevator that can respond the fastest takes the call. Real time based dispatching permits the controllers to quickly respond to actual demand for elevator service. Some of the criteria used to estimate the time of arrival are listed below: Actual elevator floor to floor runs times. Actual run time to the floor whether it is a multi‐floor run or a one floor run. Whether the elevator is in or out of service. Whether the elevator is in load weigh bypass mode. The direction and position of each elevator in the group. The average door cycle time at each stop. Status of each elevator, accelerating, full speed, decelerating, actual time in motion. Number of stops required due to car calls. Number of stops required due to previously assigned hall calls. System demand. The above performance criteria are continuously measured and stored for improved accuracy in the dispatching algorithm. All of the above data is continuously scanned and the hall calls are reassigned if the conditions change and another car can respond faster. The ability to measure actual hall waiting time virtually eliminates long waiting and improves the average hall call waiting intervals throughout the building. 1.9 Reset Mode Reset mode is initiated when the elevator power is first turned on, or when the system is reset. When the reset mode is initiated, the controller program is automatically loaded, and internal tests are run to ensure that both the car and controller are electrically operational before putting the car into service. The car will not move until reset mode is completed. Some of the internal tests that the controller performs are as follows: is the safety string made up; is the elevator on inspection operation; is the door close limit open; are the interlocks made up; is hoistway position correct. If all the safeties are made up, and the elevator is on automatic operation, and it is at floor level, the elevator will go into automatic mode. If the elevator is not at floor level, it will run slow speed down to the nearest floor, level into the floor, and reset the floor position count. Introduction 1.10 Safety String Open Mode Safety string open mode is initiated when a safety is open. Some of the safeties are listed below: Reverse phase relay. Top final Bottom final Pit switch Car top stop switch Governor over speed switch Safety operated switch Drive Ready relay When the safety string is made back up, the elevator will go back to reset mode. 1.11 Controller Inspection Mode The controller inspection mode is initiated by placing the “INSP” switch on the 1064 board in the inspection position (down). Controller inspection mode permits operation of the car from the machine room. This mode performs the following operations: Enables the controller inspection “ENABLE”, “UP” and “DOWN” push buttons Door locks are active and must be closed to move the car. Pressing the controller “ENABLE” and “UP” push‐button causes elevator to move at inspection speed in the up direction. Pressing the controller “ENABLE” and “DOWN” pushbutton causes the elevator to move at inspection speed in the down direction. 1.12 Car Top Inspection Mode This inspection mode is initiated by placing the inspection switch on top of the car in the inspection position. Inspection mode permits operation of the car from the car top inspection station. This mode performs the following operations: Disables access top and access bottom hall switches. Disables the controller "ENABLE", "UP" and "DOWN" push buttons. Door locks are active and must be closed to move the car. Enables the car top inspection station "SAFE", "UP" and "DOWN" push buttons Page |9 Pressing the inspection station "UP" and "SAFE” push buttons causes the elevator to move at inspection speed in the up direction. Pressing the inspection station "DOWN" and "SAFE" push buttons causes the elevator to move at inspection speed in the down direction. 1.13 Access Mode The access mode is initiated by placing the key operated access switch located in the car operating panel to the on position. Access mode allows entrance into the Hoistway by qualified and authorized elevator personnel for equipment inspection and service. Access to the top of the car is possible from the top landing, and access to the pit is possible from the bottom landing. Enabling this mode permits the following operation: Enables the access key switches at the top and bottom landing in the entrance door jambs. Bypasses the gate switch to allow car movement with the car door open. Bypasses the top or bottom landing hall door lock, depending on which terminal access switch is being keyed. Turning the access key switch to the up position causes the elevator to move at inspection speed in the up direction. Turning the access key switch to the down position causes the elevator to move at inspection speed in the down direction. 1.14 Independent Service Mode The independent service mode is initiated by placing the key operated independent switch located in the car operating panel to the on position, or by placing the controller toggle switch “IND” to the down position. Independent mode permits operation of the car with an operator. This mode performs the following operations: Hall initiated calls are ignored. Hall lanterns and gongs are disabled. The doors open automatically and stay open until closed by the operator. Closing the doors requires constant pressure on the door close button. When the car door is closed, the car answers the nearest car initiated call in the direction of travel. 1.15 Load Weighing Bypass Mode The load weighing bypass mode is initiated when the car is loaded to a predetermined percentage of full capacity, by closing a connection between terminals “LC” and “LW” or from serial communication from a Hall initiated calls are ignored. All other elevator functions operate as if on full automatic service. 1.16 Attendant Service Mode The attendant service mode is initiated by placing the key operated attendant switch located in the car operating panel to the on position. Attendant mode permits operation of the car with an attendant. This mode performs the following operations: The doors open automatically and stay open until closed by the attendant. Closing the doors requires a momentary pressure on the door close button, or the up or down buttons located in the car operating panel. Hall initiated calls are answered unless there is constant pressure on the bypass button. Hall lanterns and gongs are enabled. The direction of preference can be specified by momentary pressure on the up or down buttons located in the car operating panel. 1.17 Code Blue Hospital Service Mode Code blue hospital service mode is initiated by turning one of the code blue switches, located at each floor where medical emergency service is required, to the on position. A car is selected to respond to the code blue call. That car will perform the following: Cancel all car calls Any hall calls previously assigned will be transferred to another car. If traveling toward the code blue call, it will proceed nonstop to the code blue call floor. If traveling away from the code blue call, it will slow down and stop at the nearest floor, maintain doors closed, reverse direction and proceed nonstop to the code blue call floor. If at a floor other than the code blue call floor, the elevator will close the doors and proceed nonstop to the code blue call floor. Once at the code blue call floor, the doors will open and remain open. The code blue in car switch located in the car operating panel must then be turned to the on position. If the code blue in car switch is not turned to the on position within 60 seconds from the time the doors reach full open on the code blue call floor, the car will revert back to normal operation. P a g e | 11 Introduction load weighing device. Load weigh bypass mode allows the car to answer car calls and lighten the load before answering any more hall calls. This mode performs the following operations: Upon activation of the key switch, it will allow the car to accept a car call for any floor, close the doors, and proceed nonstop to the floor desired. The return of the code blue in car key switch to the normal position will restore the car to normal service. 1.18 Fire Service Phase I Mode Fire service phase I is initiated when the primary smoke sensor is activated or the fire key switch located in the hall station on the primary return floor is turned to the on position. The primary return floor is usually the lobby floor, but could be another landing if it better serves the needs of emergency personnel when fighting a fire or performing rescues. When fire service phase I is enabled: The fire emergency return light illuminates and the fire buzzer sounds. The emergency stop switch is disabled when the door closes. The car travels to the primary return floor without answering any calls, then parks with the door open. The fire buzzer turns off, but the fire emergency return light stays illuminated. If the car is at a landing with the doors open, the doors will close, and the car will return non‐ stop to the primary return floor. If the car is traveling away from the primary return floor, the car will stop at the next landing, and then go immediately to the primary return floor. Turning the fire service key switch to the bypass position will restore the elevator to normal service. The elevator will perform per ASME A17.1 requirement 2.27.3 unless otherwise specified. 1.19 Fire Service Phase I Alternate Return Mode Fire service phase I alternate return is initiated when the smoke sensor in front of the elevator at the primary return floor is activated. When fire service phase I alternate return is enabled: The fire emergency return light illuminates and the fire buzzer sounds. The emergency stop switch is disabled when the door closes. The car travels to the alternate return floor without answering any calls, then parks with the door open. The fire buzzer turns off, but the fire emergency return light stays illuminated. If the car is at a landing with the doors open, the doors will close, and the car will return nonstop to the alternate return floor. If the car is traveling away from the alternate return floor, the car will stop at the next landing, and then go immediately to the alternate return floor. Turning the fire service key switch to the bypass position will restore the elevator to normal service. The elevator will perform per ASME A17.1 requirement 2.27.3 unless otherwise specified. 1.20 Fire Service Phase II Mode To initiate fire service phase II, the car must first have been placed in fire service phase I, and, as a result, be parked at the designated level with the door fully open. Following that, the key operated fire service phase II switch, located in the car operating panel must be placed in the on position. Fire service phase II permits operation of the car by a fire fighter. This mode performs operations in accordance with ASME A17.1 requirement 2.27.3 as follows: The doors close only with constant pressure on the door close button, after they have been fully opened. The doors open only with constant pressure on the door open button, after they have been fully closed. Hall lanterns and gongs are disabled. Safety edge and electric eye are disabled All registered car calls can be canceled with momentary pressure on the call cancel button located in the car operating panel. All hall calls are disabled. To remove the car from fire service phase II the car must be at the fire return landing with the doors in the full open position and the phase II switch turned to the off position. See ASME A17.1 requirement 2.27.3 for specific operation of fire service phase II. 1.21 Emergency Power Emergency power is initiated when a connection is made between terminals “HC” and “EMP”. This mode performs the following operations: All cars are returned to the bottom floor one at a time, and remain there with their doors open. If a car is selected to run it will go back into normal operation. Removing the connection between terminals “HC” and “EMP” will remove the cars from emergency power operation. 1.22 Earthquake Mode Earthquake mode is initiated upon activation of a seismic switch or counterweight derailment switch. This mode performs the following operations: If in motion, and the seismic switch is activated, the car will decelerate into slow speed, proceed to the nearest available floor, open the doors and shut down. P a g e | 13 Introduction If in motion, and the counterweight derailment switch is activated, and the car is moving away from the counterweight, then the car will decelerate into slow speed, and proceed to the nearest available floor, open the doors and shut down. If in motion, and the counterweight derailment switch is activated, and the car is moving toward the counterweight, then the car will perform an emergency stop, then move at slow speed away from the counterweight to the nearest available floor. After stopping at the nearest floor, the doors will open and the car will shut down. 1.23 Stalled Mode Stalled mode is initiated when the elevator has been in run mode longer than the field adjustable anti‐ stall timer. This mode performs the following operations: Shuts down the elevator. Does not allow the elevator to restart until elevator is put on inspection or main line switch is cycled. The door open button remains active. 1.24 Automatic Mode Since this is the normal operating mode, the controller automatically enters this mode if none of the previously described modes are activated, and if no fault is detected. The following operations are performed in automatic mode: The car operates in selective‐ collective control sequence when answering calls. Hall calls and car calls are functional. Hall lanterns and gongs are operational. Simplex Cars Park at the last call answered unless simplex lobby parking has been enabled in the program. In a multi‐car group, a car is always parked at the lobby if no other demand exists. The doors remain closed when the car is parked Section 2 ‐ Product Description 2.1 General Information 2.2 Site Selection When choosing the installation site of the controller, several factors should be considered. If at all possible, the controller should be installed in a location where the mechanic has a good view of the machine when he is standing in front of the controller. There should be no obstructions around the controller that would prevent proper routing of necessary conduits entering the controller. The controller doors should have enough room to fully open and close. All clearances, working space, lighting, and guarding should comply with governing codes. 2.3 Environmental Considerations The standard controller package is provided with a NEMA 1 enclosure. This type of controller should be installed in a clean and dry environment. Ideally, the equipment room should be temperature controlled between 70 and 90 degrees F. However, control equipment will function properly within an ambient temperature range of 32 to 110 degrees F. If temperatures remain at the upper and lower extremes of this range for an extended period of time, the life expectancy of the control equipment may be shortened. If wet, dusty, or corrosive environments are expected, then optional non‐standard enclosures can be provided. For example, NEMA 4, NEMA 12, or NEMA 4X. The control system is designed to have a high immunity to electrical noise, radio frequency radiation, and magnetic interference. However, high levels of these items could cause interference with certain parts of the control system. The power supply feeding the controller should have a fluctuation of no greater than + or ‐ 10%. 2.4 Wiring Guidelines and Instructions 2.5 The Wiring Prints A complete set of wiring schematics will be provided for each job. Each set of wiring schematics is job specific. The job name and number will be listed in the bottom right corner of each page of the print. P a g e | 15 Section 2 – Product Description This section provides basic guidelines and recommendations for the proper installation of the controller equipment. These guidelines should be used as general instructions. They are not intended to usurp local codes and regulations. 2.6 Ground Wiring Proper grounding of the power supply, controller, elevator car, and hoistway is required. Separate conductors should be run for EG (earth ground) and GND terminals. These terminals and conductors are detailed on the wiring schematics. 2.7 Hoistway Wiring All hoistway wiring is detailed on the wiring schematics. The number of hoistway conductors is calculated and listed per job on the wiring schematics. A job specific "pull sheet" is also provided with the wiring schematics. 2.8 Elevator Car Wiring All elevator car wiring is detailed on the wiring schematics. The number of traveling cable conductors is calculated and listed per job on the wiring schematics. A job specific "pull sheet" is also provided with the wiring schematics. 2.9 Machine Room Wiring All machine room wiring is detailed on the wiring schematics. All wire sizes are listed for main power supply, motor wiring, brake wiring (traction only), and field wiring. 2.10 Wiring to Top of Car Selector The car top selector is wired according to the schematics for the job. When using tape selector system, special attention should be given to wiring the pulse sensor on the selector since the output on this device uses +15VDC. Terminal PPS on the selector is wired to PPS on the controller and selector terminal PP/US is wired to PP on the controller. 2.11 Slowdown Limits There are two sets of slowdown switches used, the UT/DT switches (including UT1, UT2, UT3, DT1, DT2, and DT3) and the UTS/DTS switches. UT, UT1, UT2, UT3 & DT, DT1, DT2, DT3 are used to clamp the speed command to the drive at the terminal landings independent of the control of the CPU. UTS & DTS are emergency slowdown limit switches used on cars with a top speed greater than 200 fpm or having reduced stroke buffers. These switches are used as the slowdown speed verification points by the Safety Processor board. If the car hits the limit at a speed greater than the preset speed parameter, power is immediately removed from the motor and brake for an emergency stop independent of the main CPU. The UT & DT limit switches are also used as speed verification points by the Safety Processor board. When the limit is first activated, the Safety Processor counts an adjustable number of pulse counts from the activation point to determine the velocity trip point. Since cars with only one slowdown limit would activate the limit at high speed when performing a recovery run, the extra pulse counts from allows the car to slow down before the trip point is reached. The distance that the limits are placed from the terminal landing depends on the speed of the car. Table 1 shows the slowdown limit locations with respect to contract speed. All distances are show in inches. Table 1: Slowdown Distances from Terminal Landings UTS/ DTS UT6/ DT6 (Reduced UT7/ DT7 UTS/ DTS Stroke buffer) FPM UT/ DT UT1/ DT1 UT2/ DT2 UT3/ DT3 UT4/ DT4 UT5/ DT5 50 10” Not Used 8” 100 21” Not Used 17” 150 31” Not Used 28” 200 41” Not Used 39” 250 52” 36” 36” 300 31” 62” 40” 40” 350 40” 80” 52” 52” 400 50” 99” 66” 66” 450 60” 120” 81” 81” 500 71” 143” 98” 98” 600 65” 130” 195” 137” 137” 700 85” 170” 255” 181” 181” 800 80” 160” 240” 320” 232” 232” 900 98” 196” 293” 391” 289” 289” 1000 93” 187” 280” 374” 467” 353” 353” 1100 110” 219” 329” 439” 548” 380” 380” 1200 106” 211” 317” 422” 528” 633” 448” 448” 1300 103” 206” 310” 413” 516” 619” 723” 521” 521” 1400 102” 204” 306” 408” 510” 612” 714” 600” 600” 816” P a g e | 17 Section 2 – Product Description The Safety Processor board uses the UT & DT limits to verify the operation of the UTS & DTS limits. The pulse input is also verified while running on automatic. 2.12 Normal and Final Limit Switches The up and down directional limit switches UN & DN should be set to open two inches past the terminal floor levels. The top and bottom final limit switches should be set to open four inches past the terminal floor levels. 2.13 Tape Selector Installation When installing the selector, please follow all steps below. 1. Mount one of the tape brackets to the rail mounting bracket as shown in Figure 2.0 2. Mount the tape to the tape bracket as show, only FINGER TIGHTEN bolts. This is necessary for proper tape alignment. 3. Measure the distance from the rail to the tape. 4. Unreel the tape from the top of the car while running down on inspection. 5. At the bottom feed the remaining tape down next to the car. Then move the car back up out of the way. 6. Mount the spring mounted tape brackets to the rail mounting bracket as shown in Figure 2.0 ensure that the distance to the rail is the same as what was measured at the top. 7. Connect the bottom of the tape to the mounting bracket with proper spring tension. 8. With tape under tension tighten top tape bolts. And double check tape position. NOTE: At this time the tape should be parallel to the rail in all directions. This is a requirement to maximize the life of the nylon guides, and minimize tape noise. While the tape head is allowed to move, it should not need to move. 9. Mount the selector couple to the tape by the nylon guides. It is preferred to mount the selector to the car sling for maximum stability. The selector location should be adjusted so the tape head is located in the center of the slot, and the tape head pivot bolts are horizontal and equally supporting the head. NOTE: As a check, observe that the head is centered in both directions when the car is at the top and bottom of the hoistway. Figure 2.1 shows a typical mounting of the selector to the crosshead. Figure 2.2 shows the new selector board (PCB‐1011BN). 1. To install floor magnets, level the door exactly at the desired floor. And mark tape at the top left of the selector through a factory cut guide hole 2. Move the car to gain access to the section of tape that was marked while the car was at floor level. 3. Place the door zone template, provided by G.A.L., at the door zone mark just made. 4. Remove backing and adhere binary preset magnets in the appropriate template locations. The location of each magnet is shown in Figure 2.3. & Figure 2.4. 5. Repeat steps 10 thru 13 for each floor. Section 2 – Product Description P a g e | 19 Figure 2.0: Typical Tape Mounting & Magnet Placement Binary Preset Magnets BP32 BP16 BP8 BP4 BP2 BP1 1 0 0 0 0 0 1 2 0 0 0 0 1 0 3 0 0 0 0 1 1 4 0 0 0 1 0 0 5 0 0 0 1 0 1 6 0 0 0 1 1 0 7 0 0 0 1 1 1 8 0 0 1 0 0 0 9 0 0 1 0 0 1 10 0 0 1 0 1 0 11 0 0 1 0 1 1 12 0 0 1 1 0 0 13 0 0 1 1 0 1 14 0 0 1 1 1 0 15 0 0 1 1 1 1 16 0 1 0 0 0 0 17 0 1 0 0 0 1 18 0 1 0 0 1 0 19 0 1 0 0 1 1 20 0 1 0 1 0 0 21 0 1 0 1 0 1 22 0 1 0 1 1 0 23 0 1 0 1 1 1 24 0 1 1 0 0 0 25 0 1 1 0 0 1 26 0 1 1 0 1 0 27 0 1 1 0 1 1 28 0 1 1 1 0 0 29 0 1 1 1 0 1 30 0 1 1 1 1 0 Section 2 – Product Description Floor P a g e | 21 Binary Preset Magnets Floor 31 32 33 34 35 36 37 BP32 0 1 1 1 1 1 1 BP16 1 0 0 0 0 0 0 BP8 1 0 0 0 0 0 0 BP4 1 0 0 0 0 1 1 BP2 1 0 0 1 1 0 0 BP1 1 0 1 0 1 0 1 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 Section 2 – Product Description Figure 2.1: Typical Mounting of Selector P a g e | 23 Figure 2.2: Selector Board GALX-1011BN Figures 2.3 & 2.4: Selector Tape Layout & Magnet Placement Section 2 – Product Description P a g e | 25 2.14 Tapeless Selector Installation Installation of the tapeless selector begins with replacing the existing governor if it does not have a rotating shaft to one that does. Mount the encoder on the governor and connect the encoder cable to the Safety Processor Board as per the job prints. Mount the selector box on top the car with the provided brackets, see figures 2.5 and 2.5A and 2.6. The magnets will be placed in the corner of the rail. The door zone sensors will face the magnet and make a 45-degree angle with the face of the rail. Use the template to position the selector head the correct distance from the rail, see figure 2.5 and 2.5a and 2.6. The mounting screws on the selector box and on the brackets are slotted to make the necessary alignments. Figure 2.5: Tapeless Selector Mounted on Crosshead Figure 2.5a: Tapeless Selector Magnet Placement Section 2 – Product Description Figure 2.6: Door Zone Template Used to Set Selector Distance P a g e | 27 Figures 2.7: Sensor Orientation and Wiring Section 2 – Product Description Figure 2.8: Sensor Orientation Upside Down The selector head can be mounted with a left or right vertical orientation. Each of the sensor wires are individually plugged into the selector board according to the orientation of how the box is mounted. The sensors are wired with UL at the top then DZU, DZD and finally DL at the bottom, see Figure 2.7. If the box has to be mounted upside down (having the PC board upside down) simply re‐wire the sensors in the order listed above always starting with the top sensor as UL, see figure 2.8. Since the PC board mounting holes are symmetrical, the board can be rotated to the right side up position. With the selector and car top box mounted on the car top, wire the selector board to the car top board. The UL and DL sensors are mounted in slotted holes to allow fine adjustment of the "floor level zone” after the elevator is running on automatic operation. However, these sensors should be set in the middle of the adjustment slot as a starting point prior to final adjustment. After the selector installation is complete and the car is running on inspection, door zone magnets can be placed at each floor. With the car dead level at the floor, place the template in the corner of the rail with the tab lined up with top of the selector door zone sensor bracket see figure 2.9. P a g e | 29 Make a mark across the flat edge of the template. Move the car down then place the template on the rail and align the position mark. Place the magnet in the slot and remove the template. It is important to limit the side‐to‐side movement of the car to 1/4" between the rails to maintain consistent floor levels. After final adjustment, magnets should be secured with an adequate amount of adhesive caulk in order to prevent movement. Figures 2.9 & 2.10: Door Zone Template Section 2 – Product Description Figure 2.11: Tapeless Selector - Sensor Adjustment P a g e | 31 Figure 2.12: Tapeless Selector – Close-up of Notch & Sensor 2.15 Tapeless Selector Assembly Installation Continue to mount the door zones using the slim door zone/rail brackets at all the intermediate floors or if preferred, proceed to a terminal landing to work from one particular end of the hoistway. Bring the car dead level to a terminal landing. There will be two wide door zone plates included that are specifically used for the terminal landings. Theses plates have three large holes to mount the normal limit magnets. The down normal limit DN is placed in the middle hole of the plate. The up normal limit UN is placed in the top hole of the plate. Notice that the bottom hole becomes the top hole if the plate is rotated 180 degrees. The door zone magnet is placed adjacent to the three normal limit holes but in line with the mounting screw holes. Mount the bracket at the terminal floor so that the door zone magnet lines up with the door zone sensors. Make sure that when at the top terminal floor, the magnet for the up normal limit is at the top of the door zone magnet. The down normal magnet at the bottom terminal floor will appear to be at the middle of the door zone magnet. Because of the placement of the limit sensors on the selector box, the up normal limit will activate 2 inches above the top floor and the bottom one will activate 2 inches below the bottom floor. The selector box should be marked on the top to show the location of each slowdown sensor. If the box is not marked, us a black marker and mark the locations from the picture in figure 2.14. Using the slowdown distance table in section 3, mount each slowdown rail bracket at the measured distance. The appropriate slowdown flat metal extension strip mounts on the rail bracket depending on the limit location on the selector box. Look at which side of the rail the selector box is mounted for the specific elevator. The slowdown limits that line up in between the rail and the door zone use the short straight flat metal strip. These metal strips are mounted vertically on the rail bracket. The slowdown limits that line up outside of the door zone from the rail will use the long slowdown flat metal extension strips and will mount diagonally from the rail bracket. Mount the magnet on the metal extension strip and verify the alignment. Make sure that the magnet is ½ inch to ¾ inch from the slowdown sensor. Once the top of car is wired and power is supplied to the selector, verify the activation of each door zone and slowdown magnet. Since the slowdown sensors will latch from passing a magnet, the sensor can possible be initially set incorrectly. To change the state of the sensor, pass a magnet across the sensor. The LEDs on the door zone sensors and on the selector board will aid in verifying the setup off all the door zone and slowdown limit magnets. Review the pictures in figures 2.15 and 2.16 for a typical tapeless installation. P a g e | 33 Section 2 – Product Description Place the car dead level at any intermediate floor. Mount the selector box on the elevator cross head with the bracket provided. Notice that the box mounting holes are slotted to adjust the position of the box. Refer to figure 2.13 for an overall view setup of the selector box and the door zone and slowdown limit brackets. Mount one of the slim door zone metal strips on the far end of a rail bracket. Mount the door zone/rail bracket on the rail where the door zone metal strip lines up with the door zone sensors on the selector box. Make sure that the rail bracket is pushed completely on to the rail while tightening the adjacent rail clip bolt. Place the door zone magnet on the slim metal strip and complete the alignment of the selector box and the door zone in the correct position. This will ensure that all the door zone and slowdown magnets line up with the correct sensor. Adjust the door zone sensors to be 1 inch from the door zone magnet. Figure 2.13 Selector, Door zone and Normal Terminal Slowdown Limit Mounting. Section 2 – Product Description Figure 2.14 Placement of Sensor Labels on Selector Box Figure 2.15 Typical Selector Box Installation P a g e | 35 Figure 2.16 Typical Slowdown Bracket Installation 2.16 Transfer Relay Diagram Section 2 – Product Description Figure 2.13 – All Controllers Off Figure 2.14 – Leftmost Controller Off Hall Call boards can be mounted in any controller in the group. The controller that has the hall call boards will have the “In Dispatcher Car Only” jumper (J25) installed. These diagrams illustrate transfer power for hall calls but applies to any type of power transfer. Actual “Dispatcher Car” is set in Adjustable Variables->Group Options->Dispatcher Car. This parameter is usually left at “0” making Car 1 the Dispatcher Car. Figure 2.13 shows all controllers with power disconnected. Figure 2.14 shows the leftmost controller off and the other two on, as if the power was disconnected on the controller with the hall call boards. As can be seen the leftmost controller now uses the 120VAC from the middle controller to power the hall call boards TR Relay – NO / NC Contacts HCI – Transfer Power Input HCO – Transfer Power Output HCP – Transfer Power P a g e | 37 Section 3 ‐ Adjustment of the GALaxy controller DSD 412 Drive In order to obtain a running platform in "car top inspection", see the "Quick Start‐up Guide for GALaxy Controller DSD‐412 DC Drive with Distance Feedback". This procedure should be used only for installation purposes. When installation of all equipment is complete, and unit is ready for adjustment, proceed to Section 3.2, Check Main Line Voltage, and follow instructions. 3.1 General Information Before adjustment begins the following items must be completed. 1. All field wiring and safety circuits installed 2. Temporary jumpers from terminal HC to terminals MES & ALT 3. All hoistway limit switches installed 4. All car and hoistway doors and interlocks installed and pre‐adjusted 5. Selector installed and magnets pre‐ adjusted 6. Familiarize yourself with all wiring schematics 7. Familiarize yourself with the DSD‐412 SCR drive, drive manual, parameter adjustment, etc. 8. Motor encoder should be properly installed and wired. 9. Car should be properly counterbalanced. 10. Initial Power‐up 3.2 Check Main Line Voltage With the main‐line disconnect in the off position, check the line‐side voltage with a volt meter to ensure the voltage matches the controller name tag “Input Power” voltage. Check to ensure all three phases are present. If voltage is not correct or all three phases are not present, do not proceed until corrected. 3.3 SCR Drive Motor Field Current Verify that the rated motor field current is set properly on the SCR drive unit by first checking the name plate field current on the hoist motor. Compare the name plate field current with the setting of the S1 dip switch on the SCR drive unit, and verify that the setting is correct. 3.4 Set Toggle Switches Set all toggle switches on the 1064 board as follows: DOOR LOCKS "OFF" IND ‐ "IND" AUTO DOOR ‐ "OFF" STOP ‐ "STOP" INSPECTION ‐ "INSP" 3.5 Make Sure the Car Is Safe Verify that all elevator doors are closed and that all safety circuits are functional. Turn the main‐line disconnect to the on position. Check the voltage at L1, L2, and L3 on the SCR drive. Verify that all three phases are present. Check the voltage at fuses L1, L2, and L3 (if present) on controller. If correct, check the voltage at terminal LIN with respect to GND. The voltage should read 120VAC. If correct, check the voltage at terminals S10, LC, & HC with respect to GND. All should read 120VAC. If not, check wiring diagram to determine the problem before continuing. 3.7 Verify the Main CPU is Operating Check to make sure that the "axy" of GALaxy on the 1021/1101/1005 LCD interface display is blinking. If the "axy" is blinking, continue to the next step. If not, check voltage at terminals 5V to 0V on the 1064 board to insure 5VDC. If 5VDC is present and the "axy" on the 1021/1101/1005 LCD interface is not blinking, then contact factory. 3.8 Preset Adjustable Variables on Safety Processor Board and Main CPU The 1066 LCD interface (safety processor board) and the 1021/1101/1005 LCD interface (main CPU) are normally preset prior to leaving the factory. However, it is prudent to check the setup values for the proper settings. Refer to Section 13 of this manual for the operation of the 1066 LCD interface, and refer to Section 10 for operation of the 1021/1101/1005 LCD interface. The following adjustable variables must be set properly. NOTE: If the controller uses an NTS board please refer to Section 14, GALX-0320AN NTSC Board. P a g e | 39 Section 3 – DSD 412 3.6 Check Controller Voltage 3.9 1066 LCD interface "Adj Var" Menu Top Spd (contract speed) Enc RPM (if Fdbk Typ=0 (Tape), not applicable) (if Fdbk Typ=1 (Encoder), set to rpm of governor) (if Fdbk Typ=4 (Incremental Encoder), set to value of Function #11 in DSD 412 drive, MOTOR RPM) Enc PPR (if Fdbk Typ=0 (Tape), not applicable) (if Fdbk Typ=1 (Encoder), set to 8192) (if Fdbk Typ=4 (Incremental Encoder), set to PPR of machine/motor encoder) Fdbk Typ (0=tape, 1=enc, 4=InEnc) Ctrl Typ (2=Tract DF) 2 Stop (0=Mult, 1=2 stop) RearDoor (0=Front only, 1=Rear) UTS Vel (Set to top speed) DTS Vel (Set to top speed) INS Vel (Set to 140) LEV Vel (Set to 140) UT Vel (Set to top speed) DT Vel (Set to top speed) UL Vel (Set to 160 if Non‐DF) DL Vel (Set to 160 if Non‐DF) SoftStop (Set to 3) NOTE: The velocity values for the terminal limit switches above are only temporary settings until car is running high speed. In the final adjustment procedure, these variables must be set according to the procedures in Section 3.33, Adjust Safety Processor Board Speed Clamps. 3.10 1021/1101/1005 LCD interface "Adjustable Variables -> Car Motion" Submenu Top Speed (set to contract speed) Inspect Speed (set to 25 fpm) Encoder PPR (set to machine/motor encoder PPR) Encoder RPM (if tape selector, set to value of Function #11 in DSD 412 drive, MOTOR RPM), (if 485 tapeless selector, set to value of Function #11 in DSD 412 drive, MOTOR RPM), (if CAN open tapeless selector, set to governor rpm) DON Start Control (set to 1) NOTE: See Section 3.25, Correct Car Speed When Using 485 Tapeless System, for determining governor rpm. 3.11 Place Stop Switch in Run Position Flip the “STOP” toggle switch on the 1064 board to the up position. Verify that input LED’s for “LC, HC, DN, UN, SS, GTS, RDY and CS” are all on. If not, then correct field wiring. 3.12 Hoist Motor Data Function #3 ‐ RATED ARM AMP (from machine/motor nameplate) Function #7 ‐ RATED ARM V (from machine/motor nameplate) Function #10 ‐ ENCODER P/R (PPR of encoder on machine/motor) Function #11 ‐ MOTOR RPM (from machine/motor nameplate) NOTE: The MOTOR RPM value may need to be fine‐tuned to provide the correct rpm to run the machine/motor at controller demanded speed. Function #17 ‐ RATED FT/MIN (from controller data) Function #21 ‐ ACC RATE FT/SEC2 (~ 4.2) Function #40 ‐ RESPONSE (~ 6.0) Function #41 ‐ SYSTEM INERTIA (~ 2.5) Function #49 ‐ WEAK FIELD AMP (from controller data) Function #50 ‐ FULL FIELD AMP (from controller data) Function #52 ‐ RATED FIELD VDC (from controller data) Function #53 ‐ STANDING FIELD AMP (from controller data) Function #56 ‐ FIELD STRENGTH SPEED (~ 75) Function #57 ‐ FIELD WEAKEN SPEED (~ 75) Function #994 ‐ to save data just entered P a g e | 41 Section 3 – DSD 412 At this time the hoist motor data must be entered into the SCR drive. The following functions must be entered or verified using the drive display unit (SCDU). Follow the instructions in the SCR drive manual to enter the following data for each function: After Function #994 has been performed successfully, proceed to the next step. 3.13 SCR Drive Self Tune To have the SCR drive unit learn the parameters of the hoist motor the drive self‐tune must be performed. Remove the drive reset “RST” wire from TB1 pin 49 of the drive. Turn on the main disconnect. Perform a FUNCTION #997 (see SCR drive manual) to self‐tune the hoist motor. During this test, the “MC” contactor will energize for short period of time. After the self‐tune is performed correctly, “PASS” will appear on the drive unit display. If a fault appears on the drive unit display, the problem must be corrected and the self‐tune performed again. If the self‐tune is successful, then the following FUNCTIONS must be viewed and recorded. Function #613 Function #614 Function #615 The value of Function #613 should be manually entered into Function #4 ‐ ARM OHMS. The value of Function #614 should be manually entered into Function #6 ‐ ARM L. The value of Function #615 should be manually entered into Function #51 ‐ FIELD L/R. 3.14 Pre‐set the Digital Speed Clamps Pre‐set the software digital speed clamps from the 1021/1101/1005 LCD interface under the “Elevator Setup Menu”. The submenus for the clamp speeds are as follows: Set INS/Leveling Clamp Set DT/UT Slowdown Clamp Set DT1/UT1 Slowdown Clamp Set DT2/UT2 Slowdown Clamp Set DT3/UT3 Slowdown Clamp Set DTS/UTS Slowdown Clamp Set the speed for Ins/Leveling for 140 fpm and all the remaining slowdown limit speeds to the contract speed of the car. Please note that the displayed value of “Clamp Speed” is the value the clamp should be set to. The slowdown limit “Clamp Speed:” will show 0000 until the car is run into the limits and the speed is recorded. Please refer to Section 10, 1021/1101/1005 LCD Interface, for the Elevator Setup Menu. NOTE: The values of the clamp speed velocities above are only temporary settings until the car is running high speed. In the final adjustment procedure, these values must be set according to the procedures in Section 3.34, Adjust Digital Slowdown Speed Clamps. 3.15 Ready to Run On Inspection The car should be ready to run on inspection if all is wired correctly. Select the “Elevator Status” on the 1021/1101/1005 LCD interface. The display should show “Out of Service” on the first line and “Inspection Mode” on the second. The 1066 LCD interface will display one of the following types of inspection: “MR INS” (Motor Room) “CT INS” (Car Top) “ACCESS” (Access) “IC INS” (In Car) “AUTO” (Not on Inspection) The “inspection string” consists of contacts from the inspection switches and the gate and lock bypass switches in series. One and only one of the five inspection inputs should be on for the car to run. Starting from the car top inspection input, the five inspection inputs are, “INS” for car top, “ACC” for access, “ICI” for in‐car, “MRI” for motor room, and “AUTO” for automatic (no inspection). The inspection string circuit is shown in Figure 3.1. Note: Any one of the following conditions will cause an inspection error: More than one inspection input is on No inspection input is on Gate or Lock bypass switch is open and the car is not on car top inspection If the controller is not on motor room inspection at this point, then verify all switch positions and wiring before proceeding. P a g e | 43 Section 3 – DSD 412 To run the car from the motor room, “MR INS” should be displayed. Figure 3.1: Inspection String 3.16 Adjust the Brake Voltage Momentarily push the inspection UP or DOWN push button on the 1064 board while checking the DC brake voltage with a meter. If the voltage is not correct, it must be adjusted according to the following procedures. If the controller utilizes an electronic brake board 1047 or 1051, then the brake voltage is adjusted through the 1021/1101/1005 LCD interface, "Car Brake" sub‐ menu. If the controller utilizes resistors and rectifiers for the brake coil circuit, then the brake voltage is adjusted by moving the adjustable tap on the brake resistor. NOTE: Remove power before adjusting the resistor taps. To adjust the brake voltage when using and electronic brake board, navigate to the "Adjustable Variables" menu, "Car Brake" and adjust "Brake Pick Volt", "Brake Hold Volt" and "Brk AC L‐L Volt" to the proper values. Make sure that the brake is lifting and setting properly before proceeding. 3.17 Check the Run Direction Momentarily push the inspection “UP” or “DOWN” push button on the 1064 board. One of the following should take place: The elevator will run controlled, in the correct direction (up for “UP” button, down for “DOWN” button) with no drive faults. If so, proceed to “Check Inspection Speed”. The elevator will run controlled, but in the wrong direction (down for “UP” button, up of “DOWN” button) with no drive faults. If so, proceed to Section 3.18, Car Runs in the Wrong Direction. The elevator will try to run, but immediately trip on a drive fault #99. If so, proceed to Section 3.19, Drive Trips immediately. 3.18 Car Runs in the Wrong Direction Also swap the encoder direction by swapping the encoder wires or if an encoder isolation board (1022N) is used, move J5 and J7 on the encoder board. Refer to the jumper diagram on the board. J5 swaps A & A NOT – J7 swaps B & B NOT. To change the encoder direction at the drive, swap the following wires: A+ (TB3‐2) with B+ (TB3‐4) A‐ (TB3‐3) with B‐ (TB3‐5) Turn the main disconnect on, run the elevator on inspection again, and it should run controlled and in the correct direction. If so, proceed to Section 3.20, Check Inspection Speed. If not contact the factory. 3.19 Drive Trips Immediately If the elevator tries to run, but immediately trips on a drive fault #99, then turn off the main disconnect, and swap the encoder direction by swapping the wires or if an encoder isolation board (1022N) is used, move J5 and J7 on the encoder board. Refer to the jumper diagram on the board. J5 swaps A & A NOT – J7 swaps B & B NOT. To change the encoder direction at the drive, swap the following wires: A+ (TB3‐2) with B+ (TB3‐4) A‐ (TB3‐3) with B‐ (TB3‐5) Turn on the main disconnect and run the elevator on inspection again. If the elevator runs controlled and in the correct direction, proceed to next section. P a g e | 45 Section 3 – DSD 412 If the elevator runs controlled but in the wrong direction, with no drive faults, then turn off the main disconnect, swap the hoist motor field wires. If the elevator runs controlled but in the wrong direction, then go back and follow the directions in Section 3.17, Car Runs the Wrong Direction. If the car still trips immediately on a drive fault #99, then contact the factory. 3.20 Check Inspection Speed With a hand held tachometer, check the speed of the elevator while running on inspection. The elevator should be running at 25 FPM. Also run the elevator while monitoring Function #600 on the SCR drive display. This parameter should also read 25 FPM. If speed is not correct, re‐check drive data in FUNCTION #10 and FUNCTION #11. From the 1021/1101/1005 LCD interface select the "Elevator Status" menu, navigate until the display shows "Dmd" and "Vel". While running on inspection, monitor the controller demand speed "Dmd", and the speed feedback "Vel". These values should both display 25. If the demand and feedback on the 1021/1101/1005 LCD interface is incorrect, check the Encoder RPM and PPR parameters from the “Adjustable Variables” menu. These variables should be set according to the procedures in Section 3.8. If the speed on the hand held tachometer and on "Dmd" and "Vel" all read approximately 25 fpm (within +/‐2 fpm) continue to the next step. If not, contact the factory. 3.21 Verify Controller Encoder Direction From the 1021/1101/1005 LCD interface "Elevator Status" menu, navigate to display "Dir" and "DP". While moving the car on inspection, monitor "Dir" (direction) and "DP" (pulse counts). "Dir" should display "Up" when the car is moving up, and "Dn" when the car is moving down. The value of "Dp" should increment when the car is moving up, and should decrement when the car is moving down. If the direction is wrong or the pulse counts change in the wrong direction, then the encoder direction to the controller must be changed. If an encoder isolation board (1022N) is used, move J1 and J3 on the encoder board. Refer to the jumper diagram on the board. J1 swaps A & A NOT – J3 swaps B & B NOT. If no encoder isolation board is used, the A+ and A‐ encoder wires from the drive must be swapped. Note that the motor encoder wires are daisy chained from the encoder to the drive and then from the drive to the controller encoder board. Only the A+ and A‐ wires from the drive to the controller board must be swapped. The wires from the encoder to the drive must remain on the same terminal locations on the drive. If the encoder is counting properly continue to the next step. If not, contact the factory. 3.22 Verify Selector and Slowdown Inputs Run the elevator up on inspection until it stops on the up normal limit. The up and down normal limits should be set two inches above and below the terminal floors respectively. Verify the selector inputs are being set properly on the controller by running the elevator down until it stops on the down normal limit. As the car approaches floor level going down, “DL” turns on first, then “DZ” and then finally “UL”. At floor level, “UL, DL, and DZ” inputs should all be on at the same time. Leaving the floor going down “DL” will turn off first, then “DZ” and last “UL”. Also verify that the up and down terminal slowdown limits inputs “UT, UTS, DT & DTS” are breaking at the proper distances as shown in the slowdown table 2.0. “UT, UTS, DT & DTS” turn off when active. 3.23 Verify Car Speed on Safety Processor Board 3.24 Correct Car Speed When Using a Tape Installed in Hoistway The tape has holes every 3/8” that are 3/8” in diameter. On the selector unit adjust the PP sensor closer to the tape until the orange LED at the end of the sensor turns on. Then turn the sensor inwards another 1/8” and lock in the sensor. While running on top of car inspection verify that the orange LED at the end of the PP sensor turns on and off as it passes by the holes on the tape. The safety processor measures the time between each pulse to calculate the velocity. If the velocity is not displayed correctly first make sure that the feedback type in the safety processor board adjustable variable is set to 0 for a tape application. Next, while the car is running, make sure that the PULSE LED on this board is pulsing. As the car increases in speed the LED will glow solid on. If the LED does not pulse, try swapping the wires at the PPS and PP terminals. If the LED still does not work, contact the factory. If the correct speed is shown proceed to Section 3.27, Learn The Hoistway. 3.25 Correct Car Speed When Using 485 Tapeless System When using the 485 tapeless system, the secondary speed feedback comes from the encoder mounted on the governor. The 1066 board uses a serial interface to a Turck absolute encoder, part # T8.5882.3F0B.3001. In the 1066 LCD interface "Adj Var" menu, set the "Fdbk Typ = 1", and set the "Enc PPR = 8192". The "Enc RPM" value must be calculated as described below. To calculate the RPM, divide the contract speed of the car by the distance traveled in one revolution with the governor as shown below: P a g e | 47 Section 3 – DSD 412 Run the car in either direction or check the car speed on the 1066 LCD interface. The speed shown should match the car’s actual speed. If the speed does not match and the secondary feedback comes from pulses from the tape go to “Correct Car Speed When Using a Tape”. If using 485 tapeless, go to "Correct Car Speed When Using 485 tapeless". If using CAN Open tapeless, go to "Correct Car Speed When Using CAN Open tapeless". If the correct speed is shown proceed to Section 3.27, Learn the Hoistway. RPM = Speed fpm/ (diameter GOV * pi) For a 1 ft. diameter governor: RPM = 350/ (1*pi) = 350/3.1415 = 111.4 For a 16 in diameter governor (16/12 = 1.33ft): RPM = 350/ (1.33* 3.1415) = 350/4.188 = 83.5 3.26 Correct Car Speed When Using CAN Open Tapeless System When using the CAN Open tapeless system, the secondary speed feedback comes from the incremental encoder mounted on the machine/motor. In the 1066 LCD interface "Adj Var" menu, set the "Fdbk Typ = 4", and set the "Enc PPR" equal to the PPR of the machine/motor‐mounted incremental encoder, and set the "Enc RPM" to the rpm of the machine/motor at contract speed. On the 1066 LCD interface, navigate to the "Pls Cnt" menu. While running the elevator on inspection, verify that the pulse count value increments when running up and decrements when running down. The "Pls Cnt" value can be considerably out of range but will automatically correct during the "Learn Hoistway" procedure. To reverse the direction of pulse counting, navigate on the 1066 LCD interface to the "Adj Var" menu, "Enc Dir" and set to "0" for clockwise or "1" for counter‐clockwise. Navigate on the 1066 LCD interface to the "Car Spd" menu. Monitor the "Car Spd" while running the car at a known inspection speed. The value displayed should match the actual car speed measured with a hand held tachometer. If not, re‐check the values set in "Enc RPM" and "Enc PPR" in the 1066 LCD interface. If the speed is correct, proceed to Section 3.27, Learn The Hoistway. 3.27 Learn the Hoistway Run the elevator down on inspection until it stops on the down normal limit switch. Verify that the “DN and DL” input LED’s are both off and that the "UL" and "DZ" LED's are on. From the 1021/1101/1005 LCD interface navigate to the "Elevator Setup" menu, "Learn Hoistway". The learn procedure can be performed automatically by choosing "Auto" from the menu items, or performed manually by choosing "Insp" from the menu items. After choosing the learn method, follow the instructions displayed on 1021/1101/1005 LCD interface. In general, the car will run up from the "down normal limit" to the "up normal limit" at 30 fpm. During this learn run, the DP count for each floor level and each limit switch will be stored in memory. NOTE: The car must run the entire hoistway without stopping. As the elevator moves up the hoistway, navigate to the "Hoistway Tables" menu, "Disp/Mod Hoistway Table", and verify that the "DP" count is incrementing as the elevator moves up. Also as the elevator passes each floor, the pulse count and distance for that floor should change and be stored. Verify that the floor distances are valid. The pulse count for the terminal slowdowns will also be stored. The elevator will stop when it reaches the up normal limit. Follow the instructions on the 1021/1101/1005 LCD interface by putting the car on inspection, and then the message "Hoistway Learn Complete" should be displayed. Move the elevator on inspection until the “DZ and DL” LED’s are on. Set the "INS" switch on the 1064 board to the "NORMAL" position and the elevator should level down to floor level at the top floor. If so, proceed to final adjustment. If the car levels down but does not run, then check “Elevator Status” and “View Fault Log” on the 1021/1101/1005 LCD interface for any fault information. Correct items causing faults and perform hoistway learn again. After problem is corrected, and a successful hoistway learn is performed, proceed to final adjustment. 3.28 Automatic Run The elevator should now be sitting idle at the top floor. The "AUTO DOOR" switch should be set to the "OFF" position and the "IND" switch should be set to the "IND" position. If the learn procedure was successful, the elevator should be ready to make an automatic run. The acceleration and deceleration of the car should be smooth and stepless regardless of the distance of the run. If the elevator does not function as described above, then the problem should be analyzed before proceeding. 3.29 Fine Tune the Ride Quality In order to fine tune the ride quality, refer to Figure 3.2 which describes what part of the S‐curve that the different parameters effect. In general, higher numbers in the given parameters, cause quicker and more abrupt changes from one mode to the next during a run. All of the S‐curve parameters have a minimum and maximum value. The controller will not allow you to enter values that are not valid. After adjusting the S‐ curve parameters, proceed to the next step. 3.30 Adjust the Stop When at floor level the “UL, DL, & DZ” input LEDs should be on. If the elevator continually tries to seek floor level by leveling up and down, check the motor field voltage to be at the nameplate voltage while leveling. If the motor field voltage is correct but the car seems sluggish then increase the response of the drive by increasing the value of Function #40 in the drive. If the car still re‐levels at the floor, try the following steps to correct the problem: Reduce the leveling and re‐leveling velocity parameters from the 1021/1101/1005 LCD interface "Adjustable Variables" menu, "Car Motion", "Leveling Speed" and "Relevel Speed". If the car still oscillates, adjust the "floor level zone" on the selector. The "floor level zone" is increased by moving the "UL" and "DL" sensors closer together. P a g e | 49 Section 3 – DSD 412 The default parameter settings for the ride quality should be adequate for an initial run. From the 1021/1101/1005 LCD interface navigate to the "Set Calls and Lockouts" menu, "Setup Car Calls" and enter a car call. The elevator should run to answer the call. When the elevator levels in and stops at the floor, the doors will remain closed. If the car stops hard on the brake, then make the following adjustments. From the 1021/1101/1005 LCD interface navigate to the "Adjustable Variables" menu, "Car Motion", and adjust both "Brake Drop Del" (brake drop delay) and "Soft Stop Time". These variables should be adjusted so that zero speed is observed at the end of the run prior to the brake setting. The controller should hold the car at zero speed for the duration of the "Soft Stop Time" which should continue while the brake is setting and for a short time after the brake sets. The "Soft Stop Time" MUST be set to at least 0.5 seconds LONGER than the "Brake Drop Del". NOTE: The "Soft Stop Time" setting in the 1021/1101/1005 LCD interface should be compared with the setting in the 1066 LCD interface "Adj Var" menu, "SoftStop". The setting of "SoftStop" in the 1066 LCD interface should be greater than the "Soft Stop Time" setting in the 1021/1101/1005 LCD interface. If the car spots when approaching the floor, the cause is usually due to the car not tracking (the drive response is set too low) or the speed profile into the floor is too aggressive. First try to increase the response of the drive by increasing the value of Function #40 in the drive. If the car still spots, from the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and increase the value of "Floor Targ Dis" (floor targeting distance). The default value for the floor targeting distance is 12 inches. Increase it by steps of 2 or 3 and continue retesting until the parameter is adjusted to 18. If no change is noticed, start again from 12 and decrease the value. The deceleration rate can also be reduced to help remove the spotting. Once the proper stop is achieved, proceed to “Adjust the Start”. Figure 3.2: S-Curve Parameters 3.31 Adjust the Start To provide a proper start, from the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and adjust "Brake Pick Del" (brake pick delay), "Pattern Delay", and "Soft Start Jerk". Initially, set the brake pick delay to 0 and increase the pattern delay by 0.1 seconds until the controller picks the brake completely before the motor starts to move. If roll back occurs, then reduce the pattern delay until there is no roll back. Sometimes, the timing works out better if the brake pick delay is set to 0.1 second. If load weighing is used, pre‐torquing can be used to provide a smoother start. See Section 3.40, Adjust the Motor Pre‐torque. Increase the soft start jerk rate in order to provide a quicker transition from the start to constant acceleration. Keep in mind that the larger the soft start number, the quicker the start. The ride should now be acceptable. 3.32 Verify Top Speed To fine tune high speed, make high speed runs while monitoring Function #600 on the SCR drive display. The display should read contract speed. 3.33 Adjust Safety Processor Board Speed Clamps The 1066 Safety Processor Board monitors the speed of the elevator at the terminal landings independently from the main CPU. When the "UT, DT, UTS, and DTS" limit switches are activated, the 1066 board calculates the velocity of the elevator and compares that velocity with a stored value of speed clamp. If the velocity when the switch activates is greater than the speed clamp value, then the 1066 board will generate a fault that stops the elevator. From the 1066 LCD interface, navigate to the "Lim Vel" menu, and view the recorded velocities displayed for the “UT, DT, UTS & DTS” slowdown limits. “UTS & DTS” are used on cars with reduced stroke buffers or with a top speed greater than 200 fpm. The velocity value is shown from the “LIM VEL” menu on the 1066 LCD interface. The velocity value shown on the display for the “UT or DT” limit is the value after the car activates the limit then counts an adjustable number of counts set from the 1066 LCD interface, "Adj Var" menu, "UT Count" or "DT Count". These count values can be adjusted to provide adequate distance, following the limit switch activation, to allow the elevator to begin its normal decel pattern. The default "UT Count" and "DT Count" values are normally adequate. However, these values may need to be field adjusted to allow enough distance for the car to begin its normal decel pattern. If the "UT Count" and "DT Count" values are modified, the limit velocities must be re‐checked Run the car again to the top repeatedly from 2 floors, then 3 floors, etc., until top speed is reached. From the 1066 LCD interface "Lim Vel" menu, record the limit velocities displayed each time the car stops at the top floor. P a g e | 51 Section 3 – DSD 412 If the speed is slightly under contract speed, then verify that Function #10 Encoder PPR and Function #11 Rated Motor RPM are set properly. The speed displayed at Function #600 should match the speed displayed on the 1021/1101/1005 LCD interface, "Elevator Status" menu, "Dmd" and "Vel". This speed should also match the speed displayed on the 1066 LCD interface, "Car Spd" menu. When all of these speeds are the same (+/‐ 2 fpm), then proceed to the next step. Make the same runs to the bottom floor starting from 1 floor, then 2 floors, then 3 floors, etc., until top speed is reached. From the 1066 LCD interface "Lim Vel" menu, record the limit velocities displayed each time the car stops at the bottom floor. Take the highest speed value recorded in the runs above and add 20 fpm to that value to use as the clamp speed values for the respective limit switches. Enter these clamp speed values into the 1066 LCD interface "Adj Var" menu, "UT Vel", "DT Vel", "UTS Vel", "DTS Vel" respectively. 3.34 Adjust Digital Slowdown Speed Clamps Having just made several runs into the top and bottom landings, the main CPU has also recorded the car’s velocity when the slowdown limits were activated. If the car has been powered down prior to this step, several runs must be made to the terminal landings to allow the main CPU to record the limit velocity values. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Set DT/UT Slowdown Clamp" and view the speed displayed for "Clamp Speed". Add 20 fpm to this "Clamp Speed" value and enter it into the "DT/UT Limit" value. Adjust speed clamps for each slowdown limits used as determined by the elevator’s contract speed. The number of slowdown limits depends on the speed of the car as show in the table below: Table 3.1: Slowdown Clamps 3.35 Verify Inspection Velocity Clamp On Safety Processor Board Place the car on inspection operation. From the 1066 LCD interface, navigate to the "Adj Var" menu, "Ins Vel" and set the speed clamp velocity to 25 fpm. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed" to 50 fpm. Run the car in either direction and verify that the car shuts down when the speed rises above 25 fpm. From the 1066 LCD interface, navigate to the "Adj Var" menu, "Ins Vel" and set the speed clamp to 140 fpm. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed" to the desired value. 3.36 Analog Load Weigher Setup If the job uses an analog load weigher purchased from G.A.L., complete the following procedure. NOTE: It is recommend using two people, one moving the weights and one in the machine room to set up the load weigher. Mount the load weigher as described by the manufacturer. The load weigher control box will also contain a board supplied by G.A.L. that connects to the controller serial CAN bus and reads in the analog output from the load weighing device. Wire the load weigher and G.A.L. board according to the controller schematics. Calibrate the load weighing device hardware according to the manufacturer’s instructions. Following proper installation of the load weighing device, proceed to Section 3.37, Empty Car Setup. 3.37 Empty Car Setup From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "Setup Load Weigher" and follow the instructions on the display as you go through the procedure. It is okay to exit the setup screen to place a call and then return to it while the setup is being performed. Run the car to the bottom floor and press Enter on the 1021/1101/1005 LCD interface when prompted to do so to start the automatic setup sequence. If the car is at the bottom floor and the doors are not closed (the doors will not close automatically from turning off the auto‐door switch) then place a car call to run the car up one floor, then back again. The doors will close when the call is placed. When the automatic sequence is activated, the car will run to each floor and measure the empty load value. The 1021/1101/1005 LCD interface will indicate when the sequence if finished. 3.38 Full Car Setup NOTE: The empty car setup must be successfully completed to run the full load setup. Once the empty car setup is complete, run to the loading floor and set the "AUTO DOOR" switch to the "ON" position to allow weights to be loaded on the car. With the car fully loaded, set the "AUTO DOOR" switch to the "OFF" position and run the car to the bottom floor. Again if the doors are not closed, make a one floor run to force the doors to close. With the car at the bottom floor, follow the instructions on the 1021/1101/1005 LCD interface to start the full load setup sequence. The car will automatically run to each floor and measure the full load value. When the full load measurement is complete, the car can be run to the loading floor and the weights removed. P a g e | 53 Section 3 – DSD 412 Verify that the load weighing device is communicating to the main CPU by performing the following steps. From the 1021/1101/1005 LCD interface, navigate to the "Diagnostics" menu, "Car Comm Status", "Car to LW Board" and verify that "On‐ line = 1". If "On‐line = 0" then verify wiring and installation of load weighing device. After the weights are removed, cycle the doors to complete the procedure. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "View/Modify LW Setup" and verify the load weigher status, "LW Device Stat: ON OK". If the status is "ON OK", then the load weigher should be accurately measuring the car load in real time. The percent load will be displayed, "Load: _%". The percent load values for different service options can now be set. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Service Options", and set the following variables: "Load Bypass" "Load Antinuisance" "Load Dispatch" "Load Overload" NOTE: Setting the values of the variables above to 0% will disable that particular option. 3.39 Load Weighing Calibration Sequence The load weigher is automatically calibrated once each week. If an error is detected during this calibration sequence, the load weigher and the pre‐torque feature (if used) is disabled. A load weighing calibration sequence can be manually activated by performing the following procedure. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "Load Weigher Calibration" and follow the instructions on the display. 3.40 Adjust the Motor Pre‐torque NOTE: The motor pre‐torque uses the load value obtained from the analog load weigher and will only work if the load weigher has been installed properly, and the "Load Weigher Setup" has been performed successfully. To enable pre‐torquing on the drive, set Function #114 on the DSD‐412 drive to “ON”. Remember to go to Function #994 to save any changed parameters. Run the empty car to a middle floor. From the 1021/1101/1005 LCD user interface, navigate to the "Adjustable Variables" menu, "Car Motion" and adjust the following parameters: "Balanced Load = 40" (typically car is 40% counterbalanced, but verify counterbalance percentage for each specific job) "Torque Amount = 10" "Pattern Delay = 2.5" "Brake Pick Del = 0.1" The long pattern delay will allow an exaggerated amount of roll back in order for the pre‐torquing to be set accurately. Make a one floor run down and observe the roll back when the brake picks at the start of the run. Increase the "Torque Amount" variable and continue to monitor the roll back while performing one floor runs in the down direction. As the "Torque Amount" is increased, the roll back should be minimized until the car will hold zero speed for the entire "Pattern Delay" time. A typical value for the "Torque Amount" is 40%. If the value is too large, the car will roll forward during the "Pattern Delay" time. Note: The pattern delay must be at least 0.15 seconds (150 milliseconds). Setting the torque amount to 0.00 will disable the pre‐torque feature. Also if the load weighing calibration sequence detects a load weighing error, the pre‐ torque feature is also automatically disabled. 3.41 Verify the Doors Are Safe 3.42 Fine Tune the Ride Quality Ride the elevator and evaluate the ride quality. Fine tune ride quality by navigating to the "Adjustable Variables" menu, "Car Motion" and adjusting the variables shown in Figure 3.2. Keep in mind that if acceleration or deceleration values are changed, the speed clamps for the safety processor board and the S‐curve board may need to be re‐adjusted. To fine tune the floor level accuracy, determine if the controller is set to stop when "UL" and "DL" signals turn on, or if controller is set to stop off of the position count. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and view the "Stop On Pos Cnt" variable. If "Stop On Pos Cnt = 0" then controller is set to stop when the "UL and "DL" signals turn on. If "Stop On Pos Cnt = 1" then controller is set to stop on a combination of the floor level magnet and the position count. With "Stop On Pos Cnt = 0", the floor levels should be set by adjusting the floor level magnet at each floor. For proper operation, the floor magnets should be set to exactly floor level. After the floor levels are set properly, perform another hoistway learn procedure. With "Stop On Pos Cnt = 1", the floor levels are set by using both the floor magnet and the position count. For proper operation with this setting, the floor magnet should be set to exactly floor level. The final stop can then be fine‐tuned by performing the following adjustments. From the 1021/1101/1005 LCD interface, navigate to the "Hoistway Tables" menu, "DZ & LZ Offset, Sel Cnt" and adjust "Dn Lev Dist" and "Up Lev Dist". The units for these variables are in "pulse counts". With "Stop On Pos Cnt =1" the car will continue to move for the "Dn Lev Dist" or "Up Lev Dist" after "UL and DL" turn on. Use the "Dn Lev Dist" and the "Up Lev Dist" parameters to make level changes at all floors. P a g e | 55 Section 3 – DSD 412 The elevator should now be adjusted. Verify that all door locks, gate switches, and safety circuits are operational. Set the "INSP" switch to the "NORM" position and set the "AUTO DOOR" switch to the "ON" position. The elevator should level into the floor and open the doors. If the doors do not open, check the door operator wiring and cam adjustment. If the doors do open, the elevator is now on independent service. To make level changes at individual floors, perform the following adjustments. From the 1021/1101/1005 LCD interface, navigate to the "Hoistway Tables" menu, "FL and FL Offset Count", and the offset count can be adjusted. These variables introduce an offset (+/‐) to the stored floor count that was determined in the hoistway learn procedure. NOTE: The number of pulse counts per inch can be viewed from the 1021/1101/1005 LCD interface, "Hoistway Tables", "DZ & LZ Offset, Sel Cnt”, "Pulses/Inch". NOTE: Regardless if "Stop On Pos Cnt=0" or if "Stop On Pos Cnt =1", the floor magnet must be set properly at floor level. If too large of values are entered into "Dn Lev Dist", "Up Lev Dist", or "Offset", the car will drive past the floor level magnet and re‐level. Check all signal devices for proper operation and remove all temporary jumpers. The adjustment should now be complete. Section 4 ‐ Adjustment of the GALaxy controller HPV‐ 600/900 (Induction Motor- Geared Machine) In order to obtain a running platform in "car top inspection", see the "Quick Start‐up Guide for GALaxy Controller HPV 600/900 with Distance Feedback". This procedure should be used only for installation purposes. When installation of all equipment is complete, and unit is ready for adjustment, proceed to Section 4.2, Check Main Line Voltage, and follow instructions. 4.1 General Setup Before adjustment begins the following items must be completed. 1. All field wiring and safety circuits installed. 2. Temporary jumpers from terminal "HC" to terminals "MES & ALT". 3. All hoistway limit switches installed. 4. All car and hoistway doors and interlocks installed and pre‐adjusted. 5. Selector installed and magnets pre‐ adjusted. 7. Familiarize yourself with the Magnetek HPV 900/600 AC Vector Elevator Drive Technical Manual. 8. Verify that the AC motor is properly wired. 9. Verify that the motor encoder is connected properly. 10. Car should be properly counterbalanced. 4.2 Check Main Line Voltage With main‐line disconnect in the off position, check the line‐side voltage with a volt meter to insure the voltage matches the controller name tag "Input Power" voltage. Check to insure all three phases are present. If voltage is not correct or all three phases are not present, do not proceed until corrected. 4.3 Set Toggle Switches Set all toggle switches on the 1064 board down except for the gate and lock bypass switches as follows: DOOR LOCKS ‐ "OFF" IND ‐ "IND" AUTO DOOR ‐ "OFF" P a g e | 57 HPV-600/900 AC Geared 6. Familiarize yourself with all wiring schematics. STOP ‐ "STOP" INSPECTION ‐ "INSP" 4.4 Make Sure the Car Is Safe Verify that all elevator doors are closed and that all safety circuits are functional. 4.5 Check Controller Voltage Turn the main‐line disconnect to the on position. Check the voltage at R, S, and T on the AC drive. Verify that all three phases are present. Check the voltage at fuses L1 and L2 on controller. If correct, check the voltage at terminal "LIN" with respect to "GND". The voltage should read 120VAC. If correct, check the voltage at terminals "S10, LC, & HC" with respect to "GND". All should read 120VAC. If not, check wiring diagram to determine problem before continuing. 4.6 Verify the Main CPU is Operating Check to make sure that the "axy" of GALaxy on the 1021/1101/1005 LCD interface is blinking. If the "axy" is blinking, continue to the next step. If not, check voltage at terminals 5V to 0V on the 1064 board to insure 5VDC. If 5VDC is present and the "axy" on the 1021/1101/1005 LCD interface is not blinking, then contact factory. 4.7 Preset Adjustable Variables on Safety Processor Board And Main CPU The 1066 LCD interface (safety processor board) and the 1021/1101/1005 LCD interface (main CPU) are normally preset prior to leaving the factory. However, it is prudent to check the setup values for the proper settings. Refer to Section 13 of this manual for the operation of the safety processor board 1066 LCD interface. The following adjustment variables must be set properly: NOTE: If the controller uses an NTS board please refer to Section 14, GALX-0320AN NTSD Board. 4.8 1066 LCD interface "Adj Var" Menu Top Spd (contract speed) Enc RPM (if Fdbk Typ=0 (Tape), not applicable) (if Fdbk Typ=1 (Encoder), set to rpm of governor) (if Fdbk Typ=4 (Incremental Encoder), set to value of "CONTRACT MTR SPD" parameter in HPV 900/600 drive) Enc PPR (if Fdbk Typ=0 (Tape), not applicable) (if Fdbk Typ=1 (Encoder), set to 8192) (if Fdbk Typ=4 (Incremental Encoder), set to PPR of motor encoder) Fdbk Typ (0=tape, 1=enc, 4=InEnc) Ctrl Typ (2=Tract DF) 2 Stop (0=Mult, 1=2 stop) RearDoor (0=Front only, 1=Rear) UTS Vel (Set to top speed) DTS Vel (Set to top speed) INS Vel (Set to 140) LEV Vel (Set to 140) UT Vel (Set to top speed) DT Vel (Set to top speed) UL Vel (Set to 160 if Non‐DF) DL Vel (Set to 160 if Non‐DF) SoftStop (Set to 3) NOTE: The velocity values for the terminal limit switches above are only temporary settings until car is running high speed. In the final adjustment procedure, these variables must be set according to the procedures in Section 4.32, Adjust Safety Processor Board Speed Clamps. Top Speed (set to contract speed) Inspect Speed (set to 25 fpm) Encoder PPR (set to motor encoder PPR) Encoder RPM (if tape selector, set to value of "CONTRACT MTR SPD" in HPV 900/600 drive), (if 485 tapeless selector, set to value of "CONTRACT MTR SPD" in HPV 900/600 drive), (if CAN open tapeless selector, set to governor rpm) NOTE: See Section 4.23, Correct Car Speed When Using 485 Tapeless System, for determining governor rpm. 4.10 Place Stop Switch in Run Position Set the "STOP" toggle switch on the 1064 board to the "RUN" position. Verify that input LED's for "LC, HC, DN, UN, SS, GTS, RDY and CS" are all on. If not, then correct field wiring. P a g e | 59 HPV-600/900 AC Geared 4.9 1021/1101/1005 LCD interface "Adjustable Variables -> Car Motion" Submenu 4.11 Hoist Motor Data At this time the hoist motor data must be entered into the AC drive. The following functions must be entered or verified using the drive digital operator. Follow the instructions in the HPV 900 or HPV 600 drive manual to enter the following data: DRIVE A1 Sub Menu CONTRACT CAR SPD (from controller data) CONTRACT MTR SPD (from motor nameplate RPM) NOTE: The CONTRACT MTR SPD value may need to be fine‐tuned to provide the correct rpm to run the machine/motor at controller demanded speed. ENCODER PULSES (PPR from encoder on motor) MOTOR A5 Sub Menu RATED MTR PWR (from motor nameplate) RATED MTR VOLTS (from motor nameplate) RATED MOTOR CURR (from motor nameplate) MOTOR POLES For 1800rpm motor set MOTOR POLES to 4. For 1200rpm motor set MOTOR POLES to 6. For 900rpm motor set MOTOR POLES to 8. RATED MTR SPEED (RPM from motor nameplate) NOTE: This is a preliminary setting for the RATED MTR SPEED parameter. The final value of this parameter will be set in the "Adaptive Tune" procedure after the car is running high speed. Most of the drive parameters have been preset to values required for your specific job. Other parameters not listed here may need to be adjusted in the field. Please refer to the Magnetek HPV Technical manual for more parameter information and troubleshooting guidelines. From the digital operator for the drive, reset any active faults and clear the fault history log. 4.12 Pre‐set the Digital Speed Clamps Pre‐set the software digital speed clamps from the 1021/1101/1005 LCD interface under the "Elevator Setup Menu". The submenus for the clamp speeds are as follows: Set Ins / Leveling Clamp Set DT/UT Slowdown Clamp Set DT1/UT1 Slowdown Clamp Set DT2/UT2 Slowdown Clamp Set DT3/UT3 Slowdown Clamp Set DTS/UTS Slowdown Clamp Set the speed for Ins/Leveling for 140 fpm and all the remaining slowdown limit speeds to the contract speed of the car. Please note that the displayed value of "Clamp Speed" is the value the clamp should be set to. The slowdown limit "Clamp Speed:" will show 0000 until the car is run into the limits and the speed is recorded. Please refer to Section 10, 1021/1101/1005 LCD Interface, for the Elevator Setup Menu. 4.13 Ready to Run On Inspection The car should be ready to run on inspection if all is wired correctly. Select the "Elevator Status" on the 1021/1101/1005 LCD interface. The display should show "Out of Service" on the first line and "Inspection Mode" on the second. The 1066 LCD interface will display one of the following types of inspection: "MR INS" (Motor Room) "CT INS" (Car Top) "ACCESS" (Access) "IC INS" (In Car)" "AUTO" (Not on Inspection) To run the car from the motor room, "MR INS" should be displayed. P a g e | 61 HPV-600/900 AC Geared NOTE: The values of the clamp speed velocities above are only temporary settings until the car is running high speed. In the final adjustment procedure, these values must be set according to the procedures in Section 4.33, Adjust Digital Slowdown Speed Clamps. The "inspection string" consists of contacts from the inspection switches and the gate and lock bypass switches in series. One and only one of the five inspection inputs should be on for the car to run. Starting from the car top inspection input, the five inspection inputs are, "INS" for car top, "ACC" for access, "ICI" for in‐car, "MRI" for motor room, and "AUTO" for automatic (no inspection). The inspection string circuit is shown in Figure 4.1 Note that any one of the following conditions will cause an inspection error: More than one inspection input is on No inspection input is on Gate or Lock bypass switch is open and the car is not on car top inspection If the controller is not on motor room inspection at this point, then verify all switch positions and wiring before proceeding. Figure 4.1: Inspection String HPV-600/900 AC Geared 4.14 Adjust the Brake Voltage Momentarily push the inspection “UP” or “DOWN” push button on the 1064 board while checking the DC brake voltage with a meter. If the voltage is not correct, it must be adjusted according to the following procedures. If the controller utilizes an electronic brake board 1047 or 1051, then the brake voltage is adjusted through the 1021/1101/1005 LCD interface, "Car Brake" sub‐ menu. If the controller utilizes resistors and rectifiers for the brake coil circuit, then the brake voltage is adjusted by moving the adjustable tap on the brake resistor. NOTE: Remove power before adjusting the resistor taps. P a g e | 63 To adjust the brake voltage when using and electronic brake board, navigate to the "Adjustable Variables" menu, "Car Brake" and adjust "Brake Pick Volt", "Brake Hold Volt" and "Brk AC L‐L Volt" to the proper values. Make sure that the brake is lifting and setting properly before proceeding. 4.15 Check the Run Direction Again momentarily push the inspection “UP” or “DOWN” push button on the 1064 board. One of the following should take place: The elevator will run controlled, in the correct direction (up for “UP” button, down for “DOWN” button) with no drive faults. If so, proceed to “Check Inspection Speed”. The elevator will run controlled, but in the wrong direction with no drive faults. If so, proceed to "Car Runs The Wrong Direction" The elevator will try to run, but immediately trips on a drive ENCODER FLT. If so, proceed to “Drive Trips Immediately”. The elevator runs much slower than the inspection speed demand. If so, follow the steps in Section 4.18, Car Runs Extremely Slow. 4.16 Car Runs the Wrong Direction If the elevator runs controlled but in the wrong direction with no drive faults, then change the run direction of the motor by one of the following two ways. Change the motor rotation on the drive from forward to reverse. USER SWITCHES C1 MOTOR ROTATION Run the elevator on inspection again and verify that the car runs controlled and in the correct direction. If so, proceed to "Check Inspection Speed". If not contact the factory. Turn off the main line disconnect and swap 2 of the motor leads. Also, reverse the encoder direction. If an encoder isolation board is not used, then change the encoder direction by swapping the wires at the drive as shown below: HPV900 – A+ (TB1‐21 with A‐ (TB1‐20) HPV600 – A+ (63) with A‐ (62) If an encoder isolation board (1022N) is used, move J5 and J7 on the encoder board instead of moving the encoder wires at the drive. Refer to the jumper diagram on the board. J5 swaps A & A NOT – J7 swaps B & B NOT. Turn the main disconnect on and run the elevator on inspection again. The car should run controlled and in the correct direction. If so proceed to “Check Inspection Speed”. If not contact the factory. 4.17 Drive Trips Immediately If the elevator tries to run, but immediately trips on a drive ENCODER FLT, recheck the drive motor parameters. This fault is most likely caused by improper parameter settings. Carefully review the drive MOTOR A5 parameters to match the motor data. Correct any invalid parameters and re‐test the car. If the parameters are correct, then measure the voltage of the encoder at the drive terminals as shown below: Voltage between A+ and A‐ should read greater than 1.5 VDC. For the HPV 900 drive, check terminals A (TB1‐21) and A‐ (TB1‐20). For the HPV 600 drive, check terminals A+ (63) and A‐ (62). Voltage between B+ and B‐ should read greater than 1.5 VDC. For the HPV 900 drive check terminals B+ (TB1‐23) and B‐ (TB1‐22). For the HPV 600 drive, check terminals B+ (65) and B‐ (64). Voltage between +5 and 0V should read roughly 5 VDC. For the HPV 900 drive check terminals +5 (TB1‐25) and 0V (TB1‐19). For the HPV 600 drive, check terminals +5 (67) and 0V (61). If the voltage is incorrect then verify the encoder cable connections. Refer to the job schematics to correct any wiring error. If no error is found, then contact the factory. If the voltage is correct then change the encoder direction. Turn off the main disconnect. If an encoder isolation board is not used, then change the encoder direction by swapping the wires at the drive as shown below: HPV 900 ‐ A+ (TB1‐21) with A‐ (TB1‐20) HPV 600 ‐ A+ (63) with A‐ (62) If an encoder isolation board (1022N) is used, move J5 and J7 on the encoder board instead of moving the encoder wires at the drive. Refer to the jumper diagram on the board. J5 swaps A & A NOT – J7 swaps B & B NOT. P a g e | 65 HPV-600/900 AC Geared Turn on the main disconnect and run the elevator on inspection again. If the elevator runs controlled and in the correct direction, proceed to “Check Inspection Speed”. If the elevator runs controlled but in the wrong direction, the go back and follow the directions in Section 4.16, Car Runs The Wrong Direction. If the car still trips immediately on an ENCODER FLT, then contact the factory. 4.18 Car Runs Extremely Slow If the car runs much slower than the inspection speed demand, then change the encoder direction. Turn off the main disconnect. If an encoder isolation board is not used, then swap the encoder direction by swapping the wires at the drive as shown below: HPV 900 ‐ A+ (TB1‐21) with A‐ (TB1‐20) HPV 600 ‐ A+ (63) with A‐ (62) If an encoder isolation board (1022N) is used, move J5 and J7 on the encoder board instead of moving the encoder wires at the drive. Refer to the jumper diagram on the board. J5 swaps A & A NOT – J7 swaps B & B NOT. Turn on the main disconnect and run the elevator on inspection again. If the elevator runs controlled and in the correct direction, proceed to "Check Inspection Speed". Otherwise contact the factory. 4.19 Check Inspection Speed With a hand held tachometer, check the speed of the elevator while running on inspection. The elevator should be running at 25 fpm. Also run the elevator while monitoring the HPV 900/600 digital operator, D1 menu, "SPEED FEEDBACK". The display should read 25 fpm. From the 1021/1101/1005 LCD interface, "Elevator Status" menu, navigate until the display shows "Dmd" and "Vel". While running on inspection, monitor the controller demand speed "Dmd", and the speed feedback "Vel". These values should both display 25. If the demand and feedback on the 1021/1101/1005 LCD interface is incorrect, check the Encoder RPM and PPR parameters from the “Adjustable Variables” menu. These variables should be set to the values listed in Section 4.9, 1021/1101/1005 LCD interface "Adjustable Variables -> Car Motion" Submenu. If the speed on the hand held tachometer and on "Dmd" and "Vel" all read approximately 25 fpm (within +/‐2 fpm) continue to the next step. If not, contact the factory. 4.20 Verify Controller Encoder Direction From the 1021/1101/1005 LCD interface "Elevator Status" menu, navigate to display "Dir" and "DP". While moving the car on inspection, monitor "Dir" (direction) and "DP" (pulse counts). "Dir" should display "Up" when the car is moving up, and "Dn" when the car is moving down. The value of "Dp" should increment when the car is moving up, and should decrement when the car is moving down. If the direction is wrong or the pulse counts change in the wrong direction, then the encoder direction to the controller must be changed. If an encoder isolation board (1022N) is used, move J1 and J3 on the encoder board. Refer to the jumper diagram on the board. J1 swaps A & A NOT – J3 swaps B & B NOT. If no encoder isolation board is used, the A+ and A‐ encoder wires from the drive must be swapped. Note that the motor encoder wires are daisy chained from the encoder to the drive and then from the drive to the controller encoder board. Only the A+ and A‐ wires from the drive to the controller board must be swapped. The wires from the encoder to the drive must remain on the same terminal locations on the drive. If the encoder is counting properly continue to the next step. If not, contact the factory. Run the elevator up on inspection until it stops on the up normal limit. The up and down normal limits should be set two inches above and below the terminal floors respectively. Verify the selector inputs are being set properly on the controller by running the elevator down until it stops on the down normal limit. As the car approaches floor level going down, “DL” turns on first, then “DZ” and then finally “UL”. At floor level, “UL, DL, and DZ” inputs should all be on at the same time. Leaving the floor going down “DL” will turn off first, then “DZ” and last “UL”. Also verify that the up and down terminal slowdown limits inputs “UT, UTS, DT & DTS” are breaking at the proper distances as shown in the slowdown table 2.0. “UT, UTS, DT & DTS” turn off when active. 4.21 Verify Car Speed on Safety Processor Board Run the car in either direction and check the car speed on the 1066 LCD interface. The speed shown should match the car’s actual speed. If the speed does not match and the secondary feedback comes P a g e | 67 HPV-600/900 AC Geared Verify Selector and Slowdown Inputs from pulses from the tape go to “Correct Car Speed When Using A Tape”. If using 485 tapeless, go to "Correct Car Speed When Using 485 tapeless". If using CAN Open tapeless, go to "Correct Car Speed When Using CAN Open tapeless". If the correct speed is shown proceed to Section 4.25, Learn the Hoistway. 4.22 Correct Car Speed When Using a Tape The tape has holes every 3/8” that are 3/8” in diameter. On the selector unit adjust the PP sensor closer to the tape until the orange LED at the end of the sensor turns on. Then turn the sensor inwards another 1/8” and lock in the sensor. While running on top of car inspection verify that the orange LED at the end of the PP sensor turns on and off as it passes by the holes on the tape. The safety processor board on the controller measures the time between each pulse to calculate the velocity. If the velocity is not displayed correctly first make sure that the feedback type in the safety processor board adjustable variable is set to 0 for a tape application. Next, while the car is running, make sure that the PULSE LED on this board is pulsing. As the car increases in speed the LED will glow solid on. If the LED does not pulse, try swapping the wires at the PPS and PP terminals. If the LED still does not work, contact the factory. If the correct speed is shown proceed to “Learn the Hoistway”. 4.23 Correct Car Speed When Using 485 Tapeless System When using the 485 tapeless system, the secondary speed feedback comes from the encoder mounted on the governor. The 1066 board uses a serial interface to a Turck absolute encoder, part # T8.5882.3F0B.3001. In the 1066 LCD interface "Adj Var" menu, set the "Fdbk Typ = 1", and set the "Enc PPR = 8192". The "Enc RPM" value must be calculated as described below. To calculate the RPM, divide the contract speed of the car by the distance travel in one revolution with the governor as shown below: RPM = Speed fpm/ (diameter GOV * pi) For a 1 ft. diameter governor: RPM = 350/ (1*pi) = 350/3.1415 = 111.4 For a 16 in diameter governor (16/12 = 1.33ft): RPM = 350/ (1.33* 3.1415) = 350/4.188 = 83.5 4.24 Correct Car Speed When Using CAN Open Tapeless System When using the CAN Open tapeless system, the secondary speed feedback comes from the incremental encoder mounted on the machine/motor. In the 1066 LCD interface "Adj Var" menu, set the "Fdbk Typ = 4", and set the "Enc PPR" equal to the ppr of the machine/motor‐mounted incremental encoder, and set the "Enc RPM" to the rpm of the machine/motor at contract speed. On the 1066 LCD interface, navigate to the "Pls Cnt" menu. While running the elevator on inspection, verify that the pulse count value increments when running up and decrements when running down. The "Pls Cnt" value can be considerably out of range but will automatically correct during the "Learn Hoistway" procedure. To reverse the direction of pulse counting, navigate on the 1066 LCD interface to the "Adj Var" menu, "Enc Dir" and set to "0" for clockwise or "1" for counter‐clockwise. Navigate on the 1066 LCD interface to the "Car Spd" menu. Monitor the "Car Spd" while running the car at a known inspection speed. The value displayed should match the actual car speed measured with a hand held tachometer. If not, re‐check the values set in "Enc RPM" and "Enc PPR" in the 1066 LCD interface. If the speed is correct, proceed to Section 4.25, Learn the Hoistway. 4.25 Learn the Hoistway Run the elevator down on inspection until it stops on the down normal limit switch. Verify that the “DN and DL” input LED’s are both off and that the "UL" and "DZ" LED's are on. From the 1021/1101/1005 LCD interface navigate to the "Elevator Setup" menu, "Learn Hoistway". The learn procedure can be performed automatically by choosing "Auto" from the menu items, or performed manually by choosing "Insp" from the menu items. After choosing the learn method, follow the instructions displayed on 1021/1101/1005 LCD interface. NOTE: The car must run the entire hoistway without stopping. As the elevator moves up the hoistway, navigate to the "Hoistway Tables" menu, "Disp/Mod Hoistway Table", and verify that the "DP" count is incrementing as the elevator moves up. Also as the elevator passes each floor, the pulse count and distance for that floor should change and be stored. Verify that the floor distances are valid. The pulse count for the terminal slowdowns will also be stored. The elevator will stop when it reaches the up normal limit. Follow the instructions on the 1021/1101/1005 LCD interface by putting the car on inspection, and then the message "Hoistway Learn Complete" should be displayed. Move the elevator on inspection until the “DZ and DL” LED’s are on. Set the "INS" switch on the 1064 board to the “NORMAL” position and the elevator should level down to floor level at the top floor. If so, proceed to final adjustment. P a g e | 69 HPV-600/900 AC Geared In general, the car will run up from the "down normal limit" to the "up normal limit" at 30 fpm. During this learn run, the DP count for each floor level and each limit switch will be stored in memory. If the car levels down but does not run, then check “Elevator Status” and “View Fault Log” on the 1021/1101/1005 LCD interface for any fault information. Correct items causing faults and perform hoistway learn again. After problem is corrected, and a successful hoistway learn is performed, proceed to final adjustment. 4.26 Automatic Run The elevator should now be sitting idle at the top floor. The "AUTO DOOR" switch should be set to the "OFF" position and the "IND" switch should be set to the "IND" position. If the learn procedure was successful, the elevator should be ready to make an automatic run. The default parameter settings for the ride quality should be adequate for an initial run. From the 1021/1101/1005 LCD interface navigate to the "Set Calls and Lockouts" menu, "Setup Car Calls" and enter a car call. The elevator should run to answer the call. When the elevator levels in and stops at the floor, the doors will remain closed. The acceleration and deceleration of the car should be smooth and stepless regardless of the distance of the run. If the elevator does not function as described above, then problem should be analyzed before proceeding. 4.27 Drive Adaptive Tune To complete the setup of the drive, an adaptive tune is required. It is necessary that the car run 70% of contract speed when running this test so that the drive does not go into flux weakening. In the DRIVE A1 Sub Menu, set the CONTRACT MTR SPD parameter to 70% of the rated motor RPM. If this value was adjusted to correct the top speed of the car, use 70% of the adjusted value. To calculate 70%, multiply the value by 0.7. For example, if the motor RPM is 1050 then 70% of the motor RPM is (1050 x 0.7 = 735). This procedure will also require a balanced load in the car. Follow the adaptive tune procedure set in the Magnetek HPV 900 or HPV 600 Technical Manual. After completing the adaptive tune, reset the CONTRACT MTR SPD parameter and then proceed to the next step. 4.28 Fine Tune the Ride Quality In order to fine tune the ride quality, refer to Figure 4.2 which describes what part of the S‐ curve that the different parameters effect. In general, higher numbers in the given parameters, cause quicker and more abrupt changes from one mode to the next during a run. All of the S‐curve parameters have a minimum and maximum value. The controller will not allow you to enter values that are not valid. After adjusting the S‐ curve parameters for the desired ride, proceed to the next step. 4.29 Adjust the Stop When at floor level the “UL, DL, & DZ” input LED’s should be on. If the elevator continually tries to seek floor level by leveling up and down, try the following steps to correct the problem: Increase the response of the drive by increasing the value of A1 RESPONSE in the HPV 900/600 drive, and retesting the car. Reduce the leveling and re‐leveling velocity parameters from the 1021/1101/1005 LCD interface "Adjustable Variables" menu, "Car Motion", "Leveling Speed" and "Relevel Speed". If the car still oscillates, adjust the "floor level zone" on the selector. The "floor level zone" is increased by moving the "UL" and "DL" sensors closer together. NOTE: The "Soft Stop Time" setting in the 1021/1101/1005 LCD interface should be compared with the setting in the 1066 LCD interface "Adj Var" menu, "SoftStop". The setting of "SoftStop" in the 1066 LCD interface should be greater than the "Soft Stop Time" setting in the 1021/1101/1005 LCD interface. If the car spots when approaching the floor, the cause is usually due to the car not tracking (the drive response is set too low) or the speed profile into the floor is too aggressive. First try to increase the response of the drive by increasing the value of parameter A1 RESPONSE in the drive. If the car still spots: from the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and increase the value of "Floor Targ Dis" (floor targeting distance). The default value for the floor targeting distance is 12 inches. Increase it by steps of 2 or 3 and continue retesting until the parameter is adjusted to 18. If no change is noticed, start again from 12 and decrease the value. The deceleration rate can also be reduced to help remove the spotting. Proceed with adjusting the start once the proper stop is achieved. P a g e | 71 HPV-600/900 AC Geared If the car stops hard on the brake, then make the following adjustments. From the 1021/1101/1005 LCD interface navigate to the "Adjustable Variables" menu, "Car Motion", and adjust both "Brake Drop Del" (brake drop delay) and "Soft Stop Time". These variables should be adjusted so that zero speed is observed at the end of the run prior to the brake setting. The controller should hold the car at zero speed for the duration of the "Soft Stop Time" which should continue while the brake is setting and for a short time after the brake sets. The soft stop time MUST be set to at least 0.5 seconds LONGER than the "Brake Drop Del". Figure 4.2: S‐Curve Parameter 4.30 Adjust the Start To provide a proper start, from the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and adjust "Brake Pick Del" (brake pick delay), "Pattern Delay", and "Soft Start Jerk". Initially, set the brake pick delay to 0 and increase the pattern delay by 0.1 seconds until the controller picks the brake completely before the motor starts to move. If roll back occurs, then reduce the pattern delay until there is no roll back. Sometimes, the timing works out better if the brake pick delay is set to 0.1 second. If load weighing is used, pre‐torquing can be used to provide a smoother start. See Section 4.39, Adjust the Motor Pre‐torque. Increase the soft start jerk rate in order to provide a quicker transition from the start to constant acceleration. Keep in mind that the larger the soft start number, the quicker the start. The ride should now be acceptable. 4.31 Verify Top Speed To fine tune high speed, make high speed runs while monitoring the SPEED FEEDBACK in the D1 submenu on the HPV drive display. The display should read contract speed, and it should match the speed displayed on the 1021/1101/1005 LCD interface, "Elevator Status" menu, "Dmd" and "Vel". This speed should also match the speed displayed on the 1066 LCD interface, "Car Spd" menu. If all of these values are the same (+/‐ 2 fpm), then proceed to the next step. If the speed is not correct increase or decrease drive parameter A1 CONTARCT MTR SPD until the AC drive display reads contract speed. When the speed displayed is correct, proceed to the next step. 4.32 Adjust Safety Processor Board Speed Clamps The 1066 Safety Processor Board monitors the speed of the elevator at the terminal landings independently from the main CPU. When the "UT, DT, UTS, and DTS" limit switches are activated, the 1066 board calculates the velocity of the elevator and compares that velocity with a stored value of speed clamp. If the velocity when the switch activates is greater than the speed clamp value, then the 1066 board will generate a fault that stops the elevator. To set the speed clamps, make a one floor run to the top floor. From the 1066 LCD interface, navigate to the "Lim Vel" menu, and view the recorded velocities displayed for the “UT, DT, UTS & DTS” slowdown limits. “UTS & DTS” are used on car with reduced stroke buffers or with a top speed greater than 200 fpm. The velocity value is shown from the “LIM VEL” menu on the 1066 LCD interface. The velocity value shown on the display for the “UT or DT” limit is the value after the car activates the limit then counts an adjustable number of counts the 1066 LCD interface, "Adj Var" menu, "UT Count" or "DT Count". These count values can be adjusted to provide adequate distance, following the limit switch activation, to allow the elevator to begin its normal decel pattern. The default "UT Count" and "DT Count" values are normally adequate. However, these values may need to be field adjusted to allow enough distance for the car to begin its normal decel pattern. If the "UT Count" and "DT Count" values are modified, the limit velocities must be re‐ checked. Make the same runs to the bottom floor starting from 1 floor, then 2 floors, then 3 floors, etc., until top speed is reached. From the 1066 LCD interface "Lim Vel" menu, record the limit velocities displayed each time the car stops at the bottom floor. Take the highest speed value recorded in the runs above and add 20 fpm to that value to use as the clamp speed values for the respective limit switches. Enter these clamp speed values into the 1066 LCD interface "Adj Var" menu, "UT Vel", "DT Vel", "UTS Vel", "DTS Vel" respectively. 4.33 Adjust Digital Slowdown Speed Clamps Having just made several runs into the top and bottom landings, the main CPU has also recorded the car’s velocity when the slowdown limits were activated. If the car has been powered down prior to this step, several runs must to be made to the terminal landings to allow the main CPU to record the limit velocity values. P a g e | 73 HPV-600/900 AC Geared Run the car again to the top repeatedly from 2 floors, then 3 floors, etc., until top speed is reached. Record the limit velocities each time the car stops at the top floor. From the 1066 LCD interface "Lim Vel" menu, record the limit velocities displayed each time the car stops at the top floor. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Set DT/UT Slowdown Clamp" and view the speed displayed for "Clamp Speed". Add 20 fpm to this "Clamp Speed" value and enter it into the "DT/UT Limit" value. The number of slowdown limits depends on the speed of the car as show in the table below: Table 4.1: Slowdown Clamps Adjust speed clamps for each slowdown limits used as determined by the elevator’s contract speed. 4.34 Verify Inspection Velocity Clamp on Safety Processor Board Place the car on inspection operation. From the 1066 LCD interface, navigate to the "Adj Var" menu, "Ins Vel" and set the speed clamp velocity to 25 fpm. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed" to 50 fpm. Run the car in either direction and verify that the car shuts down when the speed rises above 25 fpm. From the 1066 LCD interface, navigate to the "Adj Var" menu, "Ins Vel" and set the speed clamp to 140 fpm. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed" to the desired value. 4.35 Analog Load Weigher Setup If the job uses an analog load weigher purchased from G.A.L., complete the following procedure. Mount the load weigher as described by the manufacturer. The load weigher control box will also contain a board supplied by G.A.L. that connects to the controller serial CAN bus and reads in the analog output from the load weighing device. Wire the load weigher and G.A.L. board according to the controller schematics. Calibrate the load weighing device hardware according to the manufacturer’s instructions. Following proper installation of the load weighing device, proceed to Section 4.36, Empty Car Setup. NOTE: It is recommended using two people, one moving the weights and one in the machine room to set up the load weigher. 4.36 Empty Car Setup Verify that the load weighing device is communicating to the main CPU by performing the following steps. From the 1021/1101/1005 LCD interface, navigate to the "Diagnostics" menu, "Car Comm Status", "Car to LW Board" and verify that "On‐ line = 1". If "On‐line = 0" then verify wiring and installation of load weighing device. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "Setup Load Weigher" and follow the instructions on the display as you go through the procedure. It is okay to exit the setup screen to place a call and then return to it while the setup is being performed. If the car is at the bottom floor and the doors are not closed (the doors will not close automatically from turning off the auto‐door switch) then place a car call to run the car up one floor then back again. The doors will close when the call is placed. When the automatic sequence is activated, the car will run to each floor and measure the empty load value. The 1021/1101/1005 LCD interface will indicate when the sequence is finished. 4.37 Full Car Setup NOTE: The empty car setup must be successfully completed to run the full load setup. Once the empty car setup is complete, run to the loading floor and set the "AUTO DOOR" switch to the "ON" position to allow weights to be loaded on the car. With the car fully loaded, set the "AUTO DOOR" switch to the "OFF" position and run the car to the bottom floor. Again if the doors are not closed, make a one floor run to force the doors to close. P a g e | 75 HPV-600/900 AC Geared Run the car to the bottom floor and press Enter on the 1021/1101/1005 LCD interface when prompted to do so to start the automatic setup sequence. With the car at the bottom floor, follow the instructions on the 1021/1101/1005 LCD interface to start the full load setup sequence. The car will automatically run to each floor and measure the full load value. When the full load measurement is complete, the car can be run to the loading floor and the weights removed. After the weights are removed, cycle the doors to complete the procedure. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "View/Modify LW Setup" and verify the load weigher status, "LW Device Stat: ON OK". If the status is "ON OK", then the load weigher should be accurately measuring the car load in real time. The percent load will be displayed, "Load: _%". The percent load values for different service options can now be set. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Service Options", and set the following variables: "Load Bypass" "Load Antinuisance" "Load Dispatch" "Load Overload" NOTE: Setting the values of the variables above to 0% will disable that particular option. 4.38 Load Weighing Calibration Sequence The load weigher is automatically calibrated once each week. If an error is detected during this calibration sequence, the load weigher and the pre‐torque feature (if used) is disabled. A load weighing calibration sequence can be done manually by performing the following procedure. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "Load Weigher Calibration" and follow the instructions on the display. 4.39 Adjust the Motor Pre‐torque NOTE: The motor pre‐torque uses the load value obtained from the analog load weigher and will only work if the load weigher has been installed properly, and the "Load Weigher Setup" has been performed successfully. On the HPV‐600 or HPV‐900 drive under User Switches C1 parameter, set Pre‐Torque source to serial. Run the empty car to a middle floor. The long pattern delay will allow an exaggerated amount of roll back in order for the pre‐torquing to be set accurately. Make a one floor run down and observe the roll back when the brake picks at the start of the run. Increase the "Torque Amount" variable and continue to monitor the roll back while performing one floor runs in the down direction. As the "Torque Amount" is increased, the roll back should be minimized until the car will hold zero speed for the entire "Pattern Delay" time. A typical value for the "Torque Amount" is 40%. If the value is too large, the car will roll forward during the "Pattern Delay" time. NOTE: Pattern delay must be at least 0.15 seconds (150 milliseconds). Setting the torque amount to 0.0 will disable the pre‐ torque feature. Also if the load weighing calibration sequence detects a load weighing error, the pre‐torque feature is also automatically disabled. 4.40 Verify the Doors Are Safe The elevator should now be adjusted. Verify that all door locks, gate switches, and safety circuits are operational. Set the "INSP" switch to the "NORM" position and set the "AUTO DOOR" switch to the "ON" position. The elevator should level into the floor and open the doors. If the doors do not open, check the door operator wiring and cam adjustment. If the doors do open, the elevator is now on independent service. 4.41 Fine Tune the Ride Quality To fine tune the floor level accuracy, determine if the controller is set to stop when "UL" and "DL" signals turn on, or if controller is set to stop off of the position count. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and view the "Stop On Pos Cnt" variable. If "Stop On Pos Cnt = 0" then controller is set to stop when the "UL and "DL" signals turn on. If "Stop On Pos Cnt = 1" then controller is set to stop on a combination of the floor level magnet and the position count. With "Stop On Pos Cnt = 0", the floor levels should be set by adjusting the floor level magnet at each floor. For proper operation, the floor magnets should be set to exactly floor level. After the floor levels are set properly, perform another hoistway learn procedure. With "Stop On Pos Cnt = 1", the floor levels are set by using both the floor magnet and the position count. For proper operation with this setting, the floor magnet should be set to exactly floor level. The final stop can then be fine‐tuned by performing the following adjustments. P a g e | 77 HPV-600/900 AC Geared Ride the elevator and evaluate the ride quality. Fine tune ride quality by navigating to the "Adjustable Variables" menu, "Car Motion" and adjusting the variables shown in Figure 4.2. Keep in mind that if acceleration or deceleration values are changed, the speed clamps for the safety processor board and the S‐curve board may need to be re‐adjusted. From the 1021/1101/1005 LCD interface, navigate to the "Hoistway Tables" menu, "DZ & LZ Offset, Sel Cnt" and adjust "Dn Lev Dist" and "Up Lev Dist". The units for these variables are in "pulse counts". With "Stop On Pos Cnt =1" the car will continue to move for the "Dn Lev Dist" or "Up Lev Dist" after "UL and DL" turn on. Use the "Dn Lev Dist" and the "Up Lev Dist" parameters to make level changes at all floors. To make level changes at individual floors, perform the following adjustments. From the 1021/1101/1005 LCD interface, navigate to the "Hoistway Tables" menu, "FL and FL Offset Count", and the offset count can be adjusted. These variables introduce an offset (+/‐) to the stored floor count that was determined in the hoistway learn procedure. NOTE: The number of pulse counts per inch can be viewed from the 1021/1101/1005 LCD interface, "Hoistway Tables", "DZ & LZ Offset, Sel Cnt”, "Pulses / Inch". NOTE: Regardless if "Stop On Pos Cnt=0" or if "Stop On Pos Cnt =1", the floor magnet must be set properly at floor level. If too large of values are entered into "Dn Lev Dist", "Up Lev Dist", or "Offset", the car will drive past the floor level magnet and re‐level. Check all signal devices for proper operation and remove all temporary jumpers. The adjustment should now be complete. 5.1 General Setup Before adjustment begins the following items must be completed. 1. All field wiring and safety circuits installed 2. Temporary jumpers from terminal “HC” to terminals “MES & ALT” 3. All hoistway limit switches installed 4. All car and hoistway doors and interlocks installed and pre‐adjusted 5. Selector installed and magnets pre‐ adjusted 6. Familiarize yourself with all wiring schematics 7. Familiarize yourself with the appropriate Magnetek HPV 900 or HPV 600 AC Vector Elevator Drive Technical Manual. 8. Verify that the AC motor is properly wired. 9. Verify that the encoder (if closed loop) is connected properly. 10. Car should be properly counterbalanced. 5.2 Check Main‐line Voltage With main‐line disconnect in the off position, check the line‐side voltage with a volt meter to insure the voltage matches the controller name tag “Input Power” voltage. Check to insure all three phases are present. If voltage is not correct or all three phases are not present, do not proceed until corrected. 5.3 Set Toggle Switches Set all toggle switches on the 1064 board as follows: DOOR LOCKS ‐ "OFF" IND ‐ "IND" AUTO DOOR ‐ "OFF" STOP ‐ "STOP" INSPECTION ‐ "INSP" P a g e | 79 HPV-600/900 Non-Distance Feedback Section 5 ‐ Adjustment of the GALaxy Non‐ Distance Feedback controller ‐ HPV‐600/900 5.4 Make Sure the Car Is Safe Verify that all elevator doors are closed and that all safety circuits are functional. 5.5 Check Controller Voltage Turn the main‐line disconnect to the “On” position. Check the voltage at R, S, and T on the AC drive. Verify that all three phases are present. Check the voltage at fuses L1 and L2 on the controller. If correct, check the voltage at terminal “LIN” with respect to “GND”. The voltage should read 120VAC. If correct, check the voltage at terminals “S10, LC, & HC” with respect to “GND”. All should read 120VAC. If not, check wiring diagram. 5.6 Verify the Main CPU is Operating Check to make sure that the “axy” of GALaxy on the 1021/1101/1005 LCD interface is blinking. If the “axy” is blinking, continue to the next step. If not, check voltage at terminals 5V to 0V on the 1064 board to insure 5VDC. If 5VDC is present and the “axy” on the 1021/1101/1005 LCD interface is not blinking, then contact factory. 5.7 Preset Adjustable Variables on Safety Processor Board And Main CPU The 1066 LCD interface (safety processor board) and the 1021/1101/1005 LCD interface (main CPU) are normally preset prior to leaving the factory. However, it is prudent to check the setup values for the proper settings. Refer to Section 13 of this manual for the operation 1066 LCD interface, and refer to Section 10 for operation of the 1021/1101/1005 LCD interface. The following adjustment variables must be set properly: 5.8 1066 LCD interface "Adj Var" Menu Top Spd (contract speed) Fdbk Typ (0=tape) Ctrl Typ (1=Tr NDF) 2 Stop (0=Mult, 1=2 stop) RearDoor (0=Front only, 1=Rear) UTS Vel (Set to top speed) DTS Vel (Set to top speed) INS Vel (Set to 140) LEV Vel (Set to 140) UT Vel (Set to top speed) DT Vel (Set to top speed) UL Vel (Set to 160 if Non‐DF) DL Vel (Set to 160 if Non‐DF) SoftStop (Set to 3) NOTE: The velocity values for the terminal limit switches above are only temporary settings until car is running high speed. In the final adjustment procedure, these variables must be set according to the procedures in Section 5.29, Adjust Safety Processor Board Speed Clamps. 5.9 1021/1101/1005 LCD interface "Adjustable Variables -> Car Motion" Submenu Top Speed (set to contract speed) Inspect Speed (set to 25 fpm) Encoder PPR (set to motor encoder PPR) Encoder RPM (if tape selector, set to value of "CONTRACT MTR SPD" in HPV 900/600 drive) 5.10 Place Stop Switch in Run Position Set the “STOP” toggle switch on the 1064 board to the “RUN” position. Verify that input LED’s for “LC, HC, DN, UN, SS, GTS, RDY and CS” are all on. If not, then correct field wiring. 5.11 Hoist Motor Data At this time the hoist motor data must be entered into the AC drive. The following functions listed in the appropriate drive section must be entered or verified using the specific drive interface tool. Proceed to the HPV 900/600 or GPD 515 drive section below. 5.12 HPV 900/600 Drive Follow the instructions in the HPV 900 or HPV 600 drive manual to enter the following data: DRIVE A1 Sub Menu CONTRACT CAR SPD (from controller data) P a g e | 81 HPV-600/900 Non-Distance Feedback CONTRACT MTR SPD (from motor nameplate RPM) NOTE: The CONTRACT MTR SPD value may need to be fine‐tuned to provide the correct rpm to run the machine/motor at controller demanded speed. ENCODER PULSES (PPR from encoder on motor) MOTOR A5 Sub Menu RATED MTR PWR (from motor nameplate) RATED MTR VOLTS (from motor nameplate) RATED EXCIT FREQ (from motor nameplate) RATED MOTOR CURR (from motor nameplate) MOTOR POLES for 1800rpm motor set MOTOR POLES to 4 for 1200rpm motor set MOTOR POLES to 6 for 900rpm motor set MOTOR POLES to 8 RATED MTR SPEED (RPM from motor nameplate) NOTE: This is a preliminary setting for the RATED MTR SPEED parameter. The final value of this parameter will be set in the "Adaptive Tune" procedure after the car is running high speed. % NO LOAD CURR (from motor nameplate) S‐CURVES A2 Sub Menu ACCEL RATE 0 = 2.5 DECEL RATE 0 = 2.5 ACCEL JERK IN 0 = 3.0 ACCEL JERK OUT 0 = 3.0 DECEL JERK IN 0 = 3.0 DECEL JERK OUT 0 = 3.0 MULTISTEP A3 Sub Menu SPEED CMD 0 = 0 SPEED CMD 1 = Lev Speed SPEED CMD 2 = Ins Speed SPEED CMD 3 = High SPEED CMD 4 = 0 SPEED CMD 5 = 0 SPEED CMD 6 = 0 SPEED CMD 7 = 0 SPEED CMD 8 = 0 SPEED CMD 9 = 0 HPV-600/900 Non-Distance Feedback CONFIGURE C0 Sub Menu LOGIC INPUT 1 = Drive Enable LOGIC INPUT 2 = Run Up LOGIC INPUT 3 = Fault Reset LOGIC INPUT 4 = Run Down LOGIC INPUT 5 = Contact Confirm LOGIC INPUT 6 = Step Ref B0 LOGIC INPUT 7 = Step Ref B1 LOGIC INPUT 8 = no function Most of the drive parameters have been preset to values required for your specific job. Other parameters not listed here may need to be adjusted in the field. Please refer to the Magnetek HPV 900 or HPV 600 Technical manual for more parameter information and troubleshooting guidelines. From the digital operator for the drive, reset any active faults and clear the fault history log. P a g e | 83 5.13 GPD 515 Drive Follow the instructions in the GPD 515 drive manual to enter the follow data: C1‐10 Acc/Dec Time Setting = 0 C1‐01 Accel Time 1 = Top Speed/150 C1‐02 Decel Time 1 = Top Speed/150 Note: This will set the accel and decel rates to 150 fpm/s or 2.5 f/s^2. (0.66 for 100 fpm) C2‐01 S‐curve Accel Start = 0.2 C2‐02 S‐curve Accel End = 0.2 C2‐03 S‐curve Decel Start = 0.2 C2‐04 S‐curve Decel End = 0.2 D1‐01 Frequency Ref = 0 D1‐02 Frequency Ref = Lev Speed D1‐03 Frequency Ref = Ins Speed D1‐04 Frequency Ref = High Speed D1‐05 through D1‐09 = 0 E1‐01 Input Voltage = Line Voltage E1‐03 V/F Pattern = 1 E1‐04 Max Frequency = 60 E2‐01 Motor Current = Nameplate Motor Amps E2‐03 No‐Load Amps = Nameplate Motor No‐Load Amps E2‐04 Num of Poles = 4 (~1800 rpm) 6 (~1200 rpm) 8 (~900 rpm) H1‐01 Multi‐function = 24 H1‐02 Multi‐function = 14 H1‐03 Multi‐function = F H1‐04 Multi‐function = 3 H1‐05 Multi‐function = 4 H1‐06 Multi‐function = F H3‐05 Multi‐function = 1F HPV-600/900 Non-Distance Feedback With Encoder F1‐01 Encoder Const = Encoder PPR F1‐05 PG Rotation = 0 CCW, 1 CW The following data is set from the factory and is shown here for reference: A1‐02 Control Method =0 (V/F if no encoder used) A1‐02 Control Method =3 (Flux Vector if encoder used) A1‐03 Initialize Parameters = 2220 B1‐01 Reference Selection = 1 B1‐02 Operation Method = 1 B1‐03 Stopping Method = 1 B5‐01 PID Control = 0 H2‐01 Operation Ready = 6 Most of the drive parameters have been preset to values required for your specific job. Other parameters not listed here may need to be adjusted in the field. Please refer to the Magnetek GPD 515 Technical manual for more parameter information and troubleshooting guidelines. 5.14 Ready to Run On Inspection The car should be ready to run on inspection if all is wired correctly. Select the “Elevator Status” on 1021/1101/1005 LCD interface. The display should show “Out of Service” on the first line and “Inspection Mode” on the second. The 1066 LCD interface will display one of the following types of inspection: “MR INS” (Motor Room) “CT INS” (Car Top) “ACCESS” (Access) “IC INS” (In Car) “AUTO” (Not on Inspection) To run the car from the motor room, “MR INS” should be displayed. The “inspection string” (Figure 5.1) consist of contacts from the inspection switches and the gate and lock bypass switches in series. One and only one of the five inspection inputs should be on for the car to P a g e | 85 run. Starting from the car top inspection input, the five inspection inputs are, “INS” for car top, “ACC” for access, “ICI” for in‐car, “MRI” for motor room, and “AUTO” for automatic (no inspection). Note that any of the following conditions will cause an inspection error: More than one inspection input is on No inspection input is on Gate or Lock bypass switch is open and the car is not on car top inspection If the controller is not on motor room inspection at this point, then verify all switch positions and wiring before proceeding. Figure 5.1: Inspection String Circuit Momentarily push the inspection “UP” or “DOWN” push button on the 1064 board while checking the DC brake voltage with a meter. If the voltage is not correct, it must be adjusted according to the following procedures. If the controller utilizes an electronic brake board 1047 or 1051, then the brake voltage is adjusted through the 1021/1101/1005 LCD interface, "Car Brake" sub‐ menu. If the controller utilizes resistors and rectifiers for the brake coil circuit, then the brake voltage is adjusted by moving the adjustable tap on the brake resistor. NOTE: Remove power before adjusting the resistor taps. To adjust the brake voltage when using and electronic brake board, navigate to the "Adjustable Variables" menu, "Car Brake" and adjust "Brake Pick Volt", "Brake Hold Volt" and "Brk AC L‐L Volt" to the proper values. Make sure that the brake is lifting and setting properly before proceeding. 5.16 Check Run Direction Momentarily push the inspection “UP” or “DOWN” push button on the 1064 board. One of the following should take place: The elevator will run controlled, in the correct direction (up for “UP” button, down for “DOWN” button) with no drive faults. If so, proceed to “Check Inspection Speed”. The elevator will run controlled, but in the wrong direction (down for “UP” button, up of “DOWN” button) with no drive faults. If so, proceed to "Car Runs the Wrong Direction". The elevator will try to run, but immediately trips on a drive fault. Re‐check the drive parameters. If an encoder is used and the drive records an ENCODER FLT proceed to “Verify Encoder Connection”. If no encoder is used, then contact the factory. The elevator will run controlled but very slow; proceed to “Verify Encoder Connection”. P a g e | 87 HPV-600/900 Non-Distance Feedback 5.15 Adjust the Brake Voltage 5.17 Car Runs Wrong Direction If the elevator runs controlled but in the wrong direction, with no drive faults, then change rotation of the motor. For an HPV 900 or 600 drive the motor rotation can be changed from the drive command. For a GPD 515 drive the motor leads will need to be swapped. With HPV 900 or HPV 600 USER SWITCHES C1 MOTOR ROTATION With GPD 515 Turn off the power and switch any two motor leads. If an encoder is used, then swap the A+ and A‐ wires as follows: A+ (TA1‐4) with A‐ (TA1‐5) The motor should run controlled in the correct direction. If not then contact the factory, otherwise, proceed to “Run Inspection Speed”. 5.18 Verify Encoder Connection If the elevator tries to run, but immediately trips on a drive ENCODER FLT or if the car runs very slow, then the drive encoder direction needs to be changed. If the controller has an encoder isolation board (1022N), change the encoder direction for the drive by moving jumper J5 from “POS 1” to “POS 2”. This will swap the A and A‐ signals. Refer to the jumper diagram on the 1022 board. J5 swaps A & A NOT – J7 swaps B & B NOT. If the controller does not have an encoder isolation board, then turn off the main disconnect, and swap the encoder wires at the drive as follows: With HPV 900 A+ (TB1‐21) with A‐ (TB1‐20) With HPV 600 A+ (Encoder Card Terminal 63) with A‐ (Encoder Card Terminal 62) With GPD 515 A+ (TA1‐4) with A‐ (TA1‐5) If the elevator runs controlled, in the correct direction, proceed to the next step. If the elevator runs controlled but in the wrong direction, with no drive faults, then turn off the main disconnect, and swap the hoist motor field wires. Also swap the encoder wires or the encoder isolation board jumpers back as they were to begin with. Turn the main disconnect on. The car should now run controlled in the correct direction. If not, contact the factory. 5.19 Check Inspection Speed With a hand held tachometer, check the speed of the elevator while running on inspection. The elevator should be running at 25 fpm. Also run the elevator while monitoring speed feedback on the HPV 900, HPV 600 or GPD 515 drive display. The display should show the inspection speed value in feet per minute or in hertz. If the speed on both of these devices reads within +/‐ 2 fpm of the programmed speed, then continue to the next step. If not, contact the factory. If using a GPD 515 drive, the speed display will be in hertz. Top speed will usually be 60Hz. The following formula is used to calculate the speed in Hz. Speed (Hz) = (Speed (fpm)/ Top Speed (fpm)) *60 Example: Top Speed = 200 fpm Inspection Speed = 25 fpm Maximum Drive Frequency = 60 Hz Ins. Speed (Hz) = (25/200) * 60=7.5 Hz 5.20 Check Selector Inputs Run the elevator up on inspection until it stops on the up normal limit. The up and down normal limits should be set two inches above and below the terminal floors respectively. Verify the selector inputs are being set properly on the controller by running the elevator down until it stops on the down normal limit. As the car approaches floor level going down, “DL” turns on first, then “DZ” and then finally “UL”. At floor level, “UL, DL, and DZ” inputs should all be on at the same time. Leaving the floor going down “DL” will turn off first, then “DZ” and last “UL”. 5.21 Verify Slowdown Limits As the car is running down verify that the up and down slowdown sensors for each floor, “US and DS”, activate prior to reaching the landing. Also verify that the up and down terminal slowdown limits inputs “UT, UTS, DT & DTS” are breaking at the proper distances as shown in the slowdown table 2.0. “US and DS” turn on when active but “UT, UTS, DT & DTS” turn off when active. “UT & DT” should turn off one inch closer to the terminal floor levels than when the “US & DS” inputs turn on. P a g e | 89 HPV-600/900 Non-Distance Feedback Turn on the main disconnect, run the elevator on inspection again. 5.22 Verify Car Speed on Safety Processor Board Run the car in both directions and check the car speed on the 1066 LCD interface. The speed shown should match the car’s actual speed. If the speed does not match and the secondary feedback comes from pulses from the tape, go to Section 5.23, Correct Car Speed When using A Tape. If the correct speed is shown proceed to Section 5.24, Automatic Run. 5.23 Correct Car Speed When Using a Tape The tape has holes every 3/8” that are 3/8” in diameter. The safety processor measures the time between each pulse to calculate the velocity. If the velocity is not displayed correctly, first make sure that the feedback type in the safety processor board adjustable variable is set to “0” for a tape application. Next, while the car is running, make sure that the PULSE LED on this board is pulsing. As the car increases in speed the LED will glow solid on. If the LED does not pulse, try swapping the wires at the PPS and PP terminals. If the LED still does not work, contact the factory. If the correct speed is shown proceed to “Final Adjustment”. Figure 5.2: Selector Magnet Placement With the car on inspection, bring it to a normal limit at a terminal landing. Make sure the normal limit input is off. The "AUTO DOOR" switch should be set to the "OFF" position and the "IND" switch should be set to the "IND" position. Set the "INS" switch to the "NORMAL". The car should level into the floor. From the 1021/1101/1005 LCD interface navigate to the "Set Calls and Lockouts" menu, "Setup Car Calls" and enter a car call. The elevator should run to answer the call. When the elevator levels in and stops at the floor, the doors will remain closed. 5.25 Adjust the Drive Speed Profile The S‐Curve parameters in the drive adjust the ride and performance of the car. Since the slowdown distances for each floor are fixed distances, these parameters must be adjusted to bring the car into the floor without over shooting or spotting at the floor. The following parameters adjust the speed profile. With HPV 900 or HPV 600 S‐CURVE A2 Accel Rate 0 Decel Rate 0 Accel Jerk In 0 Accel Jerk Out 0 Decel Jerk In 0 Decel Jerk Out 0 MULTISTEP REF A3 Speed Command 1 Speed Command 2 Speed Command 3 Speed Command 4 With GPD 515 C1‐01 Accel Time 1 C1‐02 Decel Time 1 C2‐01 S‐curve Accel Start P a g e | 91 HPV-600/900 Non-Distance Feedback 5.24 Automatic Run C2‐02 S‐curve Accel End C2‐03 S‐curve Decel Start C2‐04 S‐curve Decel End D1‐03 Freq Ref = Lev Speed D1‐04 Freq Ref = High Speed D1‐09 Freq Ref = Ins Speed Perform a preliminary adjustment of the speed profile from the drive so that several successful runs from floor to floor can be made. If using an HPV 900 or HPV 600, run the adaptive tune procedure next, otherwise, if using a GPD 515 proceed to adjust the stop. Keep in mind that the response of the drive may need to be adjusted. 5.26 Drive Adaptive Tune (HPV 900 /600 Only) To complete the setup of the drive, an adaptive tune is required. It is necessary that the car run 70% of contract speed when running this test so that the drive does not go into flux weakening. In the DRIVE A1 Sub Menu, set the CONTRACT MTR SPD parameter to 70% of the rated motor RPM. If this value was adjusted to correct the top speed of the car, use 70% of the adjusted value. To calculate 70%, multiply the value by 0.7. For example, if the motor RPM is 1050 then 70% of the motor RPM is (1050 x 0.7 = 735). This procedure will also require balanced load in the car. Follow the adaptive tune procedure set in the Magnetek HPV 900 or HPV 600 Technical Manual. After completing the adaptive tune reset the CONTRACT MTR SPD parameter and then proceed to the next step. 5.27 Adjust the Stop When at floor level the “UL, DL, & DZ” input LEDs should be on. If the elevator continually tries to seek floor level by leveling up and down, try the following steps to correct the problem: Increase the response of the drive and retest the car. Reduce the leveling and re‐leveling velocity parameters in the car and retest. Make sure the brake is dropping quickly enough. If the car still oscillates, adjust the "floor level" on the selector. The "floor level" is increased by moving the selector sensor boards closer together. 5.28 Adjust the Start To provide a proper start, from the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and adjust "Brake Pick Del" (brake pick delay) and "Pattern Delay". Also adjust the start jerk rate in the drive. Initially, set the brake pick delay to 0 and increase the pattern delay by 0.1 seconds until the controller picks the brake completely before the motor starts to move. If roll back occurs, then reduce the pattern delay until there is no roll back. Sometimes, the timing works out better if the brake pick delay is set to 0.1 second. Adjust the drive start jerk rate to smooth out the start. With the HPV 900 or HPV 600 Adjust Jerk Rate 1 With the GPD 515 Adjust C2‐01 S‐curve Accel Start Refer to the GPD 515 manual for instructions to adjust the following parameters: B6‐01, B6‐02, B6‐03 and B6‐04 Once the ride is acceptable, proceed to the next step. 5.29 Adjust Safety Processor Board Speed Clamps The 1066 Safety Processor Board monitors the speed of the elevator at the terminal landings independently from the main CPU. When the "UT, DT, UTS, and DTS" limit switches are activated, the 1066 board calculates the velocity of the elevator and compares that velocity with a stored value of speed clamp. If the velocity when the P a g e | 93 HPV-600/900 Non-Distance Feedback If the car spots when approaching the floor, the cause is usually due to the car not tracking. Try increasing the response of the drive again. The deceleration rate can also be reduced a little to help remove the spotting. Once the proper stop is achieved, proceed to the next step. switch activates is greater than the speed clamp value, then the 1066 board will generate a fault that stops the elevator. To set the speed clamps, make a one floor run to the top floor. After the car stops, record the velocity the car hit the “UT, DT, UTS & DTS” slowdown limits. “UTS & DTS” are used on car with reduced stroke buffers or with a top speed greater than 200 fpm. The velocity value is shown from the “LIM VEL” menu on the 1066 LCD interface. The velocity value shown on the display for the “UT or DT” limit is the value after the car activates the limit then counts an adjustable number of counts set from the 1066 LCD interface, "Adj Var" menu, "UT Count" or "DT Count". These count values can be adjusted to provide adequate distance, following the limit switch activation, to allow the elevator to begin its normal decel pattern. The default "UT Count" and "DT Count" values are normally adequate. However, these values may need to be field adjusted to allow enough distance for the car to begin its normal decel pattern. If the "UT Count" and "DT Count" values are modified, the limit velocities must be re‐checked. Run the car again to the top repeatedly from 2 floors, then 3 floors, etc., until top speed is reached. From the 1066 LCD interface "Lim Vel" menu, record the limit velocities displayed each time the car stops at the top floor. Make the same runs to the bottom floor starting from 1 floor, then 2 floors, then 3 floors, etc., until top speed is reached. From the 1066 LCD interface "Lim Vel" menu, record the limit velocities displayed each time the car stops at the bottom floor. Take the highest speed value recorded in the runs above and add 20 fpm to that value to use as the clamp speed values for the respective limit switches. Enter these clamp speed values into the 1066 LCD interface "Adj Var" menu, "UT Vel", "DT Vel", "UTS Vel", "DTS Vel" respectively. The number of slowdown limits depends on the speed of the car as show in the table below: Table 5.1: Slowdown Clamps Place the car on inspection operation. From the 1066 LCD interface, navigate to the "Adj Var" menu, "Ins Vel" and set the speed clamp velocity to 25 fpm. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed" to 50 fpm. Run the car in either direction and verify that the car shuts down when the speed rises above 25 fpm. From the 1066 LCD interface, navigate to the "Adj Var" menu, "Ins Vel" and set the speed clamp to 140 fpm. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed" to the desired value. 5.31 Analog Load Weigher Setup If the job uses an analog load weigher purchased from G.A.L., complete the following procedure. NOTE: It is recommended using two people, one moving the weights and one in the machine room to set up the load weigher. Mount the load weigher as described by the manufacturer. The load weigher control box will also contain a board supplied by G.A.L. that connects to the controller serial CAN bus and reads in the analog output from the load weighing device. Wire the load weigher and G.A.L. board according to the controller schematics. Calibrate the load weighing device hardware according to the manufacturer’s instructions. Following proper installation of the load weighing device, proceed to Section 5.32, Empty Car Setup. 5.32 Empty Car Setup Verify that the load weighing device is communicating to the main CPU by performing the following steps. From the 1021/1101/1005 LCD interface, navigate to the "Diagnostics" menu, "Car Comm Status", "Car to LW Board" and verify that "On‐ line = 1". If "On‐line = 0" then verify wiring and installation of load weighing device. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "Setup Load Weigher" and follow the instructions on the display as you go through the procedure. It is okay to exit the setup screen to place a call and then return to it while the setup is being performed. P a g e | 95 HPV-600/900 Non-Distance Feedback 5.30 Verify Inspection Velocity Clamp on Safety Processor Board Run the car to the bottom floor and press Enter on the 1021/1101/1005 LCD interface when prompted, to start the automatic setup sequence. If the car is at the bottom floor and the doors are not closed, (the doors will not close automatically from turning off the auto‐door switch), then place a car call to run the car up one floor then back again. The doors will close when the call is placed. When the automatic sequence is activated, the car will run to each floor and measure the empty load value. The 1021/1101/1005 LCD interface will indicate when the sequence if finished. 5.33 Full Car Setup NOTE: The empty car setup must be successfully completed to run the full load setup. Once the empty car setup is complete, run to the loading floor and set the "AUTO DOOR" switch to the "ON" position to allow weights to be loaded on the car. With the car fully loaded, set the "AUTO DOOR" switch to the "OFF" position and run the car to the bottom floor. Again if the doors are not closed, make a one floor run to force the doors to close. With the car at the bottom floor, follow the instructions on the 1021/1101/1005 LCD interface to start the full load setup sequence. The car will automatically run to each floor and measure the full load value. When the full load measurement is complete, the car can be run to the loading floor and the weights removed. After the weights are removed, cycle the doors to complete the procedure. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "View/Modify LW Setup" and verify the load weigher status, "LW Device Stat: ON OK". If the status is "ON OK", then the load weigher should be accurately measuring the car load in real time. The percent load will be displayed, "Load: %". The percent load values for different service options can now be set. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Service Options", and set the following variables: "Load Bypass" "Load Antinuisance" "Load Dispatch" "Load Overload" 5.34 Load Weighing Calibration Sequence The load weigher is automatically calibrated once each week. If an error is detected during this calibration sequence, the load weigher and the pre‐torque feature (if used) is disabled. A load weighing calibration sequence can be manually activated by performing the following procedure. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "Load Weigher Calibration" and follow the instructions on the display. 5.35 Check the Doors The elevator should now be adjusted. Verify that all door locks, gate switches, and safety circuits are operational. Set the "INS" switch to the "NORM" position and set the "AUTO DOOR" switch to the "ON" position. The elevator should open the doors. If the doors do not open, c h e c k the door operator wiring and cam adjustment. If the doors do open, the elevator is now on independent service. 5.36 Fine Tune Ride and Stops Ride the elevator and evaluate the ride quality. Fine‐tune the ride quality with the drive S‐Curve parameters in the drive. Fine‐tune the floor level magnets. Check all signal devices for proper operation and remove any temporary jumpers. The adjustment should now be complete. P a g e | 97 HPV-600/900 Non-Distance Feedback NOTE: Setting the values of the variables above to 0% will disable that particular option. Section 6 ‐ Adjustment of the GALaxy Controller DC Quattro Drive 6.1 General Information In order to obtain a running platform in "car top inspection", see the "Quick Start‐up Guide for GALaxy Controller Quattro DC Drive with Distance Feedback". This procedure should be used only for installation purposes. When installation of all equipment is complete, and unit is ready for adjustment, proceed to Section 6.2, Check Mail Line Voltage, and follow instructions. Before adjustment begins the following items must be completed: 1. All field wiring and safety circuits installed 2. Temporary jumpers from terminal “HC” to terminals “MES & ALT” 3. All hoistway limit switches installed 4. All car and hoistway doors and interlocks installed and pre‐adjusted 5. Selector installed and magnets pre‐adjusted 6. Familiarize yourself with all wiring schematics 7. Familiarize yourself with the Quattro drive, drive manual, parameter adjustment, etc. 8. Motor encoder should be properly installed and wired. 9. Car should be properly counterbalanced. 6.2 Check Main Line Voltage With main‐line disconnect in the “OFF” position, check the line‐side voltage with a volt meter to insure the voltage matches the controller name tag “Input Power” voltage. Check to insure all three phases are present. If voltage is not correct or all three phases are not present, do not proceed until corrected. 6.3 Set Toggle Switches Set all toggle switches on the 1064 board as follows: DOOR LOCKS ‐ "OFF" IND ‐ "IND" AUTO DOOR ‐ "OFF" STOP ‐ "STOP" INSPECTION ‐ "INSP" 6.4 Make Sure the Car Is Safe Verify that all elevator doors are closed and that all safety circuits are functional. 6.5 Check Controller Voltage Turn the main‐line disconnect to the on position. Check the voltage at L1, L2, and L3 on the Quattro drive. Verify that all three phases are present. Check the voltage at fuses L1, L2, and L3 (if present) on controller. If correct, check the voltage at terminal “LIN” with respect to “GND”. The voltage should read 120VAC. If correct, check the voltage at terminals “S10, LC, & HC” with respect to “GND”. All should read 120VAC. If not, check wiring diagram to determine problem before continuing Check to make sure that the “axy” of GALaxy on the 1021/1101/1005 LCD interface is blinking. If the “axy” is blinking, continue to the next step. If not, check voltage at terminals 5V to 0V on the 1064 board to insure 5VDC. If 5VDC is present and the “axy” on the 1021/1101/1005 LCD interface is not blinking, then contact factory. 6.7 Preset Adjustable Variables on Safety Processor Board and Main CPU The 1066 LCD interface (safety processor board) and the 1021/1101/1005 LCD interface (main CPU) are normally preset prior to leaving the factory. However, it is prudent to check the setup values for the proper settings. Refer to Section 13 of this manual for the operation of the 1066 LCD interface, and refer to Section 10 for operation of the 1021/1101/1005 LCD interface. The following adjustable variables must be set properly: NOTE: If the controller uses an NTS board please refer to Section 14, GALX-0320AN NYSD Board. 6.8 1066 LCD interface "Adj Var" Menu Top Spd (contract speed) Enc RPM (if Fdbk Typ=0 (Tape), not applicable) (if Fdbk Typ=1 (Encoder), set to rpm of governor) (if Fdbk Typ=4 (, set to value of CONTRACT MTR SPD in Quattro drive) Enc PPR (if Fdbk Typ=0 (Tape), not applicable) (if Fdbk Typ=1 (Encoder), set to 8192) (if Fdbk Typ=4 (Incremental Encoder), set to ppr of machine/motor encoder) Fdbk Typ (0=tape, 1=enc, 4=InENC) P a g e | 99 DC Quattro Drive 6.6 Verify the Main CPU is Operating Ctrl Typ (2=Tract DF) 2 Stop (0=Mult, 1=2 stop) RearDoor (0=Front only, 1=Rear) UTS Vel (Set to top speed) DTS Vel (Set to top speed) INS Vel (Set to 140) LEV Vel (Set to 140) UT Vel (Set to top speed) DT Vel (Set to top speed) UL Vel (Set to 160 if Non‐DF) DL Vel (Set to 160 if Non‐DF) SoftStop (Set to 3) NOTE: The velocity values for the terminal limit switches above are only temporary settings until car is running high speed. In the final adjustment procedure, these variables must be set according to the procedures in Section 6.32, Adjust Safety Processor Board Speed Clamps. 6.9 1021/1101/1005 LCD interface "Adjustable Variables ->Car Motion" Submenu Top Speed (set to contract speed) Inspect Speed (set to 25 fpm) Encoder PPR (set to machine/motor encoder PPR) Encoder RPM (if tape selector, set to value of CONTRACT MTR SPD in Quattro drive), (if 485 tapeless selector, set to value of CONTRACT MTR SPD in Quattro drive), (if CAN open tapeless selector, set to governor rpm) NOTE: See Section 6.24, Correct Car Speed When Using 485 Tapeless System, for determining governor rpm. 6.10 Place Stop Switch in Run Position Set the “STOP” toggle switch on the 1064 board to the up position. Verify that input LED’s for “LC, HC, DN, UN, SS, GTS, RDY and CS” are all on. If not, then correct field wiring. 6.11 Hoist Motor Data At this time the hoist motor data must be entered into the Quattro drive. The following functions must be entered or verified using the drive display unit. Follow the instructions in the Quattro drive manual to enter the following data for each function: Drive A1 CONTRACT CAR SPD (from controller data) CONTRACT MTR SPD (from motor nameplate) NOTE: The CONTRACT MTR SPD value may need to be fine‐tuned to provide the correct rpm to run the machine/motor at controller demanded speed. ENCODER PULSES (PPR of encoder on machine/motor) DC Quattro Drive Line Side Power Convert A5 INPUT L‐L VOLTS (measured at drive) Motor A6 RATED MTR CURRENT (from machine/motor nameplate) ARMATURE VOLTAGE (from machine/motor nameplate) FULL FLD CURRENT (from controller data) WEAK FIELD CURRENT (from controller data) STANDBY FIELD (from controller data) 6.12 Quattro Drive Self‐Tune To have the Quattro drive unit learn the parameters of the hoist motor the drive self‐ tune must be performed. Place a temporary jumper from S10 to terminal MC on the GALX‐ 1064AN board. This will energize the MC contactor coil to enable the drive to perform a motor self‐tune. Turn on the main disconnect. Navigate to the Auto Tune option under MS Pwr Convert A4 on the Magnetek Operator. The Magnetek Operator will display “Start Tune?” Press the enter key on the Magnetek operator to start the auto tune process. During this test, the “ME” contactor in the Quattro drive will energize for short period of time. After the self‐ tune is performed correctly, “Auto Tune Finish” will appear on the Magnetek Operator. If a fault appears on the Magnetek Operator, the problem must be corrected and the self‐tune performed again. If the self‐tune is successful, then the following functions must be viewed and recorded under MS Power Data D2. Auto Meas Arm L P a g e | 101 Auto Meas IRDrop Auto Meas Arm R Auto Field Res Auto Field TC The value of MS Power Data D2 Auto Meas Arm L should be manually entered into Function MS Pwr Convert A4, Arm Inductance. The value of MS Power Data D2 Auto Meas Arm R should be manually entered into Function MS Pwr Convert A4, Arm Resistance. The value of MS Power Data D2 Auto Field Res should be manually entered into Function MS Pwr Convert A4, Motor Field Res. The value of MS Power Data D2 Auto Field TC should be manually entered into Function MS Pwr Convert A4, Motor Field TC. After these values are entered successfully, set parameter MS Pwr Convert A4, Gain Selection to “Use Self Tune”. Remove temporary jumper from S10 to MC on the GALX‐1064AN board. 6.13 Pre‐set the Digital Speed Clamps Pre‐set the software digital speed clamps from the 1021/1101/1005 LCD interface under the “Elevator Setup Menu”. The submenus for the clamp speeds are as follows: Set Ins /Leveling Clamp Set DT/UT Slowdown Clamp Set DT1/UT1 Slowdown Clamp Set DT2/UT2 Slowdown Clamp Set DT3/UT3 Slowdown Clamp Set DTS/UTS Slowdown Clamp Set the speed for Ins/Leveling for 140 fpm and all the remaining slowdown limit speeds to the contract speed of the car. Please note that the displayed value of “Clamp Speed” is the value the clamp should be set to. The slowdown limit “Clamp Speed:” will show 0000 until the car is run into the limits and the speed is recorded. Please refer to Section 10, 1021/1101/1005 LCD Interface, for the Elevator Setup Menu. NOTE: The values of the clamp speed velocities above are only temporary settings until the car is running high speed. In the final adjustment procedure, these values must be set according to the procedures in Section 6.33, Adjust Digital Slowdown Speed Clamps. 6.14 Ready to Run On Inspection The car should be ready to run on inspection if all is wired correctly. Select the “Elevator Status” on the 1021/1101/1005 LCD interface. The display should show “Out of Service” on the first line and “Inspection Mode” on the second. The 1021/1101/1005 LCD interface on the Safety Processor Board will display one of the following types of inspection: “MR INS” (Motor Room) “CT INS” (Car Top) “ACCESS” (Access) “IC INS” (In Car) “AUTO” (Not on Inspection) DC Quattro Drive To run the car from the motor room, “MR INS” should be displayed. The “inspection string” consists of contacts from the inspection switches and the gate and lock bypass switches in series. One and only one of the five inspection inputs should be on for the car to run. Starting from the car top inspection input, the five inspection inputs are, “INS” for car top, “ACC” for access, “ICI” for in‐ car, “MRI” for motor room, and “AUTO” for automatic (no inspection). The inspection string circuit is shown in Figure 6.1. NOTE: Any one of the following conditions will cause an inspection error: More than one inspection input is on No inspection input is on Gate or Lock bypass switch is open and the car is not on car top inspection If the controller is not on motor room inspection at this point, then verify all switch positions and wiring before proceeding. P a g e | 103 Figure 6.1: Inspection String Circuit 6.15 Adjust the Brake Voltage Momentarily push the inspection “UP” or “DOWN” push button on the 1064 board while checking the DC brake voltage with a meter. If the voltage is not correct, it must be adjusted according to the following procedures. If the controller utilizes an electronic brake board 1047 or 1051, then the brake voltage is adjusted through the 1021/1101/1005 LCD interface, "Car Brake" sub‐ menu. If the controller utilizes resistors and rectifiers for the brake coil circuit, then the brake voltage is adjusted by moving the adjustable tap on the brake resistor. NOTE: Remove power before adjusting the resistor taps. 6.16 Check the Run Direction Momentarily push the inspection “UP” or “DOWN” push button on the 1064 board. One of the following should take place: The elevator will run controlled, in the correct direction (up for “UP” button, down for “DOWN” button) with no drive faults. If so, proceed to “Check Inspection Speed”. The elevator will run controlled, but in the wrong direction (down for “UP” button, up of “DOWN” button) with no drive faults. If so, proceed to Section 6.17, Car Runs In The Wrong Direction. The elevator will try to run, but immediately trip on a drive fault “Encoder Fault”. If so, proceed to Section 6.18, Drive Trips immediately. 6.17 Car Runs in The Wrong Direction If the elevator runs controlled but in the wrong direction, with no drive faults, then turn off the main disconnect, swap the hoist motor field wires. Also swap the encoder direction by swapping the encoder wires or if an encoder isolation board (1022N) is used, move J5 and J7 on the encoder board. Refer to the jumper diagram on the board. P a g e | 105 DC Quattro Drive To adjust the brake voltage when using and electronic brake board, navigate to the "Adjustable Variables" menu, "Car Brake" and adjust "Brake Pick Volt", "Brake Hold Volt" and "Brk AC L‐L Volt" to the proper values. Make sure that the brake is lifting and setting properly before proceeding. J5 swaps A & A NOT – J7 swaps B & B NOT. To change the encoder direction at the drive, swap the following wires: A+ (TB3‐2) with B+ (TB3‐4) A‐ (TB3‐3) with B‐ (TB3‐5) Turn the main disconnect on, run the elevator on inspection again, and it should run controlled and in correct direction. If so, proceed to “Check Inspection Speed”. If not, contact the factory. 6.18 Drive Trips Immediately If the elevator tries to run, but immediately trips on a drive fault “Encoder Fault”, then turn off the main disconnect, and swap the encoder direction by swapping the encoder wires or if an encoder isolation board (1022N) is used, move J5 and J7 on the encoder board. Refer to the jumper diagram on the board. J5 swaps A & A NOT – J7 swaps B & B NOT. Turn on the main disconnect and run the elevator on inspection again. If the elevator runs controlled and in the correct direction, proceed to next section. If the elevator runs controlled but in the wrong direction, then go back and follow the directions in Section 6.17, Car Runs The Wrong Direction. If the car still trips immediately on a drive fault, then contact the factory. 6.19 Check Inspection Speed With a hand held tachometer, check the speed of the elevator while running on inspection. The elevator should be running at 25 f.p.m. Also run the elevator while monitoring Function Speed Feedback on the Quattro drive under Display D0, Elevator Data D1, and Speed Feedback. This function should also read 25 f.p.m. From the 1021/1101/1005 LCD interface select the "Elevator Status" menu, navigate until the display shows "Dmd" and "Vel". While running on inspection, monitor the controller demand speed "Dmd", and the speed feedback "Vel". These values should both display 25. If the demand and feedback on the 1021/1101/1005 LCD interface is incorrect, check the Encoder RPM and PPR parameters from the “Adjustable Variables” menu. These variables should be set to values listed in Section 6.9, 1021/1101/1005 LCD interface "Adjustable Variables ->Car Motion" Submenu. If the speed on the hand held tachometer and on "Dmd" and "Vel" all read approximately 25 fpm (within +/‐2 fpm) continue to the next step. If not, contact the factory. 6.20 Verify Controller Encoder Direction From the 1021/1101/1005 LCD interface "Elevator Status" menu, navigate to display "Dir" and "DP". While moving the car on inspection, monitor "Dir" (direction) and "DP" (pulse counts). "Dir" should display "Up" when the car is moving up, and "Dn" when the car is moving down. The value of "Dp" should increment when the car is moving up, and should decrement when the car is moving down. If the direction is wrong or the pulse counts change in the wrong direction, then the encoder direction to the controller must be changed. If an encoder isolation board (1022N) is used, move J1 and J3 on the encoder board. Refer to the jumper diagram on the board. J1 swaps A & A NOT – J3 swaps B & B NOT. If the encoder is counting properly continue to the next step. If not, contact the factory. 6.21 Verify Selector and Slowdown Inputs Run the elevator up on inspection until it stops on the up normal limit. The up and down normal limits should be set two inches above and below the terminal floors respectively. Verify the selector inputs are being set properly on the controller by running the elevator down until it stops on the down normal limit. As the car approaches floor level going down, “DL” turns on first, then “DZ” and then finally “UL”. At floor level, “UL, DL, and DZ” inputs should all be on at the same time. Leaving the floor going down “DL” will turn off first, then “DZ” and last “UL”. Also verify that the up and down terminal slowdown limits inputs “UT, UTS, DT & DTS” are breaking at the proper distances as shown in the slowdown table 2.0. “UT, UTS, DT & DTS” turn off when active. 6.22 Verify Car Speed on Safety Processor Board Run the car in either direction and check the car speed on the 1066 LCD interface. The speed shown should match the car’s speed actual speed. If the speed does not match and the secondary feedback comes from pulses from the tape go to “Correct Car Speed When Using A Tape”. If using 485 tapeless, go to "Correct Car Speed When Using 485 tapeless". If using CAN Open tapeless, go to "Correct Car P a g e | 107 DC Quattro Drive If no encoder isolation board is used, the A+ and A‐ encoder wires from the drive must be swapped. Note that the motor encoder wires are daisy chained from the encoder to the drive and then from the drive to the controller encoder board. Only the A+ and A‐ wires from the drive to the controller board must be swapped. The wires from the encoder to the drive must remain on the same terminal locations on the drive. Speed When Using CAN Open tapeless". If the correct speed is shown proceed to Section 6.26, Learn the Hoistway. 6.23 Correct Car Speed When Using A Tape Installed In Hoistway The tape has holes every 3/8” that are 3/8” in diameter. On the selector unit adjust the PP sensor closer to the tape until the orange LED at the end of the sensor turns on. Then turn the sensor inwards another 1/8” and lock in the sensor. While running on top of car inspection verify that the orange LED at the end of the PP sensor turns on and off as it passes by the holes on the tape. The safety processor measures the time between each pulse to calculate the velocity. If the velocity is not displayed correctly first make sure that the feedback type in the safety processor board adjustable variable is set to 0 for a tape application. Next, while the car is running, make sure that the PULSE LED on this board is pulsing. As the car increases in speed the LED will glow solid on. If the LED does not pulse, try swapping the wires at the PPS and PP terminals. If the LED still does not work, contact the factory. If the correct speed is shown proceed to “Learn the Hoistway”. 6.24 Correct Car Speed When Using 485 Tapeless System When using the 485 tapeless system, the secondary speed feedback comes from the encoder mounted on the governor. The 1066 board uses a serial interface to a Turck absolute encoder, part # T8.5882.3F0B.3001. In the 1066 LCD interface "Adj Var" menu, set the "Fdbk Typ = 1", and set the "Enc PPR = 8192". The "Enc RPM" value must be calculated as described below. To calculate the RPM, divide the contract speed of the car by the distance travel in one revolution with the governor as shown below: RPM = Speed fpm/ (diameter GOV * pi) For a 1 ft. diameter governor: RPM = 350/ (1*pi) = 350/3.1415 = 111.4 For a 16 in diameter governor (16/12 = 1.33ft): RPM = 350/ (1.33* 3.1415) = 350/4.188 = 83.5 6.25 Correct Car Speed When Using CAN Open Tapeless System When using the CAN Open tapeless system, the secondary speed feedback comes from the incremental encoder mounted on the machine/motor. In the 1066 LCD interface "Adj Var" menu, set the "Fdbk Typ = 4", and set the "Enc PPR" equal to the ppr of the machine/motor‐mounted incremental encoder, and set the "Enc RPM" to the rpm of the machine/motor at contract speed. On the 1066 LCD interface, navigate to the "Pls Cnt" menu. While running the elevator on inspection, verify that the pulse count value increments when running up and decrements when running down. The "Pls Cnt" value can be considerably out of range but will automatically correct during the "Learn Hoistway" procedure. To reverse the direction of pulse counting, navigate, on the 1066 LCD interface, to the "Adj Var" menu, "Enc Dir" and set to "0" for clockwise or "1" for counter‐clockwise. Navigate on the 1066 LCD interface to the "Car Spd" menu. Monitor the "Car Spd" while running the car at a known inspection speed. The value displayed should match the actual car speed measured with a hand held tachometer. If not, re‐check the values set in "Enc RPM" and "Enc PPR" in the 1066 LCD interface. If the speed is correct, proceed to Section 6.26, Learn the Hoistway. 6.26 Learn the Hoistway In general, the car will run up from the "down normal limit" to the "up normal limit" at 30 fpm. During this learn run, the DP count for each floor level and each limit switch will be stored in memory. NOTE: The car must run the entire hoistway without stopping. As the elevator moves up the hoistway, navigate to the "Hoistway Tables" menu, "Disp/Mod Hoistway Table", and verify that the "DP" count is incrementing as the elevator moves up. Also as the elevator passes each floor, the pulse count and distance for that floor should change and be stored. Verify that the floor distances are valid. The pulse count for the terminal slowdowns will also be stored. The elevator will stop when it reaches the up normal limit. Follow the instructions on the 1021/1101/1005 LCD interface by putting the car on inspection, and then the message "Hoistway Learn Complete" should be displayed. Move the elevator on inspection until the “DZ and DL” LED’s are on. Set the “INS” toggle switch on the 1064 board to the “NORMAL” position, and the elevator should level down to floor level at the top floor. If so, proceed to final adjustment. If the car levels down but does not run, then check “Elevator Status” and “View Fault Log” on the 1021/1101/1005 LCD interface for any fault information. Correct items causing faults and perform hoistway learn again. After problem is corrected and a successful hoistway learn is performed, proceed to final adjustment. P a g e | 109 DC Quattro Drive Run the elevator down on inspection until it stops on the down normal limit switch. Verify that the “DN and DL” input LED’s are both off. From the 1021/1101/1005 LCD interface navigate to the "Elevator Setup" menu, "Learn Hoistway". The learn procedure can be performed automatically by choosing "Auto" from the menu items, or performed manually by choosing "Insp" from the menu items. After choosing the learn method, follow the instructions displayed on 1021/1101/1005 LCD interface. 6.27 Automatic Run The elevator should now be sitting idle at the top floor. The "AUTO DOOR" switch should be set to the "OFF" position and the "IND" switch should be set to the "IND" position. If the learn procedure was successful, the elevator should be ready to make an automatic run. The default parameter settings for the ride quality should be adequate for an initial r u n . From the 1021/1101/1005 LCD interface navigate to the "Set Calls and Lockouts" menu, "Setup Car Calls" and enter a car call. The elevator should run to answer the call. When the elevator levels in and stops at the floor, the doors will remain closed. The acceleration and deceleration of the car should be smooth and stepless regardless of the distance of the run. If the elevator does not function as described above, then the problem should be analyzed before proceeding. 6.28 Fine Tune the Ride Quality In order to fine tune the ride quality, refer to Figure 6.2 which describes what part of the S‐ curve that the different parameters effect. In general, higher numbers in the given parameters, cause quicker and more abrupt changes from one mode to the next during a run. All of the S‐curve parameters have a minimum and maximum value. The control will not allow you to enter values that are not valid. After adjusting the S‐ curve parameters, proceed to the next step. Figure 6.2: S‐Curve Parameters 6.29 Adjust the Stop When at floor level the “UL, DL, & DZ” input LED’s should be on. If the elevator continually tries to seek floor level by leveling up and down, check the motor field voltage to be at the nameplate voltage while leveling. If the motor field voltage is correct but the car seems sluggish then increase the response of the drive by increasing the value of RESPONSE in the drive A1 submenu. If the car still re‐levels at the floor, try the following steps to correct the problem: 1. Reduce the leveling and re‐leveling velocity parameters from the 1021/1101/1005 LCD interface "Adjustable Variables" menu, "Car Motion", "Leveling Speed" and "Relevel Speed". 2. If the car still oscillates, adjust the "floor level zone" on the selector. The "floor level zone" is increased by moving the "UL" and "DL" sensors closer together. The "Soft Stop Time" setting in the 1021/1101/1005 LCD interface should be compared with the setting in the 1066 LCD interface "Adj Var" menu, "SoftStop". The setting of "SoftStop" in the 1066 LCD interface should be greater than the "Soft Stop Time" setting in the 1021/1101/1005 LCD interface. If the car spots when approaching the floor, the cause is usually due to the car not tracking (the drive response is set too low) or the speed profile into the floor is too aggressive. First try to increase the response by increasing the value of drive parameter A1 RESPONSE. If the car still spots, from the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and increase the value of "Floor Targ Dis" (floor targeting distance). The default value for the floor targeting distance is 12 inches. Increase it by steps of 2 or 3 and continue retesting until the parameter is adjusted to 18. If no change is noticed, start again from 12 and decrease the value. P a g e | 111 DC Quattro Drive If the car stops hard on the brake, then make the following adjustments. From the 1021/1101/1005 LCD interface navigate to the "Adjustable Variables" menu, "Car Motion", and adjust both "Brake Drop Del" (brake drop delay) and "Soft Stop Time". These variables should be adjusted so that zero speed is observed at the end of the run prior to the brake setting. The controller should hold the car at zero speed for the duration of the "Soft Stop Time" which should continue while the brake is setting and for a short time after the brake sets. The soft stop time MUST be set to at least 0.5 seconds LONGER than the brake drop delay. The deceleration rate can also be reduced to help remove the spotting. Once the proper stop is achieved, proceed to “Adjust The Start”. 6.30 Adjust the Start To provide a proper start, from the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and adjust "Brake Pick Del" (brake pick delay), "Pattern Delay", and "Soft Start Jerk". Initially, set the brake pick delay to 0 and increase the pattern delay by 0.1 seconds until the controller picks the brake completely before the motor starts to move. If roll back occurs, then reduce the pattern delay until there is no roll back. Sometimes, the timing works out better if the brake pick delay is set to 0.1 second. If load weighing is used, pre‐torquing can be used to provide a smoother start. See Section 6.39, Adjust the Motor Pre‐torque. Increase the soft start jerk rate in order to provide a quicker transition from the start to constant acceleration. Keep in mind that the larger the soft start number, the quicker the start. The ride should now be acceptable. 6.31 Verify Top Speed To fine tune high speed, make high speed runs while monitoring Elevator Data Submenu D1, Speed Feedback on the Quattro drive display. The display should read contract speed. If the speed is slightly under or over contract speed then verify that Drive A1 Submenu, Contract MTR SPD is set properly. The speed displayed on the drive should match the speed displayed on the 1021/1101/1005 LCD interface, "Elevator Status" menu, "Dmd" and "Vel". This speed should also match the speed displayed on the 1066 LCD interface, "Car Spd" menu. When all of these speeds are the same (+/‐ 2 fpm), then proceed to the next step. When the Quattro display reads contract speed, proceed to the next step. 6.32 Adjust Safety Processor Board Speed Clamps The 1066 Safety Processor Board monitors the speed of the elevator at the terminal landings independently from the main CPU. When the "UT, DT, UTS, and DTS" limit switches are activated, the 1066 board calculates the velocity of the elevator and compares that velocity with a stored value of speed clamp. If the velocity when the switch activates is greater than the speed clamp value, then the 1066 board will generate a fault that stops the elevator. To set the speed clamps, make a one floor run to the top floor. After the car stops, record the velocity the car hit the “UT, DT, UTS & DTS” slowdown limits. “UTS & DTS” are used on car with reduced stroke buffers or with a top speed greater than 200 fpm. The velocity value is shown from the “LIM VEL” menu on the 1066 LCD interface. The velocity value shown on the display for the “UT or DT” limit is the value after the car activates the limit then counts an adjustable number of counts set from the 1066 LCD interface, "Adj Var" menu, "UT Count" or "DT Count". These count values can be adjusted to provide adequate distance, following the limit switch activation, to allow the elevator to begin its normal decel pattern. The default "UT Count" and "DT Count" values are normally adequate. However, these values may need to be field adjusted to allow enough distance for the car to begin its normal decel pattern. If the "UT Count" and "DT Count" values are modified, the limit velocities must be re‐checked. Run the car again to the top repeatedly from 2 floors, then 3 floors, etc., until top speed is reached. From the 1066 LCD interface "Lim Vel" menu, record the limit velocities displayed each time the car stops at the top floor. Take the highest speed value recorded in the runs above and add 20 fpm to that value to use as the clamp speed values for the respective limit switches. Enter these clamp speed values into the 1066 LCD interface "Adj Var" menu, "UT Vel", "DT Vel", "UTS Vel", "DTS Vel" respectively. 6.33 Adjust Digital Slowdown Speed Clamps Having just made several runs into the top and bottom landings, the main CPU has also recorded the car’s velocity when the slowdown limits were activated. If the car has been powered down prior to this step, several runs must be made to the terminal landings to allow the main CPU to record the limit velocity values. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Set DT/UT Slowdown Clamp" and view the speed displayed for "Clamp Speed". Add 20 fpm to this "Clamp Speed" value and enter it into the "DT/UT Limit" value. The number of slowdown limits depends on the speed of the car as shown in the table below. Adjust speed clamps for each slowdown limits used as determined by the elevator’s contract speed. P a g e | 113 DC Quattro Drive Make the same runs to the bottom floor starting from 1 floor, then 2 floors, then 3 floors, etc., until top speed is reached. From the 1066 LCD interface "Lim Vel" menu, record the limit velocities displayed each time the car stops at the bottom floor. The number of slowdown limits depends on the speed of the car as show in the table below: Table 6.1: Slowdown Clamps 6.34 Verify Inspection Velocity Clamp On Safety Processor Board Place the car on inspection operation. From the 1066 LCD interface, navigate to the "Adj Var" menu, "Ins Vel" and set the speed clamp velocity to 25 fpm. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed" to 50 fpm. Run the car in either direction and verify that the car shuts down when the speed rises above 25 fpm. From the 1066 LCD interface, navigate to the "Adj Var" menu, "Ins Vel" and set the speed clamp to 140 fpm. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed" to the desired value. 6.35 Analog Load Weigher Setup If the job uses an analog load weigher purchased from G.A.L., complete the following procedure. NOTE: It is recommended using two people, one moving the weights and one in the machine room to set up the load weigher. Mount the load weigher as described by the manufacturer. The load weigher control box will also contain a board supplied by G.A.L. that connects to the controller serial CAN bus and reads in the analog output from the load weighing device. Wire the load weigher and G.A.L. board according to the controller schematics. Calibrate the load weighing device hardware according to the manufacturer’s instructions. Following proper installation of the load weighing device, proceed to Section 6.36, Empty Car Setup. 6.36 Empty Car Setup Verify that the load weighing device is communicating to the main CPU by performing the following steps. From the 1021/1101/1005 LCD interface, navigate to the "Diagnostics" menu, "Car Comm Status", "Car to LW Board" and verify that "On‐ line = 1". If "On‐line = 0" then verify wiring and installation of load weighing device. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "Setup Load Weigher" and follow the instructions on the display as you go through the procedure. It is okay to exit the setup screen to place a call and then return to it while the setup is being performed. If the car is at the bottom floor and the doors are not closed (the doors will not close automatically from turning off the auto‐door switch) then place a car call to run the car up one floor, then back again. The doors will close when the call is placed. When the automatic sequence is activated, the car will run to each floor and measure the empty load value. The 1021/1101/1005 LCD interface will indicate when the sequence if finished. 6.37 Full Car Setup The empty car setup must be successfully completed to run the full load setup. Once the empty car setup is complete, run to the loading floor and set the "AUTO DOOR" switch to the "ON" position to allow weights to be loaded on the car. With the car fully loaded, set the "AUTO DOOR" switch to the "OFF" position and run the car to the bottom floor. Again if the doors are not closed, make a one floor run to force the doors to close. With the car at the bottom floor, follow the LCD interface instructions to press enter to start the full load setup sequence. The car will automatically run to each floor and measure the full load value. When the full load measurement is complete, the car can be run to the loading floor and the weights removed. P a g e | 115 DC Quattro Drive Run the car to the bottom floor and press Enter on the 1021/1101/1005 LCD interface when prompted to do so to start the automatic setup sequence. After the weights are removed, cycle the doors to complete the procedure. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "View/Modify LW Setup" and verify the load weigher status, "LW Device Stat: ON OK". If the status is "ON OK", then the load weigher should be accurately measuring the car load in real time. The percent load will be displayed, "Load: %". The percent load values for different service options can now be set. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Service Options", and set the following variables: "Load Bypass" "Load Antinuisance" "Load Dispatch" "Load Overload" NOTE: Setting the values of the variables above to 0% will disable that particular option. 6.38 Load Weighing Calibration Sequence The load weigher is automatically calibrated once each week. If an error is detected during this calibration sequence, the load weigher and the pre‐torque feature (if used) is disabled. A load weighing calibration sequence can be manually activated by performing the following procedure. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "Load Weigher Calibration" and follow the instructions on the display. 6.39 Adjust the Motor Pre‐torque NOTE: The motor pre‐torque uses the load value obtained from the analog load weigher and will only work if the load weigher has been installed properly, and the "Load Weigher Setup" has been performed successfully. On the Quattro drive under User Switches C1 parameter, set Pre‐Torque source to serial. Run the empty car to a middle floor. From the 1021/1101/1005 LCD user interface, navigate to the "Adjustable Variables" menu, "Car Motion" and adjust the following parameters: "Balanced Load = 40" (typically car is 40% counterbalanced, but verify counterbalance percentage for each specific job) "Torque Amount = 10" "Pattern Delay = 2.5" "Brake Pick Del = 0.1" The long pattern delay will allow an exaggerated amount of roll back in order for the pre‐torquing to be set accurately. Make a one floor run down and observe the roll back when the brake picks at the start of the run. Increase the "Torque Amount" variable and continue to monitor the roll back while performing one floor runs in the down direction. As the "Torque Amount" is increased, the roll back should be minimized until the car will hold zero speed for the entire "Pattern Delay" time. A typical value for the "Torque Amount" is 40%. If the value is too large, the car will roll forward during the "Pattern Delay" time. 6.40 Verify the Doors Are Safe The elevator should now be adjusted. Verify that all door locks, gate switches, and safety circuits are operational. Set the "INS" switch to the "NORM" position and set the "AUTO DOOR" switch to the "ON" position. The elevator should level into the floor and open the doors. If the doors do not open, check the door operator wiring and cam adjustment. If the doors do open, the elevator is now on independent service. 6.41 Fine Tune the Ride Quality Ride the elevator and evaluate the ride quality. Fine tune the ride quality by navigating to the "Adjustable Variables" menu, "Car Motion" and adjusting the variables shown in Figure 6.2. Keep in mind that if acceleration or deceleration values are changed, the speed clamps for the safety processor board and the S‐curve board may need to be re‐adjusted. To fine tune the floor level accuracy, determine if the controller is set to stop when "UL" and "DL" signals turn on, or if controller is set to stop off of the position count. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and view the "Stop On Pos Cnt" variable. If “Stop On Pos Cnt= 0” then the controller is set to stop when the "UL and "DL" signals turn on. If "Stop On Pos Cnt = 1" then the controller is set to stop on a combination of the floor level magnet and the position count. P a g e | 117 DC Quattro Drive NOTE: The pattern delay must be at least 0.15 seconds (150 milliseconds). Setting the torque amount to 0.00 will disable the pre‐ torque feature. Also if the load weighing calibration sequence detects a load weighing error, the pre‐ torque feature is also automatically disabled. With "Stop On Pos Cnt = 0", the floor levels should be set by adjusting the floor level magnet at each floor. For proper operation, the floor magnets should be set to exactly floor level. After the floor levels are set properly, perform another hoistway learn procedure. With "Stop On Pos Cnt = 1", the floor levels are set by using both the floor magnet and the position count. For proper operation with this setting, the floor magnet should be set to exactly floor level. The final stop can then be fine‐tuned by performing the following adjustments. From the 1021/1101/1005 LCD interface, navigate to the "Hoistway Tables" menu, "DZ & LZ Offset, Sel Cnt" and adjust "Dn Lev Dist" and "Up Lev Dist". The units for these variables are in "pulse counts". With "Stop On Pos Cnt =1" the car will continue to move for the "Dn Lev Dist" or "Up Lev Dist" after "UL and DL" turn on. Use the "Dn Lev Dist" and the "Up Lev Dist" parameters to make level changes at all floors. To make level changes at individual floors, perform the following adjustments. From the 1021/1101/1005 LCD interface, navigate to the "Hoistway Tables" menu, "FL and FL Offset Count", and the offset count can be adjusted. These variables introduce an offset (+/‐) to the stored floor count that was determined in the hoistway learn procedure. NOTE: The number of pulse counts per inch can be viewed from the 1021/1101/1005 LCD interface, "Hoistway Tables", "DZ & LZ Offset, Sel Cnt”, "Pulses /Inch". NOTE: Regardless if "Stop On Pos Cnt=0" or if "Stop On Pos Cnt =1", the floor magnet must be set properly at floor level. If too large of values are entered into "Dn Lev Dist", "Up Lev Dist", or "Offset", the car will drive past the floor level magnet and re‐level. Check all signal devices for proper operation and remove all temporary jumpers. The adjustment should now be complete. Section 7 ‐ Adjustment of the GALaxy Combivert F5 AC Drive 7.1 General Setup In order to obtain a running platform in "car top inspection", see the "Quick Start‐up Guide for GALaxy Controller KEB Combivert F5 AC Drive - PM Gearless" if using a pmac gearless machine. If using a geared machine with an induction motor, see the "Quick Start-up Guide for GALaxy Controller KEB Combivis F5 Drive AC Geared". This procedure should be used only for installation purposes. When installation of all equipment is complete, and unit is ready for adjustment, proceed to Section 7.2, Check Main Line Voltage, and follow instructions. Before adjustment begins the following items must be completed. 1. All field wiring and safety circuits installed 2. Temporary jumpers from terminal “HC” to terminals “MES & ALT” 3. All hoistway limit switches installed 4. All car and hoistway doors and interlocks installed and pre‐adjusted Combivert F5 AC Drive 5. Selector installed and magnets pre‐adjusted 6. Familiarize yourself with all wiring schematics 7. Familiarize yourself with the KEB Combivert F5 Elevator Drive Technical Manual. 8. Verify that the motor is properly wired. 9. Verify that the encoder is connected properly. 10. Car should be properly counterbalanced. 7.2 Check Main Line Voltage With main‐line disconnect in the off position, check the line‐side voltage with a volt meter to insure the voltage matches the controller name tag “Input Power” voltage. Check to insure all three phases are present. If voltage is not correct or all three phases are not present, do not proceed until corrected. 7.3 Set Toggle Switches Set all toggle switches on the 1064 board as follows: DOOR LOCKS ‐ "OFF" IND ‐ "IND" P a g e | 119 AUTO DOOR ‐ "OFF" STOP ‐ "STOP" 7.4 Make Sure the Car Is Safe Verify that all elevator doors are closed and that all safety circuits are functional. 7.5 Check Controller Voltage Turn the main‐line disconnect to the on position. Check the voltage at R, S, and T on the AC drive. Verify that all three phases are present. Check the voltage at fuses L1 and L2 on controller. If correct, check the voltage at terminal “LIN” with respect to “GND”. The voltage should read 120VAC. If correct, check the voltage at terminals “S10, LC, & HC” with respect to “GND”. All should read 120VAC. If not, check wiring diagram to determine problem before continuing. 7.6 Verify the Main CPU is Operating Check to make sure that the “axy” of GALaxy on the 1021/1101/1005 LCD interface is blinking. If the “axy” is blinking, continue to the next step. If not, check voltage at terminals 5V to 0V on the 1064 board to insure 5VDC. If 5VDC is present and the “axy” on the 1021/1101/1005 LCD interface is not blinking, then contact factory. 7.7 Preset Adjustable Variables On Safety Processor Board And Main CPU The safety processor (1066) board is normally preset prior to leaving the factory; however, it is prudent to check the setup values for the proper settings. Refer to Section 13 of this manual for the operation of the safety processor board 1066 LCD interface. The following adjustment variables must be set properly. NOTE: If the controller uses an NTS board please refer to Section 14, GALX-0320AN NTSD Board. 7.8 1066 LCD interface "Adj Var" Menu Top Spd (contract speed) Enc RPM (if Fdbk Typ=0, not applicable) (if Fdbk Typ=1, set to rpm of governor) (if Fdbk Typ=4, set to value of LF.11 in KEB drive) Enc PPR (if Fdbk Typ=0, not applicable) (if Fdbk Typ=1, set to 8192) (if Fdbk Typ=4, set to 2048) Fdbk Typ (0=tape, 1=enc, 4=IncEnc) Ctrl Typ (2=Tract DF) 2 Stop (0=Mult, 1=2 stop) RearDoor (0=Front only, 1=Rear) UTS Vel (Set to top speed) DTS Vel (Set to top speed) INS Vel (Set to 140) LEV Vel (Set to 140) UT Vel (Set to top speed) DT Vel (Set to top speed) UL Vel (Set to 160 if Non‐DF) DL Vel (Set to 160 if Non‐DF) SoftStop (Set to 3) NOTE: The velocity values for the terminal limit switches above are only temporary settings until car is running high speed. In the final adjustment procedure, these variables must be set according to the procedures in Section 7.31, Adjust Safety Processor Board Speed Clamps. 7.9 1021/1101/1005 LCD interface "Adjustable Variables -> Car Motion" Submenu Top Speed (set to contract speed) Inspect Speed (set to 25 fpm) Encoder PPR (set to 2048 PPR) Encoder RPM (if tape selector, set to value of LF.11 in KEB drive), (if 485 tapeless selector, set to value of LF.11 in KEB drive), (if CAN open tapeless selector, set to governor rpm) NOTE: See Section 7.24, Correct Car Speed When Using 485 Tapeless System, for determining governor rpm. 7.10 Place Stop Switch in Run Position Set the “STOP” toggle switch on the 1064 board to the “RUN” position. Verify that input LED’s for “LC, HC, DN, UN, SS, GTS, RDY and CS” are all on. If not, then correct field wiring. P a g e | 121 Combivert F5 AC Drive 7.11 Hoist Motor Data At this time the hoist motor data must be entered into the AC drive. The following functions must be entered or verified using the drive "Operator" display unit. Follow the instructions in the Combivert F5 drive manual to enter the following data: Motor Data US.10 ‐ Motor type configuration (for pm sync gearless set to P9LSS), (for pm sync geared set to PCLSd), (for induction motor with geared machine set to ICLSd). US.83 - Encoder PPR output from drive (set to 1) US.4 – Load (Perform configuration load.) LF.10 ‐ Motor HP ‐ Read only. Cannot be entered. This is calculated from rated speed and torque for PM gearless configuration. LF.2 ‐ (Set to "SErSP") LF.11 ‐ Rated Motor Speed (from machine/motor nameplate) LF.12 ‐ Rated Motor Current (from machine/motor nameplate) LF.13 ‐ Rated Motor Frequency (from machine/motor nameplate) LF.14 ‐ Rated Motor Voltage (from machine/motor nameplate) LF.17 ‐ Rated Motor Torque (from machine/motor nameplate, or LF.17 = HP * 5258 / LF.11) Machine Data LF.20 ‐ Contract Speed (from controller data) LF.21 ‐ Sheave Diameter (in) LF.22 ‐ Gear Reduction Ration (1 if gearless), (actual gear ratio if geared) LF.23 ‐ Roping ratio (1:1 or 2:1) LF.27 ‐ 2048 for EnDat encoder with pm ac gearless), (PPR of motor mounted incremental encoder with geared traction) LF.76 ‐ 8 (absolute encoder) The number of poles is provided below if you are using one of the following PM AC Gearless machines: MAG05 = 66 poles MAG10 = 66 poles MAG15 = 66 poles Leroy Somer Z2 = 16 poles Leroy Somer Z3 = 16 poles Leroy Somer Z4 = 16 poles Leroy Somer Z6 = 32 poles Leroy Somer Z10 = 32 poles Leroy Somer Z20 = 32 poles Imperial 474 = 20 poles Imperial 475 = 24 poles Imperial 522 = 20 poles Imperial 525 = 20 poles Imperial 805 = 44 poles Hollister Whitney = 28 poles Poles= 2 X 60 X Motor Excitation Frequency (Hz)/Rated Motor Speed (RPM) The number of motor poles will always be a whole, even number. Most of the drive parameters have been preset to values required for your specific job. Other parameters not listed here may need to be adjusted in the field. Please refer to the Combivert F5 manual for more parameter information and troubleshooting guidelines. 7.12 Pre‐set the Digital Speed Clamps Pre‐set the software digital speed clamps from the 1021/1101/1005 LCD interface under the “Elevator Setup Menu”. The submenus for the clamp speeds are as follows: Set Ins /Leveling Clamp Set DT/UT Slowdown Clamp Set DT1/UT1 Slowdown Clamp Set DT2/UT2 Slowdown Clamp Set DT3/UT3 Slowdown Clamp P a g e | 123 Combivert F5 AC Drive If you are not using one of the following PM AC Gearless machines listed above and need to calculate the motor poles or motor rated speed, use the following formula based from the motor name plate data: Set DTS/UTS Slowdown Clamp Set the speed for Ins/Leveling for 140 fpm and all the remaining slowdown limit speeds to the contract speed of the car. Please note that the displayed value of “Clamp Speed” is the value the clamp should be set to. The slowdown limit “Clamp Speed:” will show 0000 until the car is run into the limits and the speed is recorded. Please refer to Section 10, 1021/1101/1005 LCD Interface, for the Elevator Setup Menu. NOTE: The values of the clamp speed velocities above are only temporary settings until the car is running high speed. In the final adjustment procedure, these values must be set according to the procedures in Section 7.32, Adjust Digital Slowdown Speed Clamps. 7.13 Adjust the Brake Voltage If the controller utilizes an electronic brake board 1047 or 1051, then the brake voltage is adjusted through the 1021/1101/1005 LCD interface, "Car Brake" sub‐ menu. If the controller utilizes resistors and rectifiers for the brake coil circuit, then the brake voltage is adjusted by moving the adjustable tap on the brake resistor. NOTE: Remove power before adjusting the resistor taps. To adjust the brake voltage when using and electronic brake board, navigate to the "Adjustable Variables" menu, "Car Brake" and adjust "Brake Pick Volt", "Brake Hold Volt" and "Brk AC L‐L Volt" to the proper values. 7.14 Motor Learn Procedure Lower the inspection speed on the controller to zero. Remove one wire from the brake coil to prevent the main brake from picking. If the unit has an emergency brake, the emergency brake and the emergency brake switch must remain operational during the learn procedure. On the drive operator keypad set parameter LF.3 to “S.Lrn”. Press Enter and the drive keypad will display “Start”. Press and hold the up or down inspection switch and the enable switch. You will hear all the contactors (BRK, RUN and MC) pick and stay energized on the controller. The drive operator keypad will change as a number of motor measurements are made. This process takes 2 to 5 minutes. When the drive operator keypad displays “Done”, release the up or down inspection button. Return the wires back to the main brake to allow the brake to pick again. 7.15 Encoder Learn Procedure, v1.62 (Unroped machine) NOTE: This procedure is not required for geared traction using an induction motor. If you are using v1.62 on the Combivert F5 drive, the encoder position must be learned with the ropes removed from the machine. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed = 0". Verify the motor wiring from the drive to the motor, U to U, V to V and W to W. Verify that drive parameter 2.LF.26 = “Conn”. This parameter indicates that serial communication is established between the encoder and the drive. If 2.LF.26 does not display “Conn”, check the encoder wiring and drive settings LF.26, LF.27, LF.28, and LF.29. This problem must be rectified before proceeding. Once communication is established with the encoder, set LF.3 to “P Lrn” and press enter on the drive operator keypad. The drive operator keypad will display “Start”. Press and hold the "UP" or "DN" inspection button. The motor sheave will begin to move back and forth and the drive display will display a numeric value. If the sheave begins to move, but an E.EnC1 error occurs on the drive, the drive will swap the encoder channels in LF.28 automatically and then display “retry”. Press and hold the "UP" or "DN" inspection button again. If the sheave does not move and an E.EnC1 occurs, verify the brake is picking and the sheave is able to move freely. When sheave is able to move freely, perform "P Lrn" again. If this does not resolve the problem, try swapping output motor phases and try the "P Lrn" procedure again. When the process is complete the sheave will stop rotating and the drive will display “done” and the "UP" or "DN" inspection button can be released. Make a note of LF.77 value which is the learned encoder position value. Return the "Inspect Speed" on the 1021/1101/1005 LCD interface to the previous setting, and set the drive parameter LF.3 to "run". Important: If the encoder is removed, absolute position will need to be relearned! NOTE: This procedure is not required for geared traction using an induction motor. If you are using v1.72 on the Combivert F5 drive you can learn the encoder position with or without the ropes removed from the machine. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed = 0". Verify the motor wiring from the drive to the motor, U to U, V to V and W to W. Verify that drive parameter 2.LF.26 = “Conn”. This parameter indicates that serial communication is established between the encoder and the drive. If 2.LF.26 does not display “Conn”, check the encoder wiring and drive settings LF.26, LF.27, LF.28, and LF.29. This problem must be rectified before proceeding. Once communication is established with the encoder, set LF.3 to “SPI” and press enter on the drive operator keypad. The drive operator keypad will display “Start”. Press and hold the "UP" or "DN" inspection button. The drive will take ten encoder position samples. When the process is complete the drive keypad will display “done” and the “UP” or “DN” inspection button can be released. Make a note of LF.77 value which is the learned encoder position value. Return the "Inspect Speed" on the 1021/1101/1005 LCD interface to the previous setting, and set the drive parameter LF.3 to "run". After making a trial run, if the current in LF.93 is excessive, change the value in LF.28 from 0 to 1 or from 2 to 3 and repeat the process. Important: If the encoder is removed, absolute position will need to be relearned! P a g e | 125 Combivert F5 AC Drive 7.16 Encoder Learn Procedure, v1.72 (Unroped or Roped machine) 7.17 Check Inspection Speed If the ropes have been removed from the sheave, adjust the following drive parameters to the values listed below prior to running on inspection speed. If the ropes are on the sheave leave these drive parameters at the initial settings listed below. Change A.LF.31 from 3000 to 300 Change d.LF.31 from 3000 to 300 Change A.LF.32 from 350 to 50 Change d.LF.32 from 250 to 50 Change A.LF.33 from 3000 to 0 Change d.LF.33 from 1000 to 0 Make sure that on the drive parameter LF.3 is set to “run”. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed = 25". Run the elevator on inspection, and verify that there is zero current draw in LF.93. Press the “UP” inspection button and verify motor is rotating in the up direction, and then press the “DOWN” inspection button and verify that the motor is rotating in the down direction. If not, then change LF.28 from 0 to 2 or from 1 to 3 and re‐ verify direction. If LF.28 is changed, you must relearn the encoder if using a PM AC Gearless machine. With a hand held tachometer, check the speed of the elevator while running on inspection. The elevator should be running at 25 fpm. From the 1021/1101/1005 LCD interface, select the "Elevator Status" menu; navigate until the display shows "Dmd" and "Vel". While running on inspection, monitor the controller demand speed "Dmd", and the speed feedback "Vel". These values should both display 25. If the demand and feedback on the 1021/1101/1005 LCD interface is incorrect, check the Encoder RPM and PPR parameters from the “Adjustable Variables” menu. These variables should be set to values listed in Section 7.9, 1021/1101/1005 LCD interface "Adjustable Variables -> Car Motion" Submenu. If the speed on the hand held tachometer and on "Dmd" and "Vel" all read 25 fpm (within +/‐ 2 fpm), continue to the next step. If not, contact the factory. 7.18 Verify Controller Encoder Direction From the 1021/1101/1005 LCD interface "Elevator Status" menu, navigate to display "Dir" and "DP". While moving the car on inspection, monitor "Dir" (direction) and "DP" (pulse counts). "Dir" should display "Up" when the car is moving up, and "Dn" when the car is moving down. The value of "Dp" should increment when the car is moving up, and should decrement when the car is moving down. If the direction is wrong or the pulse counts change in the wrong direction, then the encoder direction to the controller must be changed. On the encoder isolation board (1022N), move J1 and J3 on the encoder board. Refer to the jumper diagram on the board. J1 swaps A & A NOT – J3 swaps B & B NOT. If the encoder is counting properly and the ropes were removed from the sheave, then set the following drive parameters back to their original settings. A.LF.31 to 3000 d.LF.31 to 3000 A.LF.32 to 350 d.LF.32 to 250 A.LF.33 to 3000 d.LF.33 to 3000 Replace the ropes and proceed to Section 7.19, Run The Car On Inspection With The Ropes On The Sheave Of The Motor. If the encoder is counting properly, and the ropes were not removed, proceed to Section 7.19, Run The Car On Inspection With The Ropes On The Sheave Of The Motor. If the encoder is not counting properly, contact G.A.L. Technical Support. 7.19 Run The Car On Inspection With The Ropes On The Sheave Of The Motor 7.20 Ready to Run On Inspection From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion” and verify that "Inspect Speed = 25". Before moving the car on inspection, verify again that all door locks, gate switches, safety circuits, and limit switches are functioning properly. P a g e | 127 Combivert F5 AC Drive The car should be ready to run on inspection if all is wired correctly. Select the “Elevator Status” on the 1021/1101/1005 LCD interface. The display should show “Out of Service” on the first line and “Inspection Mode” on the second. The 1066 LCD interface will display one of the following types of inspection: “MR INS” (Motor Room) “CT INS” (Car Top) “ACCESS” (Access) “IC INS” (In Car)” “AUTO” (Not on Inspection) To run the car from the motor room, “MR INS” should be displayed. The “inspection string” consists of contacts from the inspection switches and the gate and lock bypass switches in series. One and only one of the five inspection inputs should be on for the car to run. Starting from the car top inspection input, the five inspection inputs are, “INS” for car top, “ACC” for access, “ICI” for in‐ car, “MRI” for motor room, and “AUTO” for automatic (no inspection). The inspection string circuit is shown in Figure 7.1. NOTE: Any one of the following conditions will cause an inspection error: More than one inspection input is on No inspection input is on Gate or Lock bypass switch is open and the car is not on car top inspection If the controller is not on motor room inspection at this point, then verify all switch positions and wiring before proceeding. Figure 7.1: Inspection String Circuit Combivert F5 AC Drive 7.21 Verify Selector and Slowdown Inputs Run the elevator up on inspection until it stops on the up normal limit. The up and down normal limits should be set two inches above and below the terminal floors respectively. Verify the selector inputs are being set properly on the controller by running the elevator down until it stops on the down normal limit. P a g e | 129 As the car approaches floor level going down, “DL” turns on first, then “DZ” and then finally “UL”. At floor level, “UL, DL, and DZ” inputs should all be on at the same time. Leaving the floor going down “DL” will turn off first, then “DZ” and last “UL”. Also verify that the up and down terminal slowdown limits inputs “UT, UTS, DT & DTS” are breaking at the proper distances as shown in the slowdown table 2.0. “UT, UTS, DT & DTS” turn off when active. 7.22 Verify Car Speed on Safety Processor Board Run the car in either direction and check the car speed on the 1066 LCD interface. The speed shown should match the car’s actual speed. If the speed does not match and the secondary feedback comes from pulses from the tape go to “Correct Car Speed When Using A Tape”. If using 485 tapeless, go to "Correct Car Speed When Using 485 tapeless". If using CAN Open tapeless, go to "Correct Car Speed When Using CAN Open tapeless". If the correct speed is shown proceed to Section 7.26, Learn The Hoistway. 7.23 Correct Car Speed When Using a Tape The tape has holes every 3/8” that are 3/8” in diameter. On the selector unit adjust the PP sensor closer to the tape until the orange LED at the end of the sensor turns on. Then turn the sensor inwards another 1/8” and lock in the sensor. While running on top of car inspection verify that the orange LED at the end of the PP sensor turns on and off as it passes by the holes on the tape. The safety processor board on the controller measures the time between each pulse to calculate the velocity. If the velocity is not displayed correctly first make sure that the feedback type in the safety processor board adjustable variable is set to 0 for a tape application. Next, while the car is running, make sure that the PULSE LED on this board is pulsing. As the car increases in speed the LED will glow solid on. If the LED does not pulse, try swapping the wires at the PPS and PP terminals. If the LED still does not work, contact the factory. If the correct speed is shown proceed to Section 7.26, Learn The Hoistway. 7.24 Correct Car Speed When Using 485 Tapeless System When using the 485 tapeless system, the secondary speed feedback comes from the encoder mounted on the governor. The 1066 board uses a serial interface to a Turck absolute encoder, part # T8.5882.3F0B.3001. In the 1066 LCD interface "Adj Var" menu, set the "Fdbk Typ = 1", and set the "Enc PPR = 8192". The "Enc RPM" value must be calculated as described below. To calculate the RPM, divide the contract speed of the car by the distance travel in one revolution with the governor as shown below: RPM = Speed fpm/(diameter GOV * pi) For a 1 ft. diameter governor: RPM = 350 / (1*pi) = 350/3.1415 = 111.4 For a 16 in diameter governor (16/12 = 1.33ft): RPM = 350/ (1.33* 3.1415) = 350/4.188 = 83.5 7.25 Correct Car Speed When Using CAN Open Tapeless System When using the CAN Open tapeless system, the secondary speed feedback comes from KEB drive parameter US.83 and is normally set to "1" which is 2048 ppr (US.83 set to "0” is 1024 ppr). In the 1066 LCD interface "Adj Var" menu, set the "Fdbk Typ = 4", and set the "Enc PPR" equal to the ppr from the KEB drive parameter US.83, and set the "Enc RPM" to the nameplate rpm of the machine/motor which should be the same value of parameter LF.11 in the KEB drive. On the 1066 LCD interface, navigate to the "Pls Cnt" menu. While running the elevator on inspection, verify that the pulse count value increments when running up and decrements when running down. The "Pls Cnt" value can be considerably out of range but will automatically correct during the "Learn Hoistway" procedure. To reverse the direction of pulse counting, navigate on the 1066 LCD interface to the "Adj Var" menu, "Enc Dir" and set to "0" for clockwise or "1" for counter‐clockwise. Navigate on the 1066 LCD interface to the "Car Spd" menu. Monitor the "Car Spd" while running the car at a known inspection speed. The value displayed should match the actual car speed measured with a hand held tachometer. If the speed is correct, proceed to Section 7.26, Learn The Hoistway. Run the elevator down on inspection until it stops on the down normal limit switch. Verify that the “DN and DL” input LED’s are both off and that the "UL" and "DZ" LED's are on. From the 1021/1101/1005 LCD interface navigate to the "Elevator Setup" menu, "Learn Hoistway". The learn procedure can be performed automatically by choosing "Auto" from the menu items, or performed manually by choosing "Insp” from the menu items. After choosing the learn method, follow the instructions displayed on 1021/1101/1005 LCD interface. In general, the car will run up from the "down normal limit" to the "up normal limit" at 30 fpm. During this learn run, the DP count for each floor level and each limit switch will be stored in memory. NOTE: The car must run the entire hoistway without stopping. As the elevator moves up the hoistway, navigate to the "Hoistway Tables" menu, "Disp/Mod Hoistway Table", and verify that the "DP" count is incrementing as the elevator moves up. Also as the elevator passes each floor, the pulse count and distance for that floor should change and be stored. Verify that P a g e | 131 Combivert F5 AC Drive 7.26 Learn the Hoistway the floor distances are valid. The pulse count for the terminal slowdowns will also be stored. The elevator will stop when it reaches the up normal limit. Follow the instructions on the 1021/1101/1005 LCD interface by putting the car on inspection, and then the message "Hoistway Learn Complete" should be displayed. Move the elevator on inspection until the “DZ and DL” LED’s are on. Set the “INS” toggle switch on the 1064 board to the “NORMAL” position, and the elevator should level down to floor level at the top floor. If so, proceed to final adjustment. If the car levels down but does not run, then check “Elevator Status” and “View Fault Log” on the 1021/1101/1005 LCD interface for any fault information. Correct items causing faults and perform hoistway learn again. After problem is corrected, and a successful hoistway learn is performed, proceed to final adjustment. 7.27 Automatic Run The elevator should now be sitting idle at the top floor. The "AUTO DOOR" switch should be set to the "OFF" position and the "IND" switch should be set to the "IND" position. If the learn procedure was successful, the elevator should be ready to make an automatic run. The default parameter settings for the ride quality should be adequate for an initial run. From the 1021/1101/1005 LCD interface navigate to the "Set Calls and Lockouts" menu, "Setup Car Calls" and enter a car call. The elevator should run to answer the call. When the elevator levels in and stops at the floor, the doors will remain closed. At this point the acceleration and deceleration of the car should be smooth and stepless regardless of the distance of run. The high speed of the car should be verified. To fine tune high speed, make high speed runs while monitoring parameter LF.90 on the drive. The display should read contract speed. If the speed is slightly under or over contract speed, then verify that parameter LF.11 is set properly. The speed displayed on the drive should match the speed displayed on the 1021/1101/1005 LCD interface, "Elevator Status" menu, "Dmd" and “Vel". This speed should also match the speed displayed on the 1066 LCD interface, "Car Spd" menu. If LF.11 is changed, then go to the 1021/1101/1005 LCD interface, "Adjustable Variables" menu, "Car Motion" and change the value of "Encoder RPM" to match the drive. When all of these speeds are the same (+/‐ 2 fpm), then proceed to the next step. 7.28 Fine Tune the Ride Quality NOTE: A.LF.xx' parameters refer to gains during acceleration and also high speed. In order to fine tune the ride quality, refer to Figure 7.2 which describes what part of the S‐ curve that the different parameters effect. In general, higher numbers in the given parameters, cause quicker and more abrupt changes from one mode to the next during a run. All of the S‐curve parameters have a minimum and maximum value. The controller will not allow you to enter values that are not valid. In some instances, the response of the drive may need to be adjusted so that the drive will properly follow the S‐curve (demanded speed) from the controller. The response of the drive can be increased by adjusting the gain parameters in the drive. Preliminary adjustments can be made to the following parameters to increase the response. Proportional gains ‐ A.LF.31 and d.LF.31Integral gains ‐ A.LF.32 and d.LF.32 Integral offset gains ‐ A.LF.33 and d.LF.33 (offsets added to the integral gains for more control at low speeds). The complete description of these parameters and their effect on the control and ride quality can be found in the KEB drive manual. In general, the "A" parameters affect the acceleration gains and the "d” parameters affect deceleration gains. Lower values make the drive less responsive, and higher values make the drive more responsive. As the gains are increased, the drive will cause the motor to follow the S‐curve more closely. If these values are increased too much, vibrations and audible noise may occur in the motor. After performing the adjustments above the ride quality during acceleration, high speed, and deceleration should be good. If so, proceed to Section 7.29, Adjust The Stop. 7.29 Adjust the Stop When at floor level the “UL, DL, & DZ” input LEDs should be on. If the elevator continually tries to seek floor level by leveling up and down, try the following steps to correct the problem: Reduce the leveling and re‐leveling v e l o c i t y parameters from the 1021/1101/1005 LCD interface "Adjustable Variables" menu, "Car Motion", "Leveling Speed" and "Relevel Speed". P a g e | 133 Combivert F5 AC Drive After the car is running high speed with an acceptable ride quality, it is recommended to perform a "System Inertia Learn" on the KEB drive in order to provide optimum drive performance. This procedure is outlined in the KEB manual. After this procedure is completed, the "Feed Forward Torque Control” FFTC will be enabled in the drive. With the FFTC active, the drive gains listed above can be reduced, and the drive will still follow the S‐curve from the controller. This is helpful if the higher values of the gain parameters are causing vibration and audible noise in the motor. If the car still oscillates, adjust the "floor level zone" on the selector. The "floor level zone" is increased by moving the "UL" and "DL" sensors closer together. If the car stops hard on the brake, then make the following adjustments. From the 1021/1101/1005 LCD interface navigate to the "Adjustable Variables" menu, "Car Motion", and adjust both "Brake Drop Del" (brake drop delay) and "Soft Stop Time". These variables should be adjusted so that zero speed is observed at the end of the run prior to the brake setting. The controller should hold the car at zero speed for the duration of the "Soft Stop Time" which should continue while the brake is setting and for a short time after the brake sets. The soft stop time MUST be set to at least 0.5 seconds LONGER than the brake drop delay. The "Soft Stop Time" setting in the 1021/1101/1005 LCD interface should be compared with the setting in the 1066 LCD interface "Adj Var" menu, "SoftStop". The setting of "SoftStop" in the 1066 LCD interface should be greater than the "Soft Stop Time" setting in the 1021/1101/1005 LCD interface. If the car spots when approaching the floor, the cause is usually due to the car not tracking (the drive response is set too low) or the speed profile into the floor is too aggressive. First try to increase the response of the drive, see Section 7.28, Fine Tune The Ride Quality. If the car still spots, increase the floor targeting distance and retest the ride. The default value for the floor targeting distance is 12 inches. Increase it by steps of 2 or 3 and continue retesting until the parameter is adjusted to 18. If no change is noticed, start again from 12 and decrease the value. The deceleration rate can also be reduced to help remove the spotting. Proceed with adjusting the start once the proper stop is achieved. 7.30 Adjust the Start To provide a proper start, from the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and adjust "Brake Pick Del" (brake pick delay), "Pattern Delay", and "Soft Start Jerk". Initially, set the brake pick delay to 0 and increase the pattern delay by 0.1 seconds until the controller picks the brake completely before the motor starts to move. If roll back occurs, then reduce the pattern delay until there is no roll back. Sometimes, the timing works out better if the brake pick delay is set to 0.1 second. In order to provide a smooth start with no roll back and without feeling the car move under the brake, it may be necessary to utilize the motor pre‐torque feature. There are two pre‐ torque options. The first option is using a load‐ weighing device described in Section 7.34, Analog Load Weigher Setup. The second option is using the KEB drive’s Synthetic Pre‐ Torque" feature. To enable the "Synthetic Pre‐ Torque" option, set LF.30 = 5 in the KEB drive. During the "Synthetic Pre‐Torque" sequence, the KEB drive introduces a high gain for a very short time period immediately after the brake picks and clears the machine drum or rotor. In order for the feature to work properly, with no noise or vibration, the timing and the gain values have to be coordinated with a high degree of precision. In the first phase of the sequence, the drive uses a "hold off" timer, US.17, to allow the machine brake to release prior to the high gain being introduced. US.17 should be set to expire at exactly the time the brake clears the drum or rotor. A typical initial value of US.17 = 0.2 sec. If this timer expires before the brake releases, audible noise and vibration from the motor will occur. If this timer expires after the brake releases, the car will roll back before the high gain is introduced by the drive. The brake pick delay timer may also need to be adjusted from the 1021/1101/1005 LCD interface, by navigating to the "Adjustable Variables" menu, "Car Motion" and adjusting "Brake Pick Del". In general, the value of US.17 will be greater than the value of "Brake Pick Del". Also during this second phase of the sequence, second timer, US.18, begins timing at the same point that US.17 expires. The US.18 timer sets the duration that the P.LF.32 gain parameter is asserted. A typical initial value for US.18 = 0.15 sec., but this value must be fine‐ tuned as well. As a general rule, the value US.18 will be less than the value US.17 after the adjustment is complete. It is critical that the pattern delay timer from the controller expires at exactly the same time that US.18 expires. To adjust the pattern delay from the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and adjust "Pattern Delay". If the "Pattern Delay" value is too short, then acceleration will be demanded from the controller while the high gain is being asserted and vibration and noise from the motor will occur. If the "Pattern Delay" is set too long, then roll back will occur after US.18 expires. In general, the value of "Pattern Delay" will be greater than the sum of the values of US.17 and US.18. Again, by performing small adjustments in the iterative fashion described above, the correct setting combination can be achieved. P a g e | 135 Combivert F5 AC Drive In the second phase of the sequence, the drive introduces the gain parameter, P.LF.32, after the US.17 timer expires. The value of P.LF.32 should be increased until the car is held at zero speed when the brake is released. Values as high as 20,000 are normal for parameter P.LF.32. If this value is set too low, the drive will not hold the motor at zero speed when the brake releases. If this value is set too high, then audible noise and vibration from the motor will occur. If audible noise and vibration occur, it is important to determine if it is caused by P.LF.32 being set too high, or if it is caused by US.17 expiring before the brake releases. Small increments (0.05 sec) to US.17 can be made until roll back is observed, and then decreased again until there is no roll back. By performing these small adjustments in an iterative fashion, the correct setting combination can be achieved. After the "Synthetic Pre‐Torque" is set properly, the car will start smoothly with no roll back and without feeling the brake. The soft start jerk rate can now be increased to provide a quicker transition from start to constant acceleration. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and adjust the "Soft Start Jerk Rate”. The ride quality should now be acceptable. Figure 7.2: Speed clamps 7.31 Adjust Safety Processor Board Speed Clamps The 1066 Safety Processor Board monitors the speed of the elevator at the terminal landings independently from the main CPU. When the "UT, DT, UTS, and DTS" limit switches are activated, the 1066 board calculates the velocity of the elevator and compares that velocity with a stored value of speed clamp. If the velocity when the switch activates is greater than the speed clamp value, then the 1066 board will generate a fault that stops the elevator. To set the speed clamps, make a one floor run to the top floor. After the car stops, record the velocity the car hits the “UT, DT, UTS & DTS” slowdown limits. “UTS & DTS” are used on cars with reduced stroke buffers or with a top speed greater than 200 fpm. The velocity value is shown from the “LIM VEL” menu on the 1066 LCD interface. The velocity value shown on the display for the “UT or DT” limit is the value after the car activates the limit then counts an adjustable number of counts set from the 1066 LCD interface, "Adj Var" menu, "UT Count" or "DT Count". These count values can be adjusted to provide adequate distance, following the limit switch activation, to allow the elevator to begin its normal decel pattern. The default “UT Count" and "DT Count" values are normally adequate. However, these values may need to be field adjusted to allow enough distance for the car to begin its normal decel pattern. If the "UT Count" and "DT Count" values are modified, the limit velocities must be re‐checked. Run the car again to the top repeatedly from 2 floors, then 3 floors, etc., until top speed is reached. From the 1066 LCD interface "Lim Vel" menu, record the limit velocities displayed each time the car stops at the top floor. Make the same runs to the bottom floor starting from 1 floor, then 2 floors, then 3 floors, etc., until top speed is reached. From the 1066 LCD interface "Lim Vel" menu, record the limit velocities displayed each time the car stops at the bottom floor. Take the highest speed value recorded in the runs above and add 20 fpm to that value to use as the clamp speed values for the respective limit switches. Enter these clamp speed values into the 1066 LCD interface "Adj Var" menu, "UT Vel", "DT Vel", "UTS Vel", "DTS Vel" respectively. 7.32 Adjust Digital Slowdown Speed Clamps From the main CPU LCD interface, choose “Elevator Setup” and hit enter. Next choose “DT/UT Slowdown Clamp” and again hit enter. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Set DT/UT Slowdown Clamp" and view the speed displayed for "Clamp Speed". Add 20 fpm to this "Clamp Speed" value and enter it into the "DT/UT Limit" value. The number of slowdown limits depends on the speed of the car as show in the table below: Table 7.1: Slowdown Clamps P a g e | 137 Combivert F5 AC Drive Having just made several runs into the top and bottom landings, the main CPU has also recorded the car’s velocity when the slowdown limits were activated. If the car has been powered down prior to this step, several runs must be made to the limits to allow the main CPU to record the limit velocity values. Adjust speed clamps for each slowdown limits used as determined by the elevator’s contract speed. 7.33 Verify Inspection Velocity Clamp on Safety Processor Board Place the car on inspection operation. From the 1066 LCD interface, navigate to the "Adj Var" menu, "Ins Vel" and set the speed clamp velocity to 25 fpm. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the “Inspect Speed" to 50 fpm. Run the car in either direction and verify that the car shuts down when the speed rises above 25 fpm. From the 1066 LCD interface, navigate to the "Adj Var" menu, "Ins Vel" and set the speed clamp to 140 fpm. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the “Inspect Speed" to the desired value. 7.34 Analog Load Weigher Setup If the job uses an analog load weigher purchased from G.A.L., complete the following procedure. NOTE: It is recommended using two people, one moving the weights and one in the machine room to set up the load weigher. Mount the load weigher as described by the manufacturer. The load weigher control box will also contain a board supplied by G.A.L. that connects to the controller serial CAN bus and reads in the analog output from the load weighing device. Wire the load weigher and G.A.L. board according to the controller schematics. Calibrate the load weighing device hardware according to the manufacturer’s instructions. Following proper installation of the load weighing device, proceed to Section 7.35, Empty Car Setup. 7.35 Empty Car Setup Verify that the load weighing device is communicating to the main CPU by performing the following steps. From the 1021/1101/1005 LCD interface, navigate to the "Diagnostics" menu, "Car Comm Status", "Car to LW Board" and verify that "On‐ line = 1". If "On‐line = 0" then verify wiring and installation of load weighing device. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "Setup Load Weigher" and follow the instructions on the display as you go through the procedure. It is okay to exit the setup screen to place a call and then return to it while the setup is being performed. Run the car to the bottom floor and press Enter on the 1021/1101/1005 LCD interface when prompted to do so to start the automatic setup sequence. If the car is at the bottom floor and the doors are not closed (the doors will not close automatically from turning off the auto‐door switch) then place a car call to run the car up one floor, then back again. The doors will close when the call is placed. When the automatic sequence is activated, the car will run to each floor and measure the empty load value. The 1021/1101/1005 LCD interface will indicate when the sequence is finished. 7.36 Full Car Setup The empty car setup must be successfully completed to run the full load setup. Once the empty car setup is complete, run to the loading floor and set the "AUTO DOOR" switch to the "ON" position to allow weights to be loaded on the car. With the car fully loaded, set the "AUTO DOOR" switch to the "OFF" position and run the car to the bottom floor. Again if the doors are not closed, make a one floor run to force the doors to close. After the weights are removed, cycle the doors to complete the procedure. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "View/Modify LW Setup" and verify the load weigher status, "LW Device Stat: ON OK". If the status is "ON OK", then the load weigher should be accurately measuring the car load in real time. The percent load will be displayed, "Load: _%". The percent load values for different service options can now be set. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Service Options", and set the following variables: "Load Bypass" "Load Antinuisance" "Load Dispatch" P a g e | 139 Combivert F5 AC Drive With the car at the bottom floor, follow the instructions on the 1021/1101/1005 LCD interface to start the full load setup sequence. The car will automatically run to each floor and measure the full load value. When the full load measurement is complete, the car can be run to the loading floor and the weights removed. "Load Overload" NOTE: Setting the values of the variables above to 0% will disable that particular option. 7.37 Load Weighing Calibration Sequence The load weigher is automatically calibrated once each week. If an error is detected during this calibration sequence, the load weigher and the pre‐torque feature (if used) is disabled. A load weighing calibration sequence can be manually activated by performing the following procedure. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "Load Weigher Calibration" and follow the instructions on the display. 7.38 Adjust the Motor Pre‐torque NOTE: This section describes the adjustment procedure if using the load value obtained from the analog load weigher to generate the proper pre‐torque signal to the drive. This option will only work if the load weigher has been installed properly, and the "Load Weigher Setup" has been performed successfully. If the option of "Synthetic Pre‐Torque" is used, see Section 7.30, Adjust The Start. On the KEB drive, set parameter LF.30 = 3 to enable the pre‐torque function from a load weighing device. Run the empty car to a middle floor. From the 1021/1101/1005 LCD user interface, navigate to the "Adjustable Variables" menu, "Car Motion" and adjust the following parameters: "Balanced Load = 40" (typically car is 40% counterbalanced, but verify counterbalance percentage for each specific job) "Torque Amount = 10" "Pattern Delay = 2.5" "Brake Pick Del = 0.1" The long pattern delay will allow an exaggerated amount of roll back in order for the pre‐torquing to be set accurately. Make a one floor run down and observe the roll back when the brake picks at the start of the run. Increase the "Torque Amount" variable and continue to monitor the roll back while performing one floor runs in the down direction. As the "Torque Amount" is increased, the roll back should be minimized until the car will hold zero speed for the entire "Pattern Delay" time. A typical value for the "Torque Amount" is 40%. If the value is too large, the car will roll forward during the "Pattern Delay" time. NOTE: The pattern delay must be at least 0.15 seconds (150 milliseconds). Setting the torque amount to 0.00 will disable the pre‐ torque feature. Also if the load weighing calibration sequence detects a load weighing error, the pre‐ torque feature is also automatically disabled. 7.39 Verify the Doors Are Safe The elevator should now be adjusted. Verify that all door locks, gate switches, and safety circuits are operational. Set the "INS" switch to the "NORM" position and set the "AUTO DOOR" switch to the "ON" position. The elevator should level into the floor and open the doors. If the doors do not open, check the door operator wiring and cam adjustment. If the doors do open, the elevator is now on independent service. 7.40 Fine Tune the Ride Quality Ride the elevator and evaluate the ride quality. Fine tune the ride quality by navigating to the "Adjustable Variables" menu, "Car Motion" and adjusting the variables shown in Figure 7.2. Keep in mind that if acceleration or deceleration values are changed, the speed clamps for the safety processor board and the S‐curve board may need to be re‐adjusted. With "Stop On Pos Cnt = 0", the floor levels should be set by adjusting the floor level magnet at each floor. For proper operation, the floor magnets should be set to exactly floor level. After the floor levels are set properly, perform another hoistway learn procedure. With "Stop On Pos Cnt = 1", the floor levels are set by using both the floor magnet and the position count. For proper operation with this setting, the floor magnet should be set to exactly floor level. The final stop can then be fine‐tuned by performing the following adjustments. From the 1021/1101/1005 LCD interface, navigate to the "Hoistway Tables" menu, "DZ & LZ Offset, Sel Cnt" and adjust "Dn Lev Dist" and "Up Lev Dist". The units for these variables are in "pulse counts". With "Stop On Pos Cnt =1" the car will continue to move for the "Dn Lev Dist" or "Up Lev Dist" after "UL and DL" turn on. Use the "Dn Lev Dist" and the "Up Lev Dist" parameters to make level changes at all floors. P a g e | 141 Combivert F5 AC Drive To fine tune the floor level accuracy, determine if the controller is set to stop when "UL" and "DL" signals turn on, or if controller is set to stop off of the position count. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and view the "Stop On Pos Cnt" variable. If "Stop On Pos Cnt= 0" then controller is set to stop when the "UL and "DL" signals turn on. If "Stop On Pos Cnt = 1" then controller is set to stop on a combination of the floor level magnet and the position count. To make level changes at individual floors, perform the following adjustments. From the 1021/1101/1005 LCD interface, navigate to the "Hoistway Tables" menu, "FL and FL Offset Count", and the offset count can be adjusted. These variables introduce an offset (+/‐) to the stored floor count that was determined in the hoistway learn procedure. NOTE: The number of pulse counts per inch can be viewed from the 1021/1101/1005 LCD interface, "Hoistway Tables", "DZ & LZ Offset, Sel Cnt”, "Pulses /Inch". NOTE: Regardless if "Stop On Pos Cnt=0" or if "Stop On Pos Cnt =1", the floor magnet must be set properly at floor level. If too large of values are entered into "Dn Lev Dist", "Up Lev Dist", or "Offset", the car will drive past the floor level magnet and re‐level. Check all signal devices for proper operation and remove all temporary jumpers. The adjustment should now be complete. HPV-900 PM AC Gearless Section 8 ‐ Adjustment of the GALaxy ‐ HPV‐ 900 Permanent Magnet AC Gearless Motor 8.1 General Setup Before adjustment begins the following items must be completed. 1. All field wiring and safety circuits installed. 2. Temporary jumpers from terminal “HC” to terminals “MES & ALT”. 3. All hoistway limit switches installed. 4. All car and hoistway doors and interlocks installed and pre‐adjusted. 5. Selector installed and magnets pre‐ adjusted. 6. Familiarize yourself with all wiring schematics. 7. Familiarize yourself with the Magnetek HPV 900 PM Elevator Drive Technical Manual. 8. Verify that the PM AC motor is properly wired. 9. Verify that the encoder is connected properly. 10. Car should be properly counterbalanced. 8.2 Check Main Line Voltage With main‐line disconnect in the “OFF” position, check the line‐side voltage with a volt meter to insure the voltage matches the controller name tag “Input Power” voltage. Check to insure all three phases are present. If voltage is not correct or all three phases are not present, do not proceed until corrected. 8.3 Set Toggle Switches Set all toggle switches on the 1064 board as follows: DOOR LOCKS ‐ "OFF" IND ‐ "IND" AUTO DOOR ‐ "OFF" STOP ‐ "STOP" 8.4 Make Sure the Car Is Safe Verify that all elevator doors are closed and that all safety circuits are functional. P a g e | 143 8.5 Check Controller Voltage Turn the main‐line disconnect to the on position. Check the voltage at R, S, and T on the AC drive. Verify that all three phases are present. Check the voltage at fuses L1 and L2 on controller. If correct, check the voltage at terminal “LIN” with respect to “GND”. The voltage should read 120VAC. If correct, check the voltage at terminals “S10, LC, & HC” with respect to “GND”. All should read 120VAC. If not, check wiring diagram to determine problem before continuing. 8.6 Verify the Main CPU is Operating Check to make sure that the “axy” of GALaxy on the 1021/1101/1005 LCD interface is blinking. If the “axy” is blinking, continue to the next step. If not, check voltage at terminals 5V to 0V on the 1064 board to insure 5VDC. If 5VDC is present and the “axy” on the 1021/1101/1005 LCD interface is not blinking, then contact factory. 8.7 Preset Adjustable Variables on Safety Processor Board And Main CPU The safety processor (1028N/1066) board is normally preset prior to leaving the factory; however, it is prudent to check the setup values for the proper settings. Refer to Section 13 of this manual for the operation of the safety processor board 1066 LCD interface. The following adjustment variables must be set properly: NOTE: If the controller uses an NTS board please refer to Section 14, GALX-0320AN NTSD Board. 8.8 1066 LCD interface "Adj Var" Menu Top Spd (contract speed) Enc RPM (if Fdbk Typ=0, not applicable) (if Fdbk Typ=1, set to rpm of governor) (if Fdbk Typ=4, set to value of "CONTRACT MTR SPD" parameter in HPV 900/600 drive) Enc PPR (if Fdbk Typ=0, not applicable) (if Fdbk Typ=1, set to 8192) (if Fdbk Typ=4, set to 8 times the ppr of motor encoder) Fdbk Typ (0=tape, 1=enc, 4=InEnc) Ctrl Typ (2=Tract DF) 2 Stop (0=Mult, 1=2 stop) RearDoor (0=Front only, 1=Rear) UTS Vel (Set to top speed) DTS Vel (Set to top speed) INS Vel (Set to 140) LEV Vel (Set to 140) UT Vel (Set to top speed) DT Vel (Set to top speed) UL Vel (Set to 160 if Non‐DF) DL Vel (Set to 160 if Non‐DF) SoftStop (Set to 3) HPV-900 PM AC Gearless NOTE: The velocity values for the terminal limit switches above are only temporary settings until car is running high speed. In the final adjustment procedure, these variables must be set according to the procedures in Section 8.30, Adjust Safety Processor Board Speed Clamps. 8.9 1021/1101/1005 LCD interface "Adjustable Variables -> Motion" Submenu Top Speed (set to contract speed) Inspect Speed (set to 25 fpm) Encoder PPR ((if tape selector or if 485 tapeless selector, set to 8 times ppr of motor encoder) (if CAN open tapeless selector, set to motor encoder ppr) Encoder RPM (if tape selector, set to value of "CONTRACT MTR SPD" in HPV 900/600 drive), (if 485 tapeless selector, set to value of "CONTRACT MTR SPD" in HPV 900/600 drive), (if CAN open tapeless selector, set to governor rpm) NOTE: See Section 8.22, Correct Car Speed When Using 485 Tapeless System, for determining governor rpm. 8.10 Place Stop Switch in Run Position Set the “STOP” toggle switch on the 1064 board to the "RUN" position. Verify that input LED’s for “LC, HC, DN, UN, SS, GTS, RDY and CS” are all on. If not, then correct field wiring. 8.11 Hoist Motor Data At this time the hoist motor data must be entered into the AC drive. The following functions must be entered or verified using the drive digital operator. Follow the instructions in the HPV 900 PM drive manual to enter the following data: Basics U9 Sub Menu P a g e | 145 DRIVE MODE (set to PM) DRIVE A1 Sub Menu CONTRACT CAR SPD (from controller data) CONTRACT MTR SPD (from motor nameplate RPM) ENCODER PULSES (PPR from encoder on motor) POWER Convert A4 Sub Menu INPUT L-L VOTS (Nominal line-line AC input Voltage, RMS) MOTOR A5 Sub Menu MOTOR ID (pm default) RATED MTR PWR (from motor nameplate) RATED MTR VOLTS (from motor nameplate) RATED EXCIT FREQ (rated exicitation frequency in Hz) RATED MTR SPEED (rated motor speed at full load) RATED MOTOR CURR (from motor nameplate) MOTOR POLES (number of motor poles) The number of poles is provided below is you are using one of the following motors: MAG05 = 66 poles MAG10 = 66 poles MAG15 = 66 poles Leroy Somer Z2 = 16 poles Leroy Somer Z3 = 16 poles Leroy Somer Z4 = 16 poles Leroy Somer Z6 = 32 poles Leroy Somer Z10 = 32 poles Leroy Somer Z20 = 32 poles Imperial 474 = 20 poles Imperial 475 = 24 poles Imperial 522 = 20 poles Imperial 525 = 20 poles Imperial 805 = 44 poles Hollister Whitney = 28 poles HPV-900 PM AC Gearless If you are not using one of the following motors listed and need to calculate the motor poles, use the following formula based from the motor name plate data: Poles=2 X 60 X Motor Excitation frequency (Hz) / Rated Motor Speed (RPM) The number of motor poles will always be a whole, even number. RATED MTR SPEED (motor RPM on nameplate) Most of the drive parameters have been preset to values required for your specific job. Other parameters not listed here may need to be adjusted in the field. Please refer to the Magnetek HPV Technical manual for more parameter information and troubleshooting guidelines. From the digital operator for the drive, reset any active faults and clear the fault history log. 8.12 Pre‐set the Digital Speed Clamps Pre‐set the software digital speed clamps from the 1021/1101/1005 LCD interface under the “Elevator Setup Menu”. The submenus for the clamp speeds are as follows: Set Ins/Leveling Clamp Set DT/UT Slowdown Clamp Set DT1/UT1 Slowdown Clamp Set DT2/UT2 Slowdown Clamp Set DT3/UT3 Slowdown Clamp Set DTS/UTS Slowdown Clamp Set the speed for Ins/Leveling for 140 fpm and all the remaining slowdown limit speeds to the contract speed of the car. Please note that the displayed value of “Clamp Speed” is the value the clamp should be set to. The slowdown limit “Clamp Speed:” will show 0000 until the car is run into the limits and the P a g e | 147 speed is recorded. Please refer to Section 10, 1021/1101/1005 LCD Interface, for the Elevator Setup Menu. NOTE: The values of the clamp speed velocities above are only temporary settings until the car is running high speed. In the final adjustment procedure, these values must be set according to the procedures in Section 8.31, Adjust Digital Slowdown Speed Clamps. 8.13 PM Start‐Up Procedure 8.14 Adjust the Brake Voltage If the controller utilizes an electronic brake board 1047 or 1051, then the brake voltage is adjusted through the 1021/1101/1005 LCD interface, "Car Brake" sub‐ menu. If the controller utilizes resistors and rectifiers for the brake coil circuit, then the brake voltage is adjusted by moving the adjustable tap on the brake resistor. NOTE: Remove power before adjusting the resistor taps. To adjust the brake voltage when using and electronic brake board, navigate to the "Adjustable Variables" menu, "Car Brake" and adjust "Brake Pick Volt", "Brake Hold Volt" and "Brk AC L‐L Volt" to the proper values. 8.15 Encoder Learn Procedure and Motor Auto Tune Procedure NOTE: The Magnetek manual states that for Cables longer than 15 meters (50’) the sense wires should be connected and JP1 and/or JP2 on the EnDAT board should be set to the 2-3 position. This is only applies to EnDat encoders with the EnDat option card installed in the Magnetek drive. Both JP1 & JP2 should be set to the 2-3 position on the Magnetek EnDat option board and the EnDat cable Sense +/- wired to: WHITE (S-) to TB2-75 BLUE (S+) to TB2-76 NOTE 2: It may be necessary to perform the ecoder alignment using “HF Inject” instead of “Auto” as an alignment method. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed = 0". Remove one wire from the brake coil, to prevent the main brake from picking. If the unit has an emergency brake, the emergency brake and the emergency brake switch must remain operational during the learn procedure. Change the parameter BEGIN ALIGNMENT to to ON RUN. Wire the controller to run from car top inspection. See prints or quick start‐up guide for wiring. Give the controller a command to run on inspection up or down. The procedure should only take a few seconds. If the procedure is successful, the drive will store a value in the A5 - ENCODER ANG OFFST parameter. Run the procedure multiple times to determine that a consistent value is established in the A5 - ENCODER ANG OFFST parameter. If a fault occurs on the drive please consult the section on PM Start‐Up Procedure in the HPV‐900 PM Technical manual to resolve any faults. If faults persist, contact G.A.L. Technical Support. After the encoder angular offset is established, then navigate to the U12 menu - AUTOTUNE SEL and change the parameter AUTOTUNE SELECT to ON RUN. Give the controller a command to run on inspection up or down. The procedure should only take a few seconds. If the procedure is successful, values for A5 parameters D AXIS INDUCTANCE, Q AXIX INDUCTANCE & STATOR RESISTANCE are learned and saved automatically. After the encoder learn and the motor learn procedures are complete, reconnect the brake coil wire and return the inspection speed parameter to 25 fpm. 8.16 Check Inspection Speed With a hand held tachometer, check the speed of the elevator while running on inspection. The elevator should be running at 25 fpm. Also monitor the speed on the drive digital operator D1 submenu, SPEED FEEDBACK, and verify that it displays 25 fpm while running on inspection. From the 1021/1101/1005 LCD interface, select the "Elevator Status" menu; navigate until the display shows "Dmd" and "Vel". While running on inspection, monitor the controller demand speed "Dmd", and the speed feedback "Vel". These values should both display 25. If the demand and feedback on the 1021/1101/1005 LCD interface is incorrect, check the Encoder RPM and PPR parameters from the “Adjustable Variables” menu. If the speed on the hand held tachometer and on "Dmd" and "Vel" all read 25 fpm (within +/‐ 2 fpm), continue to the next step. If not, contact the factory. 8.17 Verify Controller Encoder Direction From the 1021/1101/1005 LCD interface "Elevator Status" menu, navigate to display "Dir" and "DP". While moving the car on inspection, monitor "Dir" (direction) and "DP" (pulse counts). "Dir" should display "Up" when the car is moving up, and "Dn" when the car is moving down. The value of "Dp" should increment when the car is moving up, and should decrement when the car is moving down. P a g e | 149 HPV-900 PM AC Gearless On the HPV‐900 digital operator go to the Utilities U0 option and press enter. Scroll through the Utilities options to Rotor Align U10 and press enter. Verify ALIGNMENT METHOD is set to AUTO ALIGN. Scroll to ALIGNMENT and press enter to change parameter ALIGNMENT from DISABLE to ENABLE and press enter. If the direction is wrong or the pulse counts change in the wrong direction, then the encoder direction to the controller must be changed. On the encoder isolation board (1022N), move J1 and J3 on the encoder board. Refer to the jumper diagram on the board. J1 swaps A & A NOT – J3 swaps B & B NOT. If the encoder is counting properly then place the ropes on the sheave of the motor and continue to the next step. If not, contact G.A.L. Technical Support. 8.18 Ready to Run On Inspection From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion” and verify that "Inspect Speed = 25". Before moving the car on inspection, verify again that all door locks, gate switches, safety circuits, and limit switches are functioning properly. The car should be ready to run on inspection if all is wired correctly. Select the “Elevator Status” on the 1021/1101/1005 LCD interface. The display should show “Out of Service” on the first line and “Inspection Mode” on the second. The 1066 LCD interface will display one of the following types of inspection: “MR INS” (Motor Room) “CT INS” (Car Top) “ACCESS” (Access) “IC INS” (In Car)” “AUTO” (Not on Inspection) To run the car from the motor room, “MR INS” should be displayed. The “inspection string” consists of contacts from the inspection switches and the gate and lock bypass switches in series. One and only one of the five inspection inputs should be on for the car to run. Starting from the car top inspection input, the five inspection inputs are, “INS” for car top, “ACC” for access, “ICI” for in‐ car, “MRI” for motor room, and “AUTO” for automatic (no inspection). The inspection string circuit is shown in Figure 8.1 Note that any one of the following conditions will cause an inspection error: More than one inspection input is on No inspection input is on Gate or Lock bypass switch is open and the car is not on car top inspection Figure 8.1: Inspection String Circuit 8.19 Verify Selector and Slowdown Inputs P a g e | 151 HPV-900 PM AC Gearless If the controller is not on motor room inspection at this point, then verify all switch positions and wiring before proceeding. Run the elevator up on inspection until it stops on the up normal limit. The up and down normal limits should be set two inches above and below the terminal floors respectively. Verify the selector inputs are being set properly on the controller by running the elevator down until it stops on the down normal limit. As the car approaches floor level going down, “DL” turns on first, then “DZ” and then finally “UL”. At floor level, “UL, DL, and DZ” inputs should all be on at the same time. Leaving the floor going down “DL” will turn off first, then “DZ” and last “UL”. Also verify that the up and down terminal slowdown limits inputs “UT, UTS, DT & DTS” are breaking at the proper distances as shown in the slowdown table 2.0. “UT, UTS, DT & DTS” turn off when active. 8.20 Verify Car Speed on Safety Processor Board Run the car in either direction or check the car speed on the 1066 LCD interface. The speed shown should match the car’s actual speed. If the speed does not match and the secondary feedback comes from pulses from the tape go to “Correct Car Speed When Using A Tape”. If using 485 tapeless, go to "Correct Car Speed When Using 485 tapeless". If using CAN Open tapeless, go to "Correct Car Speed When Using CAN Open tapeless". If the correct speed is shown proceed to Section 8.24, Learn The Hoistway. 8.21 Correct Car Speed When Using a Tape The tape has holes every 3/8” that are 3/8” in diameter. On the selector unit adjust the PP sensor closer to the tape until the orange LED at the end of the sensor turns on. Then turn the sensor inwards another 1/8” and lock in the sensor. While running on top of car inspection verify that the orange LED at the end of the PP sensor turns on and off as it passes by the holes on the tape. The safety processor board on the controller measures the time between each pulse to calculate the velocity. If the velocity is not displayed correctly first make sure that the feedback type in the safety processor board adjustable variable is set to 0 for a tape application. Next, while the car is running, make sure that the PULSE LED on this board is pulsing. As the car increases in speed the LED will glow solid on. If the LED does not pulse, try swapping the wires at the PPS and PP terminals. If the LED still does not work, contact the factory. If the correct speed is shown proceed to “Learn the Hoistway”. 8.22 Correct Car Speed When Using 485 Tapeless System When using the 485 tapeless system, the secondary speed feedback comes from the encoder mounted on the governor. The 1066 board uses a serial interface to a Turck absolute encoder, part # T8.5882.3F0B.3001. RPM = Speed fpm/ (diameter GOV * pi) For a 1 ft. diameter governor: RPM = 350/ (1*pi) = 350/3.1415 = 111.4 For a 16 in diameter governor (16/12 = 1.33ft): RPM = 350/ (1.33* 3.1415) = 350/4.188 = 83.5 8.23 Correct Car Speed When Using CAN Open Tapeless System When using the CAN Open tapeless system, the secondary speed feedback comes from the HPV 900/600 drive and should be set to 8 times the ppr of the motor encoder. In the 1066 LCD interface "Adj Var" menu, set the "Fdbk Typ = 4", and set the "Enc PPR" equal to 8 times the ppr from the motor encoder. On the 1066 LCD interface, navigate to the "Pls Cnt" menu. While running the elevator on inspection, verify that the pulse count value increments when running up and decrements when running down. The "Pls Cnt" value can be considerably out of range but will automatically correct during the "Learn Hoistway" procedure. To reverse the direction of pulse counting, navigate on the 1066 LCD interface to the "Adj Var" menu, "Enc Dir" and set to "0" for clockwise or "1" for counter‐clockwise. Navigate on the 1066 LCD interface to the "Car Spd" menu. Monitor the "Car Spd" while running the car at a known inspection speed. The value displayed should match the actual car speed measured with a hand held tachometer. If the speed is correct, proceed to Section 8.24, Learn The Hoistway. 8.24 Learn the Hoistway Run the elevator down on inspection until it stops on the down normal limit switch. Verify that the “DN and DL” input LED’s are both off and that the "UL" and "DZ" LED's are on. From the 1021/1101/1005 LCD interface navigate to the "Elevator Setup" menu, "Learn Hoistway". The learn procedure can be performed automatically by choosing "Auto" from the menu items, or performed manually by choosing "Insp” from the menu items. After choosing the learn method, follow the instructions displayed on 1021/1101/1005 LCD interface. In general, the car will run up from the "down normal limit" to the "up normal limit" at 30 fpm. During this learn run, the DP count for each floor level and each limit switch will be stored in memory. NOTE: The car must run the entire hoistway without stopping. As the elevator moves up the hoistway, navigate to the "Hoistway Tables" menu, "Disp/Mod Hoistway Table", and verify that the "DP" count is incrementing as the elevator moves up. Also as the elevator P a g e | 153 HPV-900 PM AC Gearless In the 1066 LCD interface "Adj Var" menu, set the "Fdbk Typ = 1", and set the "Enc PPR = 8192". The "Enc RPM" value must be calculated as described below. To calculate the RPM, divide the contract speed of the car by the distance travel in one revolution with the governor as shown below: passes each floor, the pulse count and distance for that floor should change and be stored. Verify that the floor distances are valid. The pulse count for the terminal slowdowns will also be stored. The elevator will stop when it reaches the up normal limit. Follow the instructions on the 1021/1101/1005 LCD interface by putting the car on inspection, and then the message "Hoistway Learn Complete" should be displayed. Move the elevator on inspection until the “DZ and DL” LED’s are on. Set the "INS" toggle switch on the 1064 board to the "NORMAL" position, and the elevator should level down to floor level at the top floor. If so, proceed to final adjustment. If the car levels down but does not run, then check “Elevator Status” and “View Fault Log” on the 1021/1101/1005 LCD interface for any fault information. Correct items causing faults and perform hoistway learn again. After problem is corrected, proceed to final adjustment. 8.25 Automatic Run The elevator should now be sitting idle at the top floor. The "AUTO DOOR" switch should be set to the "OFF" position and the "IND" switch should be set to the "IND" position. If the learn procedure was successful, the elevator should be ready to make an automatic run. The default parameter settings for the ride quality should be adequate for an initial run. From the 1021/1101/1005 LCD interface navigate to the "Set Calls and Lockouts" menu, "Setup Car Calls" and enter a car call. The elevator should run to answer the call. When the elevator levels in and stops at the floor, the doors will remain closed. The acceleration and deceleration of the car should be smooth and stepless regardless of the distance of the run. If the elevator does not function as described above, then problem should be analyzed before proceeding. 8.26 Fine Tune the Ride Quality In order to fine tune the ride quality, refer to Figure 8.2 which describes what part of the S‐ curve that the different parameters effect. In general, higher numbers in the given parameters, cause quicker and more abrupt changes from one mode to the next during a run. All of the S‐curve parameters have a minimum and maximum value. The control will not allow you to enter values that are not valid. After adjusting the S‐curve parameters for the desired ride, proceed to the next step. HPV-900 PM AC Gearless Figure 8.2: S‐Curve Parameters 8.27 Adjust the Stop When at floor level the “UL, DL, & DZ” input LED’s should be on. If the elevator continually tries to seek floor level by leveling up and down, try the following steps to correct the problem: Increase the response of the drive by increasing the value of A1 RESPONSE in the HPV 900/600 drive, and retesting the car. Reduce the leveling and re‐leveling velocity parameters from the 1021/1101/1005 LCD interface "Adjustable Variables" menu, "Car Motion", "Leveling Speed" and "Relevel Speed". If the car still oscillates, adjust the "floor level zone" on the selector. The "floor level zone" is increased by moving the "UL" and "DL" sensors closer together. If the car stops hard on the brake, then make the following adjustments. From the 1021/1101/1005 LCD interface navigate to the "Adjustable Variables" menu, "Car Motion", and adjust both "Brake Drop Del" (brake drop delay) and "Soft Stop Time". These variables should be adjusted so that zero speed is observed at the end of the run prior to the brake setting. The controller should hold the car at zero speed for the duration of the "Soft Stop Time" which should continue while the brake is setting and for a short time after the brake sets. The soft stop time MUST be set to at least 0.5 seconds LONGER than the "Brake Drop Del". The "Soft Stop Time" setting in the 1021/1101/1005 LCD interface should be compared with the setting in the 1066 LCD interface "Adj Var" menu, "SoftStop". The setting of "SoftStop" in the 1066 LCD interface should be greater than the "Soft Stop Time” setting in the 1021/1101/1005 LCD interface. If the car spots when approaching the floor, the cause is usually due to the car not tracking (the drive response is set too low) or the speed profile into the floor is too aggressive. First try to increase the response of the drive by increasing the value of parameter A1 RESPONSE in the drive. P a g e | 155 If the car still spots, from the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and increase the value of "Floor Targ Dis" (floor targeting distance). The default value for the floor targeting distance is 12 inches. Increase it by steps of 2 or 3 and continue retesting until the parameter is adjusted to 18. If no change is noticed, start again from 12 and decrease the value. The deceleration rate can also be reduced to help remove the spotting. Proceed with adjusting the start once the proper stop is achieved. 8.28 Adjust the Start To provide a proper start, from the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and adjust "Brake Pick Del" (brake pick delay), "Pattern Delay", and "Soft Start Jerk". Initially, set the brake pick delay to 0 and increase the pattern delay by 0.1 seconds until the controller picks the brake completely before the motor starts to move. If roll back occurs, then reduce the pattern delay until there is no roll back. Sometimes, the timing works out better if the brake pick delay is set to 0.1 second. If load weighing is used, pre‐torquing can be used to provide a smoother start. See Section 8.37, Adjust the Motor Pre‐torque. Increase the soft start jerk rate in order to provide a quicker transition from the start to constant acceleration. Keep in mind that the larger the soft start number, the quicker the start. The ride should now be acceptable. 8.29 Verify Top Speed To fine tune high speed, make high speed runs while monitoring the SPEED FEEDBACK on the HPV drive display. The display should read contract speed, and it should match the speed displayed on the 1021/1101/1005 LCD interface, "Elevator Status" menu, "Dmd" and "Vel". This speed should also match the speed displayed on the 1066 LCD interface, "Car Spd" menu. If all of these values are the same (+/‐ 2 fpm), then proceed to the next step. If the speed is not correct increase or decrease drive parameter A1 CONTARCT MTR SPD until the AC drive display reads contract speed, If A1 CONTRACT MTR SPD is changed, then go to the 1021/1101/1005 LCD interface, "Adjustable Variables" menu, "Car Motion" and change the value of "Encoder RPM" to match the drive. When the speed displayed is correct, proceed to the next step. The 1066 Safety Processor Board monitors the speed of the elevator at the terminal landings independently from the main CPU. When the "UT, DT, UTS, and DTS" limit switches are activated, the 1066 board calculates the velocity of the elevator and compares that velocity with a stored value of speed clamp. If the velocity when the switch activates is greater than the speed clamp value, then the 1066 board will generate a fault that stops the elevator. To set the speed clamps, make a one floor run to the top floor. From the 1066 LCD interface, navigate to the "Lim Vel" menu, and view the recorded velocities displayed for the “UT, DT, UTS & DTS” slowdown limits. “UTS & DTS” are used on car with reduced stroke buffers or with a top speed greater than 200 fpm. The velocity value is shown from the “Lim Vel” menu on the 1066 LCD interface. The velocity value shown on the display for the “UT or DT” limit is the value after the car activates the limit then counts an adjustable number of counts set from the 1066 LCD interface, "Adj Var" menu, "UT Count" or "DT Count". These count values can be adjusted to provide adequate distance, following the limit switch activation, to allow the elevator to begin its normal decel pattern. The default “UT Count" and "DT Count" values are normally adequate. However, these values may need to be field adjusted to allow enough distance for the car to begin its normal decel pattern. If the "UT Count" and "DT Count" values are modified, the limit velocities must be re‐checked. Run the car again to the top repeatedly from 2 floors, then 3 floors, etc., until top speed is reached. From the 1066 LCD interface "Lim Vel" menu, record the limit velocities displayed each time the car stops at the top floor. Make the same runs to the bottom floor starting from 1 floor, then 2 floors, then 3 floors, etc., until top speed is reached. From the 1066 LCD interface "Lim Vel" menu, record the limit velocities displayed each time the car stops at the bottom floor. Take the highest speed value recorded in the runs above and add 20 fpm to that value to use as the clamp speed values for the respective limit switches. Enter these clamp speed values into the 1066 LCD interface "Adj Var" menu, "UT Vel", "DT Vel", "UTS Vel", "DTS Vel" respectively. 8.31 Adjust Digital Slowdown Speed Clamps Having just made several runs into the top and bottom landings, the main CPU has also recorded the car’s velocity when the slowdown limits were activated. If the car has been powered down prior to this step, several runs must be made to the terminal landings to allow the main CPU to record the limit velocity values. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Set DT/UT Slowdown Clamp" and view the speed displayed for "Clamp Speed". Add 20 fpm to this "Clamp Speed" value and enter it into the “DT/UT Limit" P a g e | 157 HPV-900 PM AC Gearless 8.30 Adjust Safety Processor Board Speed Clamps The number of slowdown limits depends on the speed of the car as show in the table below: Adjust speed clamps for each slowdown limits used as determined by the elevator’s contract speed. Table 8.1: Slowdown Clamps 8.32 Verify Inspection Velocity Clamp On Safety Processor Board Place the car on inspection operation. From the 1066 LCD interface, navigate to the "Adj Var" menu, "Ins Vel" and set the speed clamp velocity to 25 fpm. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the "Inspect Speed" to 50 fpm. Run the car in either direction and verify that the car shuts down when the speed rises above 25 fpm. From the 1066 LCD interface, navigate to the "Adj Var" menu, "Ins Vel" and set the speed clamp to 140 fpm. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and set the “Inspect Speed" to the desired value. 8.33 Analog Load Weigher Setup If the job uses an analog load weigher purchased from G.A.L., complete the following procedure. NOTE: It is recommended using two people, one moving the weights and one in the machine room to set up the load weigher. Mount the load weigher as described by the manufacturer. The load weigher control box will also contain a board supplied by G.A.L. that connects to the controller serial CAN bus and reads in the analog output from the load weighing device. Wire the load weigher and G.A.L. board according to the controller schematics. Calibrate the load weighing device hardware according to the manufacturer’s instructions. Following proper installation of the load weighing device, and proceed to Section 8.34, Empty Car Setup. Verify that the load weighing device is communicating to the main CPU by performing the following steps. From the 1021/1101/1005 LCD interface, navigate to the "Diagnostics" menu, "Car Comm Status", "Car to LW Board" and verify that "On‐ line = 1". If "On‐line = 0" then verify wiring and installation of load weighing device. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "Setup Load Weigher" and follow the instructions on the display as you go through the procedure. It is okay to exit the setup screen to place a call and then return to it while the setup is being performed. Run the car to the bottom floor and press Enter on the 1021/1101/1005 LCD interface when prompted to do so to start the automatic setup sequence. If the car is at the bottom floor and the doors are not closed (the doors will not close automatically from turning off the auto‐door switch) then place a car call to run the car up one floor then back again. The doors will close when the call is placed. When the automatic sequence is activated, the car will run to each floor and measure the empty load value. The 1021/1101/1005 LCD interface will indicate when the sequence if finished. 8.35 Full Car Setup NOTE: The empty car setup must be successfully completed to run the full load setup. Once the empty car setup is complete, run to the loading floor and set the "AUTO DOOR" switch to the "ON" position to allow weights to be loaded on the car. With the car fully loaded, test the "AUTO DOOR" switch to the "OFF" position and run the car to the bottom floor. Again if the doors are not closed, make a one floor run to force the doors to close. With the car at the bottom floor, follow the instructions on the 1021/1101/1005 LCD interface to start the full load setup sequence. The car will automatically run to each floor and measure the full load value. When the full load measurement is complete, the car can be run to the loading floor and the weights removed. After the weights are removed, cycle the doors to complete the procedure. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "View/Modify LW Setup" and verify the load weigher status, "LW Device Stat: ON OK". If the status is "ON OK", then the load weigher should be accurately measuring the car load in real time. The percent load will be displayed, "Load: _%". P a g e | 159 HPV-900 PM AC Gearless 8.34 Empty Car Setup The percent load values for different service options can now be set. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Service Options", and set the following variables: "Load Bypass" "Load Antinuisance" "Load Dispatch" "Load Overload" NOTE: Setting the values of the variables above to 0% will disable that particular option. 8.36 Load Weighing Calibration Sequence The load weigher is automatically calibrated once each week. If an error is detected during this calibration sequence, the load weigher and the pre‐torque feature (if used) is disabled. A load weighing calibration sequence can be manually activated by performing the following procedure. From the 1021/1101/1005 LCD interface, navigate to the "Elevator Setup" menu, "Load Weigher Setup", "Load Weigher Calibration" and follow the instructions on the display. 8.37 Adjust the Motor Pre‐torque NOTE: The motor pre‐torque uses the load value obtained from the analog load weigher and will work only if the load weigher is installed and successfully setup. On the HPV‐900 PM drive under User Switches C1 parameter, set Pre‐Torque source to serial. Run the empty car to a middle floor. From the 1021/1101/1005 LCD user interface, navigate to the "Adjustable Variables" menu, "Car Motion" and adjust the following parameters: "Balanced Load = 40" (typically car is 40% counterbalanced, but verify counterbalance percentage for each specific job) "Torque Amount = 10" "Pattern Delay = 2.5" "Brake Pick Del = 0.1" The long pattern delay will allow an exaggerated amount of roll back in order for the pre‐torquing to be set accurately. Make a one floor run down and observe the roll back when the brake picks at the start of the run. Increase the "Torque Amount" variable and continue to monitor the roll back while performing Note: The pattern delay must be at least 0.15 seconds (150 milliseconds). Setting the torque amount to 0.00 will disable the pre‐torque feature. Also if the load weighing calibration sequence detects a load weighing error, the pre‐ torque feature is also automatically disabled. 8.38 Verify the Doors Are Safe The elevator should now be adjusted. Verify that all door locks, gate switches, and safety circuits are operational. Set the "INS" switch to the "NORM" position and set the "AUTO DOOR" switch to the "ON" position. The elevator should level into the floor and open the doors. If the doors do not open, check the door operator wiring and cam adjustment. If the doors do open, the elevator is now on independent service. 8.39 Fine Tune the Ride Quality Ride the elevator and evaluate the ride quality. Fine tune ride quality by navigating to the "Adjustable Variables" menu, "Car Motion" and adjusting the variables shown in Figure 4.2. Keep in mind that if acceleration or deceleration values are changed, the speed clamps for the safety processor board and the S‐curve board may need to be re‐adjusted. To fine tune the floor level accuracy, determine if the controller is set to stop when "UL" and "DL" signals turn on, or if controller is set to stop off of the position count. From the 1021/1101/1005 LCD interface, navigate to the "Adjustable Variables" menu, "Car Motion" and view the "Stop On Pos Cnt" variable. If "Stop On Pos Cnt= 0" then controller is set to stop when the "UL and "DL" signals turn on. If "Stop On Pos Cnt = 1" then controller is set to stop on a combination of the floor level magnet and the position count. With "Stop On Pos Cnt = 0", the floor levels should be set by adjusting the floor level magnet at each floor. For proper operation, the floor magnets should be set to exactly floor level. After the floor levels are set properly, perform another hoistway learn procedure. With "Stop On Pos Cnt = 1", the floor levels are set by using both the floor magnet and the position count. For proper operation with this setting, the floor magnet should be set to exactly floor level. The final stop can then be fine‐tuned by performing the following adjustments. From the 1021/1101/1005 LCD interface, navigate to the "Hoistway Tables" menu, "DZ & LZ Offset, Sel Cnt" and adjust "Dn Lev Dist" and "Up Lev Dist". The units for these variables are in "pulse counts". With "Stop On Pos Cnt =1" the car will continue to move for the "Dn Lev Dist" or "Up Lev Dist" after "UL and DL" turn on. Use the "Dn Lev Dist" and the "Up Lev Dist" parameters to make level changes at all floors. To make level changes at individual floors, perform the following adjustments. From the 1021/1101/1005 LCD interface, navigate to the "Hoistway Tables" menu, "FL and FL Offset Count", and P a g e | 161 HPV-900 PM AC Gearless one floor runs in the down direction. As the "Torque Amount" is increased, the roll back should be minimized until the car will hold zero speed for the entire "Pattern Delay" time. A typical value for the "Torque Amount" is 40%. If the value is too large, the car will roll forward during the "Pattern Delay" time. the offset count can be adjusted. These variables introduce an offset (+/‐) to the stored floor count that was determined in the hoistway learn procedure. NOTE: The number of pulse counts per inch can be viewed from the 1021/1101/1005 LCD interface, "Hoistway Tables", "DZ & LZ Offset, Sel Cnt”, "Pulses /Inch". NOTE: Regardless if "Stop On Pos Cnt=0" or if "Stop On Pos Cnt =1", the floor magnet must be set properly at floor level. If too large of values are entered into "Dn Lev Dist", "Up Lev Dist", or "Offset", the car will drive past the floor level magnet and re‐level. Check all signal devices for proper operation and remove all temporary jumpers. The adjustment should now be complete. Section 9 ‐ Troubleshooting 9.1 General Information 9.2 Microprocessor CPU The CPU is very reliable and normally trouble free. With power turned on, the “axy” in GALaxy on the 1021/1101/1005 LCD interface should be blinking at one second intervals to indicate that the CPU is running. If it is not blinking, then check voltage at the 5V terminal with respect to the 0V terminal on the 1064 board. This voltage should read 5VDC. If not, then check the input and output voltage of the DC power supply. If the “axy” is not blinking and 5VDC is present at the 5V terminal with respect to the 0V terminal, then contact the factory. All job parameters that are field adjustable are stored in a non‐volatile SRAM chip on the GALX-1036 memory (older) board, or GALX-1100AN (newer) CPU board. If the field adjustable parameters return to the default settings when the main power is turned off, check that the J1 (Pin Devices) jumper on the 1036 board is set to 28 pin and the J2 (VDROP) jumper on the 1036 board is on. Both jumpers are located on the lower right hand corner of the 1036 board, the GALX-1100 CPU board does not have this option. 9.3 Input/Output Boards The two main sections of all the I/O boards are the low voltage and the high voltage sections. The low voltage section consists of all the digital interfacing necessary for the CPU to communicate with the field components. The high voltage section consists of the field components (buttons, switches, lights, relays and sensors) and their associated input and output signals. The standard voltage for all I/O is 120VAC. However, if necessary, the I/O boards can accept a voltage range from 24V to 120V AC and 24V DC. The GALX-1064AN main board only accepts 120V AC. See Figure 9.0. P a g e | 163 Section 9 - Troubleshooting The GALaxy controller is equipped with a number of features that aid in troubleshooting any problems that may occur. The physical layout of the controller provides ready access to all I/O in order to make voltage measurements. All inputs have LED’s that monitor the state of the input. The controller is equipped with the 1021/1101/1005 LCD interface for the Main CPU and the 1066 LCD interface for the Safety Processor Board. Section 10 describes the use of the 1021/1101/1005 LCD interface, and Section 13 describes the use of the 1066 LCD interface. In this section the basic points of troubleshooting will be detailed. Figure 9.0 - High Voltage & Low Voltage It is very important that the wiring schematics are reviewed in order to determine the voltages for which the controller was designed before applying power. The majority of problems that may arise with the control system are due to faulty inputs or outputs on the high voltage side of the system. For example, having a limit switch not feeding or an acknowledgment light out. The GALaxy control system is designed to enable the technician to check both the high voltage section and the low voltage section to correct the problem. The high voltage section is checked with a digital voltmeter or with the individual LEDs that are associated with each input. Depending on the particular input or output, the voltage measured at the terminal will either be “high” or “low” with respect to its reference point. For example, to determine whether or not the up terminal slowdown limit switch was feeding, the voltage should be measured at terminal “UT” with respect to “GND”. Another means by which to determine whether the switch is feeding is to view the “UT” input LED. If the LED is on, the switch is feeding. If the LED is off, the switch is open. The previous example determines whether or not the field component is functioning properly. However, to determine if the signal is actually being communicated to the CPU the signal must be checked on the low voltage section of the board. The low voltage section is checked from the 1021/1101/1005 LCD interface. Using the previous example, from the 1021/1101/1005 LCD interface, navigate to the "Inputs and Outputs" menu, "Car Inputs and Outputs" and scroll through the I/O list until the "UT" input is located. The LCD will display "UT=1" if the "UT" switch is feeding and "UT=0" if the switch is open. A second example will show how to determine if an output is working properly. With the car at the first floor and the controller designed for 120VAC discrete position indicators, the “P1” output should be on. The voltage measured at terminal “P1” with respect to “GND”, should read 120VAC. If the voltage reads less than 50VAC, the voltage supplied to the output device must be checked. The schematic, in this case, would show the “P1” voltage is supplied at the “PIC” terminal. A voltmeter would be used to measure the voltage between “PIC” and “GND”. If that voltage is at the terminal but the indicator is not on. The 1021/1101/1005 LCD interface could be used to view if the CPU is turning the “P1” output on. From the 1021/1101/1005 LCD interface, navigate to the "Inputs and Outputs" menu, "Car Inputs and Outputs" and, scroll through the I/O list until the “P1” is located. The display will show “P1=1” which indicates that the CPU is sending a signal to turn on the “P1” output. For this example, since the CPU is turning on the output, and the correct voltage is at the output common but not at the output terminal, it would indicate that the output solid‐state relay for “P1” is defective and should be replaced. All of the I/O and their associated IC’s are listed in the wiring schematics. The following diagram in Figure 9.1 shows the run sequence of the controller. The timing of BRK changes with the adjustment variable DON Start Control. When set to 0 the BRK output turns on before DON and when set to 1 BRK turns on after DON. The BRK timing typical works best with the adjustable variable set to 0 for VVVF and 1 for DC SCR. Figure 9.1 Run Sequence P a g e | 165 Section 9 - Troubleshooting All of the I/O’s are optically isolated between the high voltage section and the low voltage section. The input optoisolators and the output solid‐ state relays are socketed IC's that are labeled on the silk screen of the various I/O boards with a "U" number (for example U45). If it is determined through the previous troubleshooting procedures that the input signal is present at the terminal, but is not being communicated to the CPU, the input optoisolator may be defective and can be replaced in the field. If it is determined that the CPU is communicating the output signal to the solid‐state relay, but the voltage does not go high at the terminal, the solid‐state relay may be defective and can be replaced in the field. Any time IC’s are replaced, the power should be turned off and care should be taken in removal of the old chip and replacement of the new one. Figure 9.2 – Safety Processor Board The Safety Processor Board has two fault LED’s, one on the top center and one on the bottom center of the board. The top center LED is for PAL inhibit and the bottom center one is for PIC inhibit (See Figure 9.2). Important: When either LED is on, this board will prevent the car from running. The Safety Processor Board performs the following functions (See “Safety Processor Functions” in Section 13): Verifies the speed of the car when terminal limits are activated Verifies that the doors are closed and safe to run Verifies all inspection operations Verifies that the car velocity is not greater than 150 fpm in the door zone and with the doors open. While the Safety Processor Board cannot turn on any run control signals, it can turn off the follow signals from the main CPU: RUNA, BRK, UP, DNR, UPF and DF. The SFC relay in the safety string is also controlled by the Safety Processor Board. The Safety Processor board detects two types of faults, active faults and velocity faults. Active faults are input conditions that are considered as unsafe or an error such as the lock bypass switch place on while the car is on automatic. Velocity faults are generated when the Safety Processor Board detects that the car speed is too high during certain conditions, such as hitting the DTS terminal limit at a speed greater than the speed setting for that limit. Both types of faults are reset after a 2 second delay, the condition is corrected and the main CPU is not commanding an up or down run. When troubleshooting errors detected by the Safety Processor board, take the following steps: Check LED status. Either PAL inhibit or PIC inhibit LED on indicates an error. View the elevator service “Elev Serv”. Anything other than Automatic or a valid inspection service is an error. From the 1066 LCD interface, navigate to the "Inp/Out" menu, and view all of the I/O status. See Section 13 for a complete description of the input and output signals. From the 1066 LCD interface, navigate to the "Faults" menu, and view the recorded faults. The Safety Processor Board faults are recorded in ram and will be lost when power is turned off. As mentioned earlier, RUNA is one of the signals that can be turned off by the Safety Processor Board. If a "RUNA Off" error is generated on the 1021/1101/1005 LCD interface (main CPU), it is typically caused by the Safety Processor detecting an error at the instant the run is starting. When a RUNA Off error is recorded, check the status of the Safety Processor board first. During a fault condition when the Safety Processor drops the SFC relay, every input after the SFC terminal will lose voltage including the inputs for the normal and terminal limits. This could cause an Up or Down directional limit error on the main CPU. Additional fault information is shown in the next section, System Faults. 9.4 System Faults Faults that are detected by the main CPU can be viewed on the 1021/1101/1005 LCD interface by navigating to the "Fault Log" menu, "View Fault Log". The possible faults detected by the main CPU are listed in Section 11, Main CPU Faults. By pressing the "ENTER" button on the 1021/1101/1005 LCD interface when the particular fault is being displayed, the interface will display detailed information for that fault. The Detailed Faults Section (Section 11) describes this information. In general, when a fault occurs, the system records the state of all the items listed in the Detailed Fault and makes that information available for troubleshooting purposes. Faults that are detected by the Safety Processor board can be viewed on the 1066 LCD interface by navigating to the "Faults" menu. The possible faults detected by the Safety Processor are listed in Section 13, Safety Processor 1066 LCD Interface. P a g e | 167 Section 9 - Troubleshooting Section 10 – 1021/1101/1005 LCD Interface 10.1 Operating the 1021/1101/1005 LCD Interface UP button is used to scroll up to the next menu item or to increment a data value. DOWN button is used to scroll down to the next menu item or to decrement a data value. MODE button is used to go back to the previous menu or to select a digit of a data value. ENTER button is used to select the menu item or to complete the operation of changing a data value. Potentiometer is used to adjust the viewing angle. It will make the display lighter or darker. The LCD display interface board uses a 2 line by 24-character display and four buttons. This interface allows the user to adjust parameters, view critical controller information, to implement the controller setup and to view the elevator status. Upon power‐up the display shows a blinking GALaxy name to indicate the controller is running as show above. The four inputs buttons used with the LCD display are, UP, DOWN, MODE and ENTER. The UP and DOWN buttons are used to scroll up and down to each menu item. When an appropriate menu item is reached, the ENTER button is used to select the item. Some menu items, once selected, show a second menu. Again, use the UP and DOWN buttons to scroll through the menu items and the ENTER button to select a particular item. The MODE button is used to go back to the previous menu. When a menu item is an adjustable variable, select the item with the ENTER button and change the variable with the UP or DOWN button. The MODE button is used to move the cursor to the next digit. When the appropriate value is reached, used the ENTER button to complete the variable change operation and return to the current menu. The following are descriptions of the flowcharts at the end of the chapter. The descriptions and flowcharts are separated to allow more page territory to the graphics and make them more readable. The descriptions are in the same order as the flowcharts. This flowchart shows all the top level menus in the system. 10.3 Elevator Status The elevator status display continuously updates to show the current status and fault information. The Up and Down keys allows access to both the status display and the velocity display. When a system fault occurs, it will be displayed on the top line of the status display while the fault exists and will remain for 60 seconds after the fault is cleared. The following status information can be displayed: P a g e | 169 Section 10 – 1021/1101/1005 LCD Interface 10.2 1021/1101/1005 LCD Interface Main Menu 10.4 Elevator Service Out of Service Automatic Service Independent Service Load Weighing By Pass Attendant Service Code Blue Service Fire Service Phase 2 Emergency Power Service Earth Quake Service Fire Phase 1 Main Return Fire Phase 1 Alt Return Homing Reset Going Up Reset Going Down Stalled Out of Service 10.5 Fault Status Reset Fault Out Of Step Fault Binary Input Fault Safety String Fault Door Zone Fault Stalled Fault Door Open Fault Door Close Fault Up Directional Fault Dn Directional Fault No Potential Fault Stop Switch Fault Gate or Interlock LC Fuse Blown Fault HC Fuse Blown Fault Drive Ready Fault 'P' Input Off Fault Car Safe Fault UL or DL off Fault Delta off Fault UT count Fault UT1 count Fault UT2 count Fault UT3 count Fault DT count Fault DT1 count Fault DT2 count Fault DT3 count Fault Rear Door Open Flt Rear Door Close Flt Group Comm Loss Car 1 Comm Loss Car 2 Comm Loss Car 3 Comm Loss Car 4 Comm Loss Car 5 Comm Loss Car 6 Comm Loss RUN I/O Failed ON RUN I/O Failed OFF RUNA I/O Failed ON RUNA I/O Failed OFF UP I/O Failed ON UP I/O Failed OFF DNR I/O Failed ON DNR I/O Failed OFF UPF I/O Failed ON Section 10 – 1021/1101/1005 LCD Interface P a g e | 171 UPF I/O Failed OFF DF I/O Failed ON DF I/O Failed OFF MCC I/O Failed ON MCC I/O Failed OFF MCA I/O Failed ON MCA I/O Failed OFF BRK I/O Failed ON BRK I/O Failed OFF DON I/O Failed ON DON I/O Failed OFF RUN I/O or UP Fail RUN I/O or DNR Fail Top Door Lock Fault Mid Door Lock Fault Bot Door Lock Fault Gate Switch Fault Rear Top Lock Fault Rear Mid Lock Fault Rear Bot Lock Fault Rear Gate Sw Fault 'P' Input On Fault Estop Fault Inspection Input Flt Gate/Lock Byp Sw Flt GRT1 input ON Fault GRT1 input OFF Fault GRT2 input ON Fault GRT2 input OFF Fault Gripper did not Pick Gripper Trip Fault 10.6 Elevator Status Reset Mode PI= 1 Inspection Mode PI= 1 Up Fast PI= 1 Up Transition PI= 1 Leveling Up PI= 1 Down Fast PI= 1 Down Transition PI= 1 Leveling Down PI= 1 Soft Start Mode PI= 1 Constant Accel PI= 1 Roll Over Max Vel PI= 1 Constant Velocity PI= 1 Roll Over Deccel PI= 1 Constant Deccel PI= 1 Targeting Floor PI= 1 Emergency Slowdown PI= 1 Safety String Open PI= 1 Elevator Off Line PI= 1 Elevator Parked PI= 1 Waiting Assignment PI= 1 Door Procedure PI= 1 Elevator Stalled PI= 1 Section 10 – 1021/1101/1005 LCD Interface 10.7 Door Status Elev Door Closed PI= 1 Elev Door Opening PI= 1 Elev Door Dwelling PI= 1 Elev Door Open PI= 1 Elev Door Closing PI= 1 Elev Door Nudging PI= 1 F1RET Door Open PI= 1 P a g e | 173 F2CPO Door Open PI= 1 F2CPO Door Opening PI= 1 F2CPO Door Closed PI= 1 F2CPO Door Closing PI= 1 F2CPC Door Open PI= 1 F2CPC Door Opening PI= 1 F2CPC Door Closed PI= 1 F2CPC Door Closing PI= 1 F2HLD Door Open PI= 1 F2HLD Door Opening PI= 1 F2HLD Door Closed PI= 1 F2HLD Door Closing PI= 1 F2MBC Door Open PI= 1 F2MBC Door Opening PI= 1 F2MBC Door Closed PI= 1 F2MBC Door Closing PI= 1 10.8 Rear Door Status Rear Door Closed PI= 1 Rear Door Opening PI= 1 Rear Door Dwelling PI= 1 Rear Door Open PI= 1 Rear Door Closing PI= 1 Rear Door Nudging PI= 1 F1RET RDor Open PI= 1 F2CPO RDor Open PI= 1 F2CPO RDor Opening PI= 1 F2CPO RDor Closed PI= 1 F2CPO RDor Closing PI= 1 F2CPC RDor Open PI= 1 F2CPC RDor Opening PI= 1 F2CPC RDor Closed PI= 1 F2CPC RDor Closing PI= 1 F2HLD RDor Open PI= 1 F2HLD RDor Opening PI= 1 F2HLD RDor Closed PI= 1 F2HLD RDor Closing PI= 1 F2MBC RDor Open PI= 1 F2MBC RDor Opening PI= 1 F2MBC RDor Closed PI= 1 F2MBC RDor Closing PI= 1 10.9 Set Calls and Lockouts When a car is in the group the menu system allows access to setting both hall calls and car calls. When not the group, only car calls can be set. Rear lockouts are only displayed only when the car has a rear door. This menu allows the mechanic to initiate a continuous test of the elevator. The test can be conducted with the “AUTO DOORS” switch set to “ON” or “OFF”. By following the instructions from the menu, the “Car Call Test” can be initiated or discontinued. When performing the “Car Call Test”, the car will answer all of the registered calls in one direction. When the last call has been answered, the calls will be re‐ initiated automatically, and the car will answer the calls in the opposite direction. This operation will continue until one of the following occurs. 1. The test is discontinued from the 1021/1101/1005 LCD interface 2. The car is taken out of automatic operation 3. A fault occurs NOTE: The car will not perform the “Car Call Test” if it is on “Independent Service”. NOTE: When performing the “Car Call Test” with the “AUTO DOORS” switch set to “OFF”, it is recommended to set the “Non‐interference Time” to at least 5 seconds. From the 1021/1101/1005 LCD interface, navigate to the “Adjustable Variables” menu, “Car Timers” and set “Non Interfer T = 5”. P a g e | 175 Section 10 – 1021/1101/1005 LCD Interface 10.10 Car Call Test 10.10a CAN Encoder Comm Status Submenu This menu indicates if the CAN Open Encoder is on-line and communicating. 10.10b UPS Comm Status Submenu This menu indicates is the UPS System is on-line and also gives battery status. 10.11 Lockouts Front Car Calls Procedure to lock out front car calls. 10.12 Car/Group Inputs & Outputs Inputs and outputs show a “1” for ON and a “0” for OFF. A list every input and output used on the controller and the board it is located on is shown in Appendix A. The controller determines which boards are used depending on the options selected and the number of front and rear floors. All the I/Os for a given board are displayed even if a particular I/O is not used. 10.13 Job Statistics – Clear Job Statistics The Job Statistics menu shows the number car calls and the number and percent of hall calls serviced since the job was started or since the job statistics were cleared. Below is a list of all the categories maintained: Number of Car Calls Number of Up Hall Calls Number of Down Hall Calls Number of Up Hall Calls with < 15 second wait time Number of Up Hall Calls with < 30 second wait time Number of Up Hall Calls with < 45 second wait time Number of Up Hall Calls with < 60 second wait time Number of Up Hall Calls with > 60 second wait time Number of Down Hall Calls with < 15 second wait time Number of Down Hall Calls with < 30 second wait time Number of Down Hall Calls with < 45 second wait time Number of Down Hall Calls with < 60 second wait time Number of Down Hall Calls with > 60 second wait time Percent of Hall Calls with < 15 second wait time Percent of Hall Calls with < 30 second wait time Percent of Hall Calls with < 45 second wait time Percent of Hall Calls with < 60 second wait time Percent of Hall Calls with > 60 second wait time 10.14 Adjustable Variables This is the Adjustable Variables sub‐ menu. 10.15 Car Timers This is an example of a sub‐menu in Adjustable Variables. 10.16 Date and Time It is important to set the date and time on the controller clock so that the fault log shows the correct time sequence that faults occur. In this menu the car comm, group comm, and drive communications can be verified. 10.18 View System Status This is a running log of all the steps taken during operation of the elevator. 10.19 Group Comm Status The group communications status shows the number of data packets successfully transmitted and received from the group to the cars, for the “group” car, and from the car to the group for the remaining cars. The communication sequence is always initiated by the group. The group sends a data packet to the car and after the car validates the checksum of the packet, it responds with a data packet to the group. The transmit and receive counters should always be incrementing in both the car and the “group” car. If either counter does not increment, it would indicate a poor cable connection or that there is electrical noise on the communications cable. Electrical noise is usually caused by installing the communications cable in the same conduit with high voltage wires. P a g e | 177 Section 10 – 1021/1101/1005 LCD Interface 10.17 Diagnostics 10.20 Car Comm Status The car communications status shows the number of data packets successfully transmitted and received from the car to devices on the car’s CAN bus. These devices can be mounted in the motor room, in the car operating panel or on the car top. The second line of the car status shows the device software version number and if the device is currently on line communicating. The transmit and receive counters should always be incrementing for all devices. If the receive counter does not increment, it would indicate a poor cable connection or that there is electrical noise on the communications cable. Electrical noise is usually caused by installing the communications cable in the same conduit with high voltage wires. 10.21 Drive Comm Status The drive communications status shows the number of data packets successfully transmitted and received from the car to the drive. The second line of the drive status shows the drive’s software version number and if the drive is currently on line communicating. The transmit and receive counters should always be incrementing for all devices. If the receive counter does not increment, it would indicate a poor cable connection or that there is electrical noise on the communications cable. 10.22 Software Utilities The software utilities menu allows the user to view the controller’s software version or to place the controller in file transfer mode to upload or download the controller software to another version. To place the car in file transfer mode, the car must be on inspection. As shown in the above diagram, the controller is programmed to be Car # 1, having software version 6.00.31. 10.23 LCD Interface - SD Card Read - Write Data Submenu In this menu various data can be written/backed up to the SD Card and also read from the SD Card. 10.24 LCD Interface - Power-Up Mode Power-Up mode is reached by powering up the controller without an SD Card, or it can be activated from Software Utilities. In this mode you can reset the watchdog timer, update/verify software and run the controller program. 10.25 LCD Interface - Update - Verify Program Submenu This menu is used to update the GALaxy controller software. 10.26 Select Video Display This flowchart is valid when the monitor is installed on the dispatcher car. If the monitor is installed on a non‐dispatcher car, then only information for that car is displayed on the monitor. 10.27 Display Hoistway Table This menu is useful for checking the direction of the encoder by watching if pulse counts are counting up or down. Once the hoistway is learned, the pulse count values for each floor can be displayed. If the pulse count for each floor is zero, the hoistway has not been learned or retained in memory. The velocity displayed here is the speed of the car read from the motor encoder. 10.28 Auto/Inspection Learn Hoistway This operation is used to automatically learn the hoistway on initial setup. From the LCD Interface, select the “Elevator Setup” menu, use the up or down button to select the “Learn Hoistway” item and then hit enter. Follow the directions displayed for each step. Learn Hoistway can be initiated with the car located anywhere in the hoistway but is usually quicker to run the car to the bottom first. This operation is used to manually learn the hoistway on initial setup. From the LCD Interface, select the “Elevator Setup” menu, use the up or down button to select the “Learn Hoistway” item and then hit enter. Follow the directions displayed for each step. Learn Hoistway can be initiated with the car located anywhere in the hoistway but is usually quicker to run the car to the bottom first. This menu provides status information when using a CAN open encoder. It also allows the mechanic to adjust the “Dn Lev Dist” and “Up Lev Dist” parameters in order to “fine tune” the floor levels after the car is running high speed. These parameters are valid when the “Stop on Pos” adjustable variable is enabled. Refer to Sections “Fine Tune The Ride Quality” in Sections 3,4,6,7, & 8 for proper adjustment. 10.30 FL & FL Offset Count This menu allows the mechanic to adjust the stored floor count for each floor level. It also allows offsets to be used to “fine tune” the floor levels after the car is running high speed. The “Floor Level Offset” is valid when the “Stop on Pos” adjustable variable is enabled. Refer to Sections “Fine Tune The Ride Quality” in Sections 3,4,6,7, & 8 for proper adjustment. 10.31 Reset Update Count Trig, Pulse Count Update Data This menu is valid when the “Pos Count Upd” variable is enabled. When this variable is enabled, the DP count will be updated while the car is in motion. The “Pulse Count Update Data” menu provides detailed information in order to properly set this variable. The “Reset Update Count Trig” menu allows the mechanic to manually reset the “Update Trigger”. P a g e | 179 Section 10 – 1021/1101/1005 LCD Interface 10.29 DZ & DZ Offset, Sel Cnt 10.32 Elevator Setup/Speed Clamps From this menu, the user can select to set all of the speed clamps, learn the hoistway, run an overspeed test, run a car buffer test or run a counterweight buffer test, open and close the doors on inspection and setup the load weigher. Once the car is running on automatic, the acceleration and deceleration rates are adjusted, and several runs have been made to the top and bottom terminals at contract speed, the speed clamps can then be adjusted. Using the set speed clamp menus on the LCD interface, select the clamp to adjust and hit enter to access that particular speed clamp setting. In the above illustration, the suggested setting is shown as the “Clamp Speed” and the actual clamp setting is shown as “Ins/ Level Spd”. The enter button is used to enter and exit the edit mode. Once in the edit mode, the mode button selects the next digit to edit. The up and down buttons increment or decrement the clamp speed setting. All speed clamps are adjusted in the same manor. The speed clamps that can be adjusted are the inspection/leveling speed clamp, the Down and Up Terminal Slowdown speed clamps (DT/UT, DT1/UT1, DT2/UT2 and DT3/UT3) and the Down and Up Emergency Terminal Speed clamp (DTS/UTS). 10.33 Inspection Open – Close Doors The menu allows the user to open or close the elevator doors from the up or down LCD interface buttons while the car is on inspection. 10.34 Lift Brake on Inspection WARNING: Brake will lift during this test. Make sure all safety procedures are observed. The flowchart describes the steps needed to lift the brake on inspection. 10.35 Load Weigher Setup The load weigher hardware is setup according to the manufacturer’s instructions. The controller is then setup to read the empty and full load values at every floor 10.36 View - Modify Load Weigher Limits In this menu the load limits can be modified. 10.37 Calibrate Load Weigher This is the procedure for calibrating the Loadweigher. 10.38 Counterweight & Buffer Test The car and counterweight buffer test follow the same menu operation. For specific instruction on executing a buffer test, refer to Appendix B. 10.39 Overspeed Test The overspeed test disables the velocity check for the car traveling faster than 15% over contract speed. The mechanism is disabled for one run. See Appendix B for instruction on running an overspeed test. 10.40 Reset Gripper Menu This shows the procedure for resetting a Gripper Fault 10.41 Fault Log This menu allows the user to view or clear the fault log. P a g e | 181 Section 10 – 1021/1101/1005 LCD Interface The fault display shows the fault, the car position, time and date the fault occurred and the number of occurrences. Faults are displayed in the order of occurrence with the order number displayed on the top left. The largest order number signifies the last fault that has occurred. Faults are stored in a circular buffer that fits up to 50 faults. Once the buffer is full the next fault over writes the oldest fault. Refer to the system faults in the troubleshooting section of this manual for possible causes of the fault and a description of the detailed fault data. LCD Interface Flowcharts LCD Interface Main Menu Power Up GALaxy CONTROLLER Up GALaxy Fault Log Mode GALaxy Elevator Status GALaxy Elevator Setup GALaxy Set Calls and lockouts GALaxy Hoistway Tables GALaxy Inputs and outputs GALaxy Service Activation Timer GALaxy Job Statistics GALaxy Select Video Display GALaxy Adjustable Variables GALaxy Software Utilities GALaxy Date and Time GALaxy Diagnostics LCD Interface Main Menu - Elevator Status GALaxy Elevator Status Mode Enter Elevator Status Brake Voltage Requested Voltage Input to Brake Board BkV Rq=120 BkV In=220 BkvOut=118.5 Bk Amp=3.5 Brake Voltage Output Brake Amperage output Above is valid if job has electronic brake board Run=6.50 Lev=2.70 PDO=0 SFI=0 Roll=0 Indication of Short Floor Run Temp of Safety Processor board Floor Position EXT Temp = 76 F SPB Temp = 93 F Time In Leveling Mode Indication of early roll out on short floor run EXT Temp valid if temp sensor provided Feedback Velocity Demand Velocity Velocity Difference Dmd=350 Vel=350 Dir=Up Dif=0 DP=1778556 PI=26 Feedback Direction Floor Position Digital Pulses P a g e | 183 Section 10 – 1021/1101/1005 LCD Interface Brake to Brake Run Time Time In Pre-Opening Mode Automatic Service Waiting Assignment PI=L LCD Interface - Set Calls and Lockouts GALaxy Set Calls and Lockouts Enter Mode Set Calls and Lockouts Setup Hall Calls Enter Press Enter to Setup a Car Call at Floor L Up Up Down Down Set Calls and Lockouts Car Call Test Press Enter to Setup a Car Call at Floor PH Enter to Car Call Test Menu Set Calls and Lockouts Lockout Front Car Calls Press Enter to Setup a Car Call at Floor 21 Enter to Front Car Calls Submenu Section 10 – 1021/1101/1005 LCD Interface If car has rear openings, Rear call menus will appear. Set Calls and Lockouts Setup Up Hall Calls Enter to UP Hall Calls Submenu Set Calls and Lockouts Setup Down Hall Calls Press Enter to Setup a Car Call at Floor 2 Enter Sets Car Call at Floor 2 Enter to Down Hall Calls Submenu LCD Interface - Car Call Test Submenu P a g e | 185 Enter Se Calls and Lockouts Car Call Test Enter if CC test is enabled Do you want to continue with previous CC test? Y Enter if CC test is disabled Enter Are you sure you want to enable CC test? No Do you want to continue with previous CC test? N Down Enter Up Are you sure you want to enable CC test? Yes Press ENTER to Setup a Car Call at Floor 1* Enter Enter Press ENTER to Setup a Car Call at Floor 1 Enter Mode Asterisk appears beside floor number to denote CC test is enabled for that floor. Mode Press ENTER to Setup a Car Call at Floor 1* Up Down To enable CC test at other floors. LCD Interface - Lockout Front Car Calls Submenu Removes asterisk to disable CC test at that floor. Press ENTER to Setup a Car Call at Floor 1 Up Down To disable CC test at other floors. Set Calls and Lockouts Lockout Front Car Calls Enter NOTE: Navigation to lock out Rear Car Calls is similar to procedure below. Enter Are you sure you want to secure car calls? No Down Up Are you sure you want to secure car calls? Yes Enter Enter Mode Asterisk appears beside floor number to denote Car call is locked out. Press ENTER to Modify Front CC Access At: 6* To lock out car calls at other floors. Up ENTER Removes asterisk to unlock car call Down LCD Interface Main Menu - Inputs and Outputs P a g e | 187 Section 10 – 1021/1101/1005 LCD Interface Press ENTER to Modify Front CC Access At: 6 GALaxy Inputs and Outputs Enter Mode Mode Inputs and Outputs Car Inputs and Outputs Enter Main I/O Board Block #1 Up Up Down Mode If Car is Group Dispatcher Inputs and Outputs Group Inputs and Outputs Down EPLH=0 FLH=0 EPRL=0 EPSL=0 FS=0 MES=1 FSX=0 RTL=1 BP=1 MRS=1 DN=1 DT1=1 DT=1 DT2=1 DTS=1 DT3=1 Up Down Mode Hall Call Board #1 Comm Status = 1 Up Down Mode 3U=0 6U=0 4U=0 7U=0 5U=1 8U=1 Up Down Mode 2D=0 5D=0 3D=1 6D=0 4D=0 7D=1 LCD Interface Main Menu - Job Statistics GALaxy Job Statistics Enter Mode Mode Job Statistics View Job Statistics Enter Up Mode Car Calls 15 Up Down Down Job Statistics Clear Job Statistics Hall Calls > 60 Sec. 0% Enter Up Down Press Enter to Clear Job Statistics Hall Calls < 60 Sec. 100% Section 10 – 1021/1101/1005 LCD Interface Mode Enter Mode Job Statistics Cleared Hall Calls < 60 Sec. 100% LCD Interface Main Menu - Adjustable Variables P a g e | 189 GALaxy Adjustable Variables Enter Adjustable Variables Car Motion Up Adjustable Variables Car Brake Down Adjustable Variables Modified Motion Adjustable Variables Drive Parameters The above is only on jobs with KEB drive. Enter To Submenu Adjustable Variables Car Timers Mode From Submenu Adjustable Variables Car Options Adjustable Variables System options Adjustable Variables Service options Adjustable Variables CB, VIP, & HSec Call Light Adjustable Variables Fire Options Adjustable Variables HC & IR Call Lights Adjustable Variables Group Dispatch Adjustable Variables CC & COP Lights Adjustable Variables Group Options LCD Interface Main Menu - Car Timers Submenu MODE To Adjustable Variables Menu ENTER From Adjustable Variables Menu NOTE: This flowchart shows the “Car Timers” submenu. Other “Adjustable Variables” submenus are similar. Car Timers Y Delta Time = 000.15 Up Down Enter Stores the value Car Timers OSER Sopen Tim = 0060.0 Min=0 Max=10.0 Sec Fault Tome = 0002.0 Up Increments Number Car Timers OSER BTFlr Tim = 0060.0 Min=0 Max=10.0 Sec Fault Time = 0002.1 Enter Stores the value Down Decrements Number Min=0 Max=10.0 Sec Fault Time = 0002.0 Enter Stores the value Mode Selects Next Field Min=0 Max=10.0 Sec Fault Time = 0002.0 Enter Car Timers Reset Time = 0005.0 Car Timers Fault Time = 0002.0 Enter Stores the value Enter LCD Interface Main Menu - Date and Time P a g e | 191 Section 10 – 1021/1101/1005 LCD Interface Car Timers OSER Ncall Tim = 0600.0 GALaxy Date and Time Enter Mode Date and Time Set Date and Time Mode Enter Down Date and Time View Day of the Week Press Enter to Set 14:45 3/28/2014 Enter Stores the Value Enter Mode Day of the Week Saturday Selects the next field. Press Enter to Set 14:45 3/28/2014 Up Increments Number Press Enter to Set 14:46 3/28/2014 Down Enter Stores the Value Decrements Number Press Enter to Set 14:45 3/28/2014 LCD Interface Main Menu - Diagnostics Enter Stores the Value Enter Stores the Value GALaxy Diagnostics Enter Mode Diagnostics View System Status Log Up Enter to select Down Diagnostics Clear Drive Comm Status Diagnostics Drive Comm Status Press Enter to Clear the Drive Comm Status Mode Drive Comm Status Cleared NOTE: Similar procedure to clear: System Status Log Car Comm Status Group Comm Status Diagnostics Group Comm Status Diagnostics Clear System Status Log LCD Interface - View System Status Log Submenu P a g e | 193 Section 10 – 1021/1101/1005 LCD Interface Diagnostics Clear Group Comm Status Enter Diagnostics View System Status Log Enter Mode 000 Status Buffer PI=1 Automatic Service Down Up 000 Status Buffer PI=1 Waiting Assignment 000 Status Buffer PI=1 Status OK Status Buffer is grouped into 256 blocks with 4 events per block 000 Status Buffer PI=1 No faults -001 Status Buffer PI=1 Automatic Service -001 Status Buffer PI=1 Waiting Assignment -255 Status Buffer PI=1 Reset Fault LCD Interface - Group Comm Status Submenu Buffer Index Floor Position -001 Status Buffer PI=1 Automatic Service Status Messages Elevator Status Type of service Condition status Fault status Diagnostics Group Comm Status Enter Mode For car that is the group dispatcher Group to Car #1 Internal Comm Down Enter For car that is not the group dispatcher Car #2 to Group TxCnt 10132 RxCnt 10235 Down Up Group to Car #1 Ver: 7.00 On-line=1 Up Car #2 to Group Ver: 7.00 On-line=1 Software version Group to Car #2 TxCnt 3196 RxCnt 3195 Enter to update count Section 10 – 1021/1101/1005 LCD Interface Group to Car #2 Ver: 7.00 On-line=1 Name of comm device Group to Car #3 TxCnt 4567 RxCnt 4569 Transmit count Receive count Group to Hall #1 Ver: 5.54 On-line=1 If On-line=1, device is communicating. If On-line=0 device is not communicating LCD Interface – Car Comm Status Submenu P a g e | 195 Diagnostics Car Can Comm Status Enter Mode Mode Diagnostics Can Bus Error Count CAN Encoder TxErr 0 Comm StatusRxErr 0 EnterDown Up Can Enc Bus Error Count TxErr 0 CarRxErr 0 #9 to TOC Ver: 5.54 Down On-line=1 If On-line=1 device is communicating. If On-line=0, device is not communicating. Up If On-line=1 device is Car to Can EncoderPPR: communicating. 10000 On-Line = 1 If On-line=0, device is Car to TOC #9 not communicating. TxCnt 3196 RXCnt 3195 ENTER To update count Car to Can Encoder TxCnt 0 CarRxCnt ENTER to SEB0#21 Ver: 5.54 On-line=1To update count Transmit count Receive count Name of comm device Car to SEB #21 TxCnt 4567 RxCnt 4569 Transmit count Receive count Car to Brake TxCnt 2183 RXCnt 2165 LCD Interface CAN Encoder Comm Status LCD Interface – UPS Comm Status Submenu Diagnostics UPS Comm Status Enter Mode Car to UPS TxCnt 460 RxCnt 466 Transmit count Receive count Car to UPS Battery Capacity 0.00 % If On-line=1 device is communicating. If On-line=0, device is not communicating. Section 10 – 1021/1101/1005 LCD Interface Car to UPS Status: 00 On-Line = 1 P a g e | 197 LCD Interface - Drive Comm Status Submenu Diagnostics Drive Comm Status Enter Name of drive type Mode Car to HPV-6/900 TxCnt 5387 RxCnt 5163 Transmit count ENTER To increment count Receive count Down Up Car to HPV-6/900 Ver: 1.01 On-line=1 If On-line=1, device Is communicating. If On-line=0, device Is not communicating LCD Interface Main Menu - Software Utilities GALaxy Software Utilities Mode Enter Software Utilities View Software Version Enter Mode Car #1 HR Software Ver: 6.00.31 Software Utilities Clear Trace Software Utilities Initialize & Start Trace Used for CPU replacement Software Utilities Load 1036 Field variables Used for CPU replacement Software Utilities SD Card Status Software Utilities SD Card Read / Write data Software Utilities Reset Debug Variables SD Card Status Press Enter for Status Enter Mode Enter Mode Enter SD Card Status Init=1, HC=1, Vstat=1 Mode Press Enter to Select SD Card Read Write Data Menu Press Mode to return Debug Variables Reset Enter Software Utilities Test Watchdog Reset Software Utilities Run Power-Up Mode Mode Enter Mode Place car on Inspection and then hit Enter Enter Place car on Inspection and then hit Enter Enter Main CPU performs reset Main CPU jumps to Power-Up Mode P a g e | 199 Section 10 – 1021/1101/1005 LCD Interface Software Utilities Load 1036 Hoistway Setup LCD Interface - SD Card Read - Write Data Submenu Software Utilities SD Card Read / Write Data Mode NOTE: All submenus work In a similar manner. Enter Place Car on Ins / Press Enter Write Field variables Enter Mode Write Field Variables Overwrite Existing File? Y Enter Up/Down Place Car on Ins / Press Enter Write Job Statistics Write Field Variables Writing…..Please Wait Press Enter to select Write Faul Log submenu Write Field Variables Data Written to File Place Car on Ins / Press Enter Write Long Term Faults Press Enter to select Write Long Term Faults submenu Place Car on Ins / Press Enter Write Fault Log Press Enter to select Write Fault Log submenu Place Car on Ins / Press Enter Read Security Data Press Enter to select Read Security Data submenu Place Car on Ins / Press Enter Read Field Variables Enter Press Enter to select Read Field Variables submenu Enter Y/N LCD Interface - Power-Up Mode Power-Up mode is reached by powering up the controller without an SD Card, or it can be activated from Software Utilities. GALaxy Power-Up Mode GALaxy Test Watchdog Reset GALaxy View Software Version GALaxy Update / Verify Program Mode Enter Mode Enter Mode Press Enter to run Watchdog reset ENTER Main CPU performs Reset Power-Up Routine Software Ver: 1.00.05 Press Enter to Run Or Mode to Cancel ENTER Main CPU jumps to Controller Program ENTER to select Update / Verify Program Menu P a g e | 201 Section 10 – 1021/1101/1005 LCD Interface GALaxy Run Controller program Enter LCD Interface - Update - Verify Program Submenu GALaxy Update / Verify Program Update / Verify Program Load Program from SD Card Enter Mode Press Enter to Begin Or Mode to Cancel Enter Load Program from SD Card Erasing Flash….. Flash Erased Load Program from SD Card Programming Flash….. Flash Programming Finished Mode Update / Verify Program SD Card Status Enter Mode Load Program from SD Card Operation Complete SD Card Status Init=1, HC=1, Vstat=1 SD Card Initialized - High Capacity - Voltage Status Update / Verify Program Cons File Status Enter Mode Cons File Status Cons File Okay Cons File Verified OK Program File Verified OK Update / Verify Program Program Status Enter Mode Program Verify OK mRam225B39C0,Pgm225B39C0 Mram Checksum Program Checksum LCD Interface Main Menu - Select Video Display GALaxy Select Video Display Enter Mode NOTE: This flowchart is valid when the video monitor is installed on the dispatcher car. If the monitor is installed on a non-dispatcher car, then only information from that car is displayed on the monitor Press Enter to Set Video To Group Display Press Enter to Set Video To Group I/O Display Press Enter to Set Video To Car 1, I/O Screen 2 Press Enter to Set Video To Car 1, Fault Log Press Enter to Set Video To Car 3, Fault Log Sets Monitor To Group Display Enter Sets Monitor To Group I/O display Enter Section 10 – 1021/1101/1005 LCD Interface Press Enter to Set Video To Car 1, I/O Screen 1 Enter Sets Monitor To Car 1, page 1 I/O Screen Enter Sets Monitor To Car 1, page 2 I/O Screen Enter Sets Monitor To Car 1 fault screen Enter Sets Monitor To Car 3 fault screen P a g e | 203 LCD Interface Main Menu - Hoistway Tables – Display - Mod Hoistway Tables Submenu GALaxy Hoistway Tables Enter Current pulse count Mode Hoistway Tables Disp / Mod Hoistway Tables Up Enter Mode Current demand Current velocity direction DP=1483661 Vel=350 Dir=U P1=9778 .1 Floor level and Stored pulse count Distance from DN Normal limit Down Hoistway Tables Reset Update Count trig DP=1483661 Vel=350 Dir=U UT1=6683179 232.9 Limit switch and stored pulse count Up Hoistway Tables Pulse Count Update Data Down Hoistway Tables FL & FL Offset Count DP=1483661 Vel=350 Dir=U P2=353841 12.1 Enter Hoistway Tables DZ & LZ Offset, Sel Cnt To force value in Floor table DP=1483661 Vel=350 Dir=U P2=353841 12.1 ENTER selects count value MODE selects digit UP increments digit DN decrements digit ENTER stores value LCD Interface - Hoistway Tables - Learn Hoistway Submenu NOTE: Hoistway Learn procedure below begins with elevator on down normal limit, with “UL” and “DZ” signals “ON”; and “DL” signal “OFF”. Hoistway Setup Learn Hoistway Enter Mode Up Downto Select then to Learn Auto to Select then to Learn Insp Enter Enter Keep Existing UL and DL Level Zone Offsets N UP or DOWN Selects Y or N Keep Existing UL and DL Level Zone Offsets Y Press the Enter Button To Start the Learn Mode Put Elevator on Automatic Operation Run Elevator UP on Ins Non Stop to Top Dir Stop Set “ISNP” switch to “NORM” DP=678935 Vel=30 Dir=U PI=7 653821 87.4 ft Elevator will run to top normal limit Put Elevator on Inspection Operation DP=678935 Vel=30 Dir=U PI=7 653821 87.4 ft Run elevator non-stop To top of normal limit Hoistway Learn Complete Set “INSP” switch to “INSP” Hoistway Learn Complete P a g e | 205 Section 10 – 1021/1101/1005 LCD Interface Press the Enter Button To Start the Learn Mode LCD Interface Main Menu - DZ & DZ Offset, Sel Cnt Submenu Distance from DL to DZ In down direction Dn DZD Dist=000115 Up DZU Dist-000115 GALaxy Hoistway Tables Distance from UL to DZ in up direction Enter Mode ENTER to change values ENTER selects DZD UP & DN switches to DZU ENTER selects value MODE selects digit ENTER stores value MODE deselects value MODE returns to menu Hoistway Tables Disp / Mod Hoistway Table Up CAN open encoder PPR Down PPR=2048 DPP=20984 Hoistway Tables Reset Update Count Trig Difference of encoder count and DP count Base=10 IC=12 DP count Encoder reset count Demand velocity Encoder velocity Vel=5 EncVel=6 Pulses/Inch = 40.5 Hoistway Tables Pulse Count Update Data Up # of pulses per inch Down UL/DL Count = 000084146 Offset Cnt = 000084146 Hoistway Tables FL & FL Offset Count Selector top count Hoistway Tables DZ & DZ Offset, Sel Cnt Sel Top Cnt = 000316263 Sel Bot Cnt = 000005316 Enter Selector bottom count Down level distance Mode ENTER to change values Dn Lev Dist = 000000 Up Lev Dist = 000000 Up level distance Valid when adjustable variable “Stop On Pos Cnt” is enabled. ENTER selects Dn Lev Dist UP & DN switches to Up Lev Dist ENTER selects value MODE selects digit ENTER stores value MODE deselects value MODE returns to menu LCD Interface Main Menu - FL & FL Offset, Sel Cnt Submenu NOTE: The “Offset value below is valid when the “Stop On Pos Count” adjustable variable is enabled. FL 1 = 00006416 Offset = 000000 GALaxy Hoistway Tables Up Enter Down Mode Hoistway Tables Disp / Mod Hoistway Table Fl 17 = 01483661 Offset = 000000 Up Down Hoistway Tables Reset Update Count Trig Hoistway Tables Pulse Count Update Data FL 2 = 00012357 Offset = 000000 ENTER to add offset or change stored floor count Hoistway Tables FL & FL Offset Count Hoistway Tables DZ & DZ Offset, Sel Cnt Enter FL 2 = 00012357 Offset > 000000 ENTER selects offset UP & DN switches from Offset to FL ENTER selects value MODE selects digit UP & DN increments and decrements value ENTER stores value MODE deselects Offset or FL MODE returns to menu P a g e | 207 Section 10 – 1021/1101/1005 LCD Interface Mode LCD Interface Main Menu - Reset Update Count Trig, Pulse Count Update Data Submenu GALaxy Hoistway Tables Enter Mode Hoistway Tables Disp / Mod Hoistway Table NOTE: The “Reset Update Count Trig” and the “Pulse Count Update Data” are valid when the “Pos Count Upd” adjustable variable is enabled. They are used to provide information to properly set this variable. Enter Press Enter To Reset the Update Trigger Up Down Hoistway Tables Reset Update Count Trig Mode Pulse Count Update Trigger Reset Process flag Trace flag Floor Position Hoistway Tables Pulse Count Update Data Mode P1 pf=7 Tr=2 Max=0 VUDif=000023 Vel=000389 Up Down Hoistway Tables FL & FL Offset Count Enter P1 pf=7 Diff=00023 DP count difference Hoistway Tables DZ & DZ Offset, Sel Cnt Tr=2 Max=0 VErC=000000 Velocity error count P1 pf=7 Tr=2 Max=0 VUDif=000015 Vel=000398 Velocity count update difference Velocity at update LCD Interface Main Menu - Elevator Setup GALaxy Elevator Setup Enter Mode Elevator Setup Learn Hoistway Up Down Elevator Setup Lift Brake on Inspection Clamp Speed: Ins / Lev spd: 0140 fpm 0140 fpm Enter Clamp Speed: Ins / Lev spd: Up Elevator Setup Set Ins / Leveling Clamp Enter 0140 fpm 0140 fpm Mode Down Enter Increments value Decrements value Selects next digit Elevator Setup Learn Limit Velocities Mode Clamp Speed: Ins / Lev spd: Stores value 0140 fpm 0140 fpm P a g e | 209 Section 10 – 1021/1101/1005 LCD Interface Elevator Setup Reset Gripper / EBK Fault LCD Interface - Open - Close doors Elevator Setup Open / Close Front Door Elevator Setup Open / Close Rear Door Enter Enter Mode Mode Press UP to open F Door Press DN to close F Door Up Down Car must be on Inspection or Safeties Press UP to open R Door Press DN to close R Door Car must be on inspection. If not message below is displayed Up Down Car must be on Inspection or Safeties LCD Interface - Lift Brake On Inspection Submenu Elevator Setup Lift Brake On Inspection Enter If car is on inspection Enter If car is not on inspection Lift Brake On Inspection Car must be on Inspection If Inspection buttons “UP” or “DN” are on. Lift Brake On Inspection Ins Up & Dn Must Be Off If inspection “UP” or “DN” buttons are off If door lock and gate switch are closed If door lock or gate switch is open Car Not Safe Press Dn to Override WARNING: Brake will lift during this test. Make sure that all safety procedures are observed. NOTE: This flowchart describes the navigation required to prepare the LCD interface to allow the service brake to be lifted for testing of the rope-gripper or emergency brake. Other actions must also be performed which are specific to the controller type. See “Controller Test Procedure” document for complete details. Down Car Not Safe Press Mode to Continue Mode Car Not Safe Press Up and Enter Buttons Mode Car Not Safe Press Up and Enter Buttons Car Not Safe Lifting Brake 15 Seconds UP & Enter Car Not Safe Lifting Brake 15 Seconds UP & Enter Released Up & Enter pressed for 15 seconds Car Not Safe Brake Dropped: Timed-out Up & Enter pressed for 15 seconds Car Not Safe Brake Dropped: Timed-out UP & Enter Released UP & Enter Released MODE to return to menu UP & Enter Released P a g e | 211 Section 10 – 1021/1101/1005 LCD Interface If car is on inspection and door lock and gate switch are closed. LCD Interface - Load Weigher Setup Submenu Elevator Setup Load Weigher Setup Place Car on Independent With Autodoor Switch off Enter Mode Run Car to the Bottom Floor Enter Load Weigher Setup Setup Load Weigher Up Down Press Enter to Start Load Weigher Empty Setup Load Weigher Setup Load Weigher Calibration Enter Enter To Load Weigher Calibration Load Weigher Setup View / Modify load Limits Enter Empty car runs to all floors and records load readings To View / Modify Load Limits Load Weigher Setup View / Modify LW Setup Place Full Load in Car Turn Autodoor Switch Off LW Device Stat: ON:OK Input: 0283 Load: 027% Enter Down To force status change Set “AUTO DOOR” switch “OFF” after loading car Percent Load Status blinks to modify LW Device Stat: ON:OK Input: 0283 Load: 027% Up Empty Car Setup Finished Run Car to Loading Floor Set “AUTO DOOR” switch “ON” to load car Enter A/D input reading from load weigher Car Running Empty Car Load Weigher Setup Enter To store Status options ON:OK – LW on and device is ok ON:ERR – LW on and device has error OFF:OK – LW off and device is ok OFF:ERR – LW off and device has error NOT:SET – LW device is not set With Full Load In car Press Enter to Start Enter Car Running Full Load Setup Full car runs to all the floors and records load reading Load Weigher Setup Complete LCD Interface - View - Modify Load Weigher Limits Elevator Setup Load Weigher Setup Floor #1 Empty> 0126 Enter Arrow indicates value to edit Mode Load Limits Full: 0768 Down Up Load Weigher Setup Setup Load Weigher Floor #1 Empty: 0126 Up Down Down Load Limits Full> 0768 Switches arrow to next value to edit Up Load Weigher Setup Load Weigher Calibration Floor #2 Empty> 0145 Load Limits Full: 0785 Down Section 10 – 1021/1101/1005 LCD Interface Up Load Weigher Setup View / Modify Load Limits Enter Floor #2 Empty: 0145 Load Limits Full> 0785 Mode Load Weigher Setup View Modify LW Setup Floor #15 Load Limits Empty: 0158 Full> 0796 MODE selects digit UP increments value DN decrements value ENTER stores value MODE returns to menu Enter Selects value Floor #15 Load Limits Empty: 0158 Full> 0796 P a g e | 213 LCD Interface - Calibrate Load Weigher Elevator Setup Load Weigher Setup Place car on Auto, Door Closed and D Switch Off Enter Car on Automatic with “AUTO” door switch set to “OFF” Mode Load Weigher Setup Setup Load Weigher Press Enter to Calibrate Load Weigher Up Enter Down Load Weigher Setup Load Weigher Calibration Enter Load Weigher Calibration Flag has been Activated Mode Load Weigher Setup View / Modify Load Limits Load Weigher Setup View / Modify LW Setup Car runs to bottom floor and calibrates load weigher Load Weigher Calibration Complete LCD Interface - Car Buffer Test Submenu Elevator Setup Car Buffer Test Mode Enter Put Elevator on Inspection Operation Turn Machine Room Inspection switch to “INSP” Press Enter to Continue with Test Procedure Enter If “AUTO DOOR” Switch is “OFF” Turn Automatic Door Switch Off Set “AUTO DOOR” Switch to “OFF” Section 10 – 1021/1101/1005 LCD Interface WARNING: Car / Counterweight will run at high speed to pit buffer during this test. Make sure that all safety procedures are observed. Turn Inspection Sw to Norm and Place Car on Ind Car is on independent and door is disabled Car not on a Terminal floor On a terminal floor. To position car press Enter Enter Mode Up Press Enter to position car or press UP to skip Buffer Test Complete Press Mode for Menu Enter Car must be positioned so that it will reach top speed when hitting buffer Mode Waiting for car to reach test position Car in position Buffer Test Cancelled Press Mode for Menu Terminal limits are disabled automatically in software during test so physical limits do not need to be jumped out Press Enter Button to Run Buffer Test Enter Car runs to buffer Enter Press Enter Button to Cancel Buffer Test LCD P a g e | 215 Interface – Overspeed Test Submenu Hoistway Setup Overspeed Test NOTE: Before performing Overspeed test procedure, the following parameters should be adjusted to force the car to run faster than Enter contract speed. For DSD 412 drive - drive function #11 Mode Motor RPM For HPV600/900 – drive parameter A1 Turn Automatic Door Contract MTR Speed Switch to Off For KEB F5 – from the Controller’s LCD interface, “Adjustable Variables”, “Car Motion” adjust “DRV Speed Mult”. Set “AUTO DOOR” After test s complete, return parameters to Switch to “OFF” proper values for contract speed. Mode Press the Enter Button To Enable Overspeed Test Enter WARNING: Car will overspeed during this test. Make sure that all safety procedures are observed. Overspeed Test Active Hit Up & Enter to Hold Brk Up & Enter Mode To navigate to set car call Mode This step allows main brake to stay picked until test is complete in order for gripper or e-brake to stop and hold car when overspeed switch trips. To run test, set car call and navigate back to screen above to keep main brake picked during test. Overspeed Test Complete Press Mode for Menu LCD Interface - Reset Gripper Fault Elevator Setup Reset Gripper / EBK Fault Enter If governor is tripped Mode GOV must not be tripped To Reset Gripper Fault Reset governor Mode Press and Hold Enter To Reset Gripper Fault Enter If car not on inspection Car must be on Inspection To Reset Gripper Fault Gripper Sets Rope Gripper Is Reset Release Enter button Press Mode to return to menu If gripper fault is reset and GTS input remains off Mode No Rope Gripper Fault GTS Input Off P a g e | 217 Section 10 – 1021/1101/1005 LCD Interface Mode Car placed on Inspection operation. Must hold Enter button Until LCD displays: “Rope Gripper is Reset” LCD Interface - Fault Log GALaxy Fault Log Enter Order of ocurrence Mode Enter Fault Log View Fault Log 1 P=12 Up Up Down Fault Log Clear Fault Log 2 P=12 Reset Fault 15:28:53 08/27 #1 Mode Enter Press Enter to Clear the Fault Log Enter Mode Inspection Input Flt 15:21:06 08/27 #1 Down Mode Mode Type of fault Mode Fault Log Cleared 8 P=17 At Floor Shutdown 08:12:27 08/29 #1 Car Time of position fault Date of fault Enter Mode srv=1 rdf=0 prc=15 dpr=0 drf=0 dri=0 Up Down Dp= 833619 Dmd=0 emp=0 equ=0 med=0 fir=0 cbl=0 rfl=0 Tg=833619 Enc Vel=0 Detailed Fault data All services have either an input trigger or a timer condition that makes the service become active. The "Service Activation Timers" can be used to allow a feature to be turned on during specific times of the day without the need of a specific condition or switch to be turned on and off. All GALaxy traction and complex hydro controllers have the “Service Activation Timers” feature that allows up to ten different timers to be separately programmed. These timers will turn on services that will operate only during these predefined times. The different services that can be programmed are listed below. Parking Alternate Parking Next Up Up Peak Down Peak Alternate Lobby Alternate Floor Security Car Call Lockouts Group Car Call Lockouts Car Call Override Group Car Call Override Sabbath CC Push Button Security Floor Security Table 2‐ 4 There are two different settings to choose from to determine when the timers will operate: Day of the Week: this will allow the timer to turn on and off services for each individual day of the week. There are a total of seven on and off time settings. Month and Day: this will allow the timer to turn on and off only for the date that is programmed. There are three on and off settings for this type. P a g e | 219 Section 10a – Service Activation Timers Section 10a - Service Activation Timers The most common setting will be “day of the week” but “month and day” timers will be useful for programming special events or holidays. You could set day of the week timers. When the “day of week” timers are set, the chosen service will operate repeatedly for each day of the week that is programmed. Month and Day timers will operate only once a year. Programming the timers can be accomplished through the LCD interface or the Galileo Interface. Once the timers are programmed they can be “disabled” or “enabled” without modifying other settings. In other words, a timer could be programmed completely and remain disabled until the building is ready for implementation. At that point the timer can be” enabled” and it will function as programmed. GALaxy Service Activation Timer Service Activation Timer Service Timer # 0 Up Down Mode Enter NOTE: This flow chart shows the Sub-Menu for Service Timer # 0. The Sub-menus for Service Timers #1 through #9 are similar. Service Timer # 0 Set Month/Day Timers Up Down Enter to Set Month/ Day Timers Service Activation Timer Service Timer # 0 Service Timer # 9 Clear Timer Enter to Clear Timer Service Timer # 0 Copy Day Of Week Timers Enter to Copy Day of Week Timers Service Timer # 0 View/Modify Timer Status Enter to View/Modify Timer Status Service Activation Timer Service Timer # 0 Service Timer # 1 Set Timer Service Enter to Set Timer Service Service Timer # 0 Set Day of Week Timers Enter to Set Day of Week timers P a g e | 221 Section 10a – Service Activation Timers LCD Interface Main Menu - Service Activation Timer LCD Interface - Set Month/Day Timers Submenu From Service Activation Timer Main Menu Service Timer # 0 Set Month/Day Timers Month/Day Timer Date # 0 Month/Day: 00/00 Enter Enter Up Month/Day Timer Date #0 Month/Day: 00/00 MODE selects digit UP increments value DN decrements value DOWN ENTER stores value MODE returns to sub-menu Set Month/Day Timers Service Timer # 0 Enter Down Month/Day Timer Date # 0 Off Time: 00:00 Set Month/Day Timers Month/Day Timer # 0 Enter Enter Up Up Month/Day Timer Date # 0 Off Time: 00:00 MODE selects digit UP increments value DN decrements value DOWN ENTER stores value Down Set Month/Day Timers Month/Day Timer # 2 MODE returns to sub-menu Down Month/Day Timer Date # 0 On Time: 00:00 Enter Set Month/Day Timers Month/Day Timer # 1 NOTE: This flow chart shows the sub-menu for Month/Day Timer Date # 0 Month/Day Timer Date # 1 and #2 are similar. Month/Day Timer Date # 0 On Time: 00:00 MODE selects digit UP increments value DN decrements value DOWN ENTER stores value MODE returns to sub-menu Section 10a – Service Activation Timers LCD Interface - Clear Timer Submenu From Service Activation Timer Main Menu Service Timer #0 Clear Timer Mode Enter Mode Clear Timer Hit Enter to Clear Timer Enter Clear Timer Timer Cleared LCD Interface - Copy Day of Week Timers Submenu From Service Activation Timer Main Menu Service Timer # 0 Copy Day Of Week Timers Enter Enter copies the timer setting for Monday into the timer setting for Tuesday through Friday and the display shows “Copied” Mode Copy Day Of Week Timers Monday -> Tuesday - Friday Enter Mode Copy Day Of Week Timer Monday -> Tue-Fri Copied P a g e | 223 LCD Interface – View/Modify Timer Status Submenu From Service Activation Timer Main Menu Service Timer # 0 View/Modify Timer Status Enter Mode View/Modify Timer Status Timer Off / Disabled If time of day on the real time clock falls within window of the timer setting, and the timer is enabled, then display shows this screen. Enter View/Modify Timer Status Timer On / Enabled Mode View/Modify Timer Status Timer Off / Disabled ENTER Disables Timer Up Down View/Modify Timer Status Timer Off / Enabled ENTER Enables Timer Section 10a – Service Activation Timers LCD Interface - Set Timer Service Submenu From Service Activation Timer Main Menu Service Timer # 0 Set Timer Service Set Timer Service Car Call Override Set Timer Service Group Car Call Override Enter Set Timer Service Sabbath Set Timer Service Group Car Call Lockouts Set Timer Service CC Push Button Security Enter Set Timer Service Floor Security Table 2 Set Timer Service Group Car Call Lockouts Set Timer Service Floor Security Table 3 Set Timer Service Car Call Lockouts Set Timer Service Floor Security Table 4 Set Timer Service Alternate Floor Security Set Timer Service No Service Selected Set Timer Service Alternate Lobby Set Timer Service Parking Set Timer Service Down Peak Set Timer Service Alternate Parking Set Timer Service Up Peak Set Timer Service Next Up P a g e | 225 LCD Interface - Set Day of Week Timers Submenu From Service Activation Timer Main Menu NOTE: This flow chart shows the sub-menu for DOW Timer: Saturday. Other days of week are similar. Service Timer # 0 Set Day of Week Timers Enter Set Day of Week Timers DOW Timer: Saturday Up Enter DOW Timer: Saturday On Time: 00:00 Enter Up Down Set Day of Week Timers DOW Timer: Friday DOW Timer: Saturday On Time: 00:00 MODE selects digit UP increments value DN decrements value ENTER stores value MODE returns to sub-menu Down DOW Timer: Saturday Off Time: 00:00 Enter DOW Timer: Saturday Off Time: 00:00 Set Day of Week Timers DOW Timer: Sunday MODE selects digit UP increments value DN decrements value ENTER stores value MODE returns to sub-menu Section 11 Main CPU Faults Faults Description Possible Cause/Suggested Fix • Advance pre-torque is enabled. When it activated, the controller waits for 5 seconds and expects the car to have Did not get safe on advance moved by then. if the car has not moved in the 5 seconds the Adv PreTrq Start Flt pre-torque start fault gets declared. Possible Door operator or door lock failure caused car not to go. • Car was not able to answer group hall call within the Automatic Service Time-out automatic service time-out timer. Look for fault condition on ASV Time-out Car 2 Car 2 car. ASV Time-out Car 3 • Car was not able to answer group hall call within the Automatic Service Time-out automatic service time-out timer. Look for fault condition on Car 3 car. ASV Time-out Car 4 • Car was not able to answer group hall call within the Automatic Service Time-out automatic service time-out timer. Look for fault condition on Car 4 car. ASV Time-out Car 5 • Car was not able to answer group hall call within the Automatic Service Time-out automatic service time-out timer. Look for fault condition on Car 5 car. ASV Time-out Car 6 • Car was not able to answer group hall call within the Automatic Service Time-out automatic service time-out timer. Look for fault condition on Car 6 car. ASV Time-out Car 7 • Car was not able to answer group hall call within the Automatic Service Time-out automatic service time-out timer. Look for fault condition on Car 7 car. • Car was not able to answer group hall call within the Automatic Service Time-out automatic service time-out timer. Look for fault condition on ASV Time-out Car 8 Car 8 car. P a g e | 227 Section 11 – Main CPU Faults • Car was not able to answer group hall call within the Automatic Service Time-out automatic service time-out timer. Look for fault condition on ASV Time-out Car 1 Car 1 car. Faults Description At Floor Shutdown At floor shutdown Possible Cause/Suggested Fix • Car faulted out while at floor. Look at the fault log for a different fault at the same time to determine cause of failure. Aut Swg Fr Door Open Automatic Swing Front Door Open Fault. The swing door can only close by removing the door open signal and allowing the door to close mechanically. This fault is declaring the door stayed open when the open signal was removed. • Verify that the ADO output has not failed on. If so then replace the output chip. • Verify that the door is not binding and is being prevented from closing. Aut Swg Rr Door Open Automatic Swing Rear Door Open Fault. The swing door can only close by removing the door open signal and allowing the door to close mechanically. This fault is declaring the door stayed open when the open signal was removed. • Verify that the ADOR output has not failed on. If so then replace the output chip. • Verify that the door is not binding and is preventing from closing. Binary Input Fault • Excessive wear on the selector guides. • Preset magnet is missing or misaligned. The floor position, read • Faulty hall effect sensor on sensor board. from binary inputs on the • Faulty output on selector driver board. selector, does not match the • Improper wiring between selector and the Top of Car board car position. (1037 or 1040 board). • Faulty BP1, BP2 or BP4 input BKS Fault Slowdown BKS Brake Switch Fault Slowdown. The brake lift switch dropped during the run causing the car to slow down at the next available floor • Faulty brake lift switch. • Low brake hold voltage Bot Final Limit Flt Bottom Final Limit Open • Car traveled onto the bottom final limit. • Faulty wiring of the final limit circuit. Description Possible Cause/Suggested Fix Bottom Door Lock Fault • Faulty door lock. • Door lock not adjusted properly. • Jumper placed on door lock circuit. The Bottom Door Lock failed • Faulty wiring to DLB input. on while the door was open. • Faulty DLB and DLB-1 inputs (For this to occur both DLB and DLB-1 inputs must fail on). • DOL input failed. Replace DOL input chip. • Door operator open limit DOL is not adjusted properly Brake Drop Fault Brake failed to drop. The BKS input did not close while stopped. Brake Pick Fault Brake failed to pick. The BKS • Improper adjustment of brake switch. input did not open during • Brake failed to pick. the run. Section 11 – Main CPU Faults Faults • Improper adjustment of brake switch. • Brake failed to drop. Brake Test Stall Fault. The elevator stalled during a brake test. A stall timer is running during the test using the Learn HW Stall time in the Car Timers menu. There is a protection timer that should never time out. In an event that the car does not move during the test, the 6 second velocity timer should always expire first. • Make sure the elevator can run properly at high speed. • Make sure the Learn HW Stall timer is set to 30 seconds or higher. The value set during a successful automatic hoistway learn would work fine. BRK CAN Com Error Brake Board CAN Communication Error. • Faulty CAN communication wire connection. Verify proper twisted pair wires to the canh and canl terminals on the brake board. • Noise on the CAN bus. Verify that the shield wire is connected according to the job print. Brk Flt Set EM Brake Emergency brake set from brake fault • 'Brake Lift Sw' parameter is set to 2 in 'Car Options'. There was a brake fault and this triggered an emergency brake/ gripper fault. Brake Test Stall Flt P a g e | 229 Faults Description Possible Cause/Suggested Fix Brk Flt Set Gripper The Rope Gripper was tripped when the brake did not drop. The 'Brake Lift Sw' • Improper adjustment of brake switch. adjustable variable in 'Car Options' can be set to only • Brake failed to drop. show the brake drop fault if the brake does not drop. BRK I/O Failed Off The BRKi input or BRK output chip has failed off. The BRK contactor coil is wired through a NO contact of MC, a NO regulator release contact of the drive (DON) and a BRK triac of the controller. BRK I/O Failed On • Improper wiring of the brake BRK coil. Refer to prints for The BRK input or output has wire connections. • Faulty BRKi input. Replace BRKi input chip on 1038 board. failed on. • Faulty BRK output. Replace BRK output chip on 1038 board. BRK Low DC Bus Volts Brake DC Bus Voltage (BK+, BK-) is less than 80% of expected • Incorrect Setting of Line to Line Brake voltage in Adjustable Variables • Incorrect dipswitch setting for Three Phase or Single Phase • Low Line Voltage • Rectifiers Blown or have bad connection BRK No Currnt w/Volt Reading a resistance value (Vout/Aout) of 1000Ω or greater • No Brake Connected • Bad Current Sensor BRK No DC Bus Volts DC Bus Voltage (BK+, BK-) is • No AC Voltage Coming into AC1-AC2-AC3 less than 5VDC • Rectifiers Blown or have bad Connection BRK No Output Volts If no DC Bus Faults, Requested Output Voltage is greater than 0, Actual • IGBT Not Gating Output voltage is less than 3VDC • Improper wiring of the brake BRK coil. Refer to prints for wire connections. • Faulty BRKi input. Replace BRKi input chip on 1038 board. • Faulty BRK output. Replace BRK output chip on 1038 board. Faults Description BRK Over Current Flt Average Current is higher • IGBT Shorted than Preset Limit (based on • Free Wheeling Diode Shorted board configuration) • Gating Circuitry Shorted ON BRK Over Voltage Flt Output Voltage is at least 20V greater than the Voltage Requested. BRK Rq Volt > DC Bus Requested Output Voltage is • Incorrect Setting of Pick/Hold/Relevel Voltage in Adjustable 5% greater than Variables the DC Bus Voltage (BK+, BK• Low Line Voltage ) • IGBT Shorted • Gating Circuitry shorted ON • Verify that the buffer switch is set and the switch is closed. • Faulty wiring on the buffer switch circuit. • Car hit the buffer Can Bus Off Error CAN Bus Off Error. The can bus has been inactive for too long a period of time. • Faulty CAN bus wiring. Check the CAN bus terminal connections on all boards. CAN spb bad command Unintended Motion Command to Safety Processor unintentionally set • This fault should never occur. Contact GAL. Car 1 Comm Loss Controller can't have this fault. • Faulty ram-flash memory chip. • Reset fault. If faults returns, replace memory chips. The group car is not communicating with Car 2. • Faulty wiring from R/T+ and R/T- from car to car. • Faulty 75176 driver chip on 1036 board. • Noise on shield wire. Connect shield only on one end. • Noise on the communication wires. Run wires in separate conduit. The group car is not communicating with Car 3. • Faulty wiring from R/T+ and R/T- from car to car. • Faulty 75176 driver chip on 1036 board. • Noise on shield wire. Connect shield only on one end. • Noise on the communication wires. Run wires in separate conduit. Car 2 Comm Loss Car 3 Comm Loss P a g e | 231 Section 11 – Main CPU Faults Buffer Switch Fault Buffer Switch Open Possible Cause/Suggested Fix Faults Description Possible Cause/Suggested Fix The group car is not communicating with Car 4. • Faulty wiring from R/T+ and R/T- from car to car. • Faulty 75176 driver chip on 1036 board. • Noise on shield wire. Connect shield only on one end. • Noise on the communication wires. Run wires in separate conduit. The group car is not communicating with Car 5. • Faulty wiring from R/T+ and R/T- from car to car. • Faulty 75176 driver chip on 1036 board. • Noise on shield wire. Connect shield only on one end. • Noise on the communication wires. Run wires in separate conduit. The group car is not communicating with Car 6 • Faulty wiring from R/T+ and R/T- from car to car. • Faulty 75176 driver chip on 1036 board. • Noise on shield wire. Connect shield only on one end. • Noise on the communication wires. Run wires in separate conduit. The group car is not communicating with Car 7 • Faulty wiring from R/T+ and R/T- from car to car. • Faulty 75176 driver chip on 1036 board. • Noise on shield wire. Connect shield only on one end. • Noise on the communication wires. Run wires in separate conduit. Car 8 Comm Loss The group car is not communicating with Car 8 • Faulty wiring from R/T+ and R/T- from car to car. • Faulty 75176 driver chip on 1036 board. • Noise on shield wire. Connect shield only on one end. • Noise on the communication wires. Run wires in separate conduit. Car Call Light Fuse Car Call Light Fuse Blown • Check for short on the Car Call Light circuit. Car 4 Comm Loss Car 5 Comm Loss Car 6 Comm Loss Car 7 Comm Loss Car Call Power Fuse Car Call Power Fuse Blown Car Com Device Reset Serial Car board reset unexpectedly. Usually caused by loss of power to the individual board. • Check for short on Car Call Power circuit. • Usually caused by loss of power to the individual board. Check for loose connection on power terminal of the board. • Faulty I/O board. Faults Description Car Gate Safe Fault Car Gate safe fault Possible Cause/Suggested Fix • After Controller was safe with doors, gate switch and locks made, and ready to run, a Gate switch (front or rear) input turned OFF. Car Safe Fault Car Safe Fault Preop The car had a car safe fault • The car lost the DZ input while leveling into the floor and the while pre-opening the door. door was open. The car had an onward call, had the door close limit but • The locks are not making properly when the door closes. Car Safe Fault Start the car gate or door locks • The door is not closing properly. did not make after a 3 second time-out. Car Safety Sw. Fault Car Safety Switch Fault • Safety String Fault • Verify that the car safety is not tripped. • Faulty wiring in the car safety circuit Car Top Stop Switch Car top stop switch • Safety String Fault. Refer to Safety String Page on diagrams. Check/replace CTS input Chip. • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN CCB FET Open Blue Car Call Board FET open blue device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. CCB FET Open Green Car Call Board FET open green • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. P a g e | 233 Section 11 – Main CPU Faults • The car does not have the gate or lock inputs and is running or trying to run • The gripper GTS input is not on. • The stop switch is open. • An Inspection String input fault. Only one input should be on in the inspection string (AUTO, CTI, ICI, ACC or MRI) • Gate or Lock Bypass switch is on when not on car top inspection. The Car Safe Fault occurs from the wanting to run but does not have a critical input energized. Some of the conditions for a car safe fault will also cause other faults to be logged. Faults Description Possible Cause/Suggested Fix CCB FET Open Red • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN Car Call Board FET open red device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. CCB FET Short Blue Car Call Board FET short blue • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. CCB FET Short Green Car Call Board FET short green • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. CCB FET Short Red • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN Car Call Board FET short red device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. CCB LED Open Blue Car Call Board LED open blue • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. CCB LED Open Green Car Call Board LED open green • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN CCB LED Open Red Car Call Board LED open red device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. Car Call Board LED short CCB LED Short Blue blue • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. Faults Possible Cause/Suggested Fix CCB LED Short Green Car Call Board LED short green • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. CCB LED Short Red • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN Car Call Board LED short red device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. CCB No Comm Aux Car Call Board local aux Bd 1 board 1 comm loss • Comm loss to RGB Auxiliary Car Call Board. Check wiring and bus termination jumpers on boards. If problem persists, check Car Comm Status under diagnostics. CCB No Comm Aux Car Call Board local aux Bd 2 board 2 comm loss • Comm loss to RGB Auxiliary Car Call Board. Check wiring and bus termination jumpers on boards. If problem persists, check Car Comm Status under diagnostics. CCB No Comm Board 1 • Comm loss to RGB Car Call Board. Check wiring and bus Car Call Board local board 1 termination jumpers on boards. If problem persists, check Car comm loss Comm Status under diagnostics. CCB No Comm Board 2 • Comm loss to RGB Car Call Board. Check wiring and bus Car Call Board local board 2 termination jumpers on boards. If problem persists, check Car comm loss Comm Status under diagnostics. CCB No LED Board CCB Stuck Button Car Call LED board missing • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. Car Call Board stuck button • Faulty LED signal from RGB Board. Look at detailed car faults log to determine device. 'dev' gives you address for global CAN device, 'dv2' gives you local CAN device and 'pf1' the number for the IO location within the local board. Compensating Rope Switch Comp. Switch Fault Open • Verify that the compensating rope switch is set and the switch is closed. • Improper cabling of the compensating ropes on the sheave. P a g e | 235 Section 11 – Main CPU Faults Description Faults Description Possible Cause/Suggested Fix Car “above cwt” flag was set for above the counterweight CWT Sw Error at DT when the car hit the down terminal slowdown limit. • The counterweight switch was not hit during the run or the car was lost when powered up. • Faulty wiring of the counterweight switch. • Improper adjustment of the counterweight switch. Car “above cwt” flag was set for below the counterweight CWT Sw Error at UT when the car hit the up terminal slowdown limit. • The counterweight switch was not hit during the run or the car was lost when powered up. • Faulty wiring of the counterweight switch. • Improper adjustment of the counterweight switch. DBR Temperature Flt Delta Off Fault Dynamic Braking Resistor Temperature Fault. The temperature for the dynamic braking resistors is read through a temperature sensor mounted above the resistors. The temperature sensor connects to the temperature sensor input board mounted on the DIO1 connector on the CPU board. When the temperature sensor opens a contact, the CPU detects a temperature fault, an error is recorded, the car is shut down at the next floor and the DBC relay is deenergized to open the DB Resistor circuit. • Faulty Temperature Sensor. If the DB Resistors are not hot, check the temperature sensor input board connected to the CPU board. The input LED should be on when the temperature is okay. If the LED is not on, jump the two terminals on the temperature input board and the LED should go on. If the LED goes on then the Temperature Sensor is bad. Replace the Temperature Sensor mounted near the resistors • Faulty Temperature Sensor Input Board. Test the sensor input as above. If the LED does not turn on when the input terminals are jumped together, replace the Temperature Sensor Input Board connected to the CPU. Traction DEL=1 (on) at beginning and during a run. This fault means DEL never turned on or maybe dropped off during a run. • Faulty DEL input. Replace the DEL input chip. Hydro DEL input did not come on • The delta contact did not make on a Y-Delta starter. at start or went off during a • The MC contact did not make on an across-the- line starter run. • The “at speed” contact did not make on an electronic softstarter. NOTE: On a Hyrdo DEL only turns on when moving UP, it is off when the car is moving down. Description Possible Cause/Suggested Fix Delta On Fault Traction DEL=0 when the car is not running. This fault means that the input did not turn off when it was supposed to. DEL input failed on when is • Faulty DEL input (failed on). Check the input and output should have been off. This status on the LCD interface. would occur at the start of a • Faulty contact for DEL input failed on. Replace the DEL input run when the I/Os are chip. checked. The input failed on Hydro or the contact for the input DEL did not turn off when it should have. failed closed. • Faulty DEL input. Replace the DEL input chip. NOTE: On a Hyrdo DEL only turns on when moving UP, it is off when the car is moving down. DL & DL-1 Opposite Input failure on one of the Down Level sensor input DL Failed On Fault • DL hall effect sensor bad on selector sensor board. Replace sensor board. • DL Output Driver failed on. Replace output on selector driver DL Failed On Fault. The DL board GALX-1011. leveling sensor did not turn • DL traveling cable wire is shorted to 120 VAC. Remove input wire to 1038 or 1064 board and verify that LED goes out. off during a run. Correct short condition. • DL inputs failed on. Short on 1038 or 1064 main I/O board. Replace main I/O board. DL20 Phone Test Failed Phone Test from DL20 phone monitoring device indicated a failure • Refer to the manufacturers troubleshooting guide for the DL20. DLB & DLB-1 Opposite Input failure on one of the Door Lock Bottom (DLB) inputs. • Faulty DLB or DLB-1 input (replace input chip). DLM & DLM-1 Opposite Input failure on one of the Door Lock Middle (DLM) inputs. • Faulty DLM or DLM-1 input (replace input chip). DLT & DLT-1 Opposite Input failure on one of the • Faulty DLT or DLT-1 input (replace input chip). Door Lock Top (DLT) inputs. • Faulty DL or DL-1 input (replace input chips). P a g e | 237 Section 11 – Main CPU Faults Faults Faults Description Possible Cause/Suggested Fix Dn Normal SW Setup Down Normal must always be on unless the car is below the lowest landing. • The down normal needs to be moved down so when the car is Dead level at the bottom landing DN is ON. Allow at least 2 inches run before DN turns OFF DNR I/O Failed Off DNR I/O Failed On Traction • Fault on Safety Processor Board. This board can disable the run control to the DNR output chip. Check if the PIC or PAL inhibit LED turns on when the car attempts to run. Check the elevator service, faults, and inputs/outputs on the Safety Processor Board LCD display. • Faulty DNR output or DNRi input. Replace the DNR output and DNRi input chip. • No 24VDC from the drive. Refer to Schematics. The DNR input or output has • Incorrect jumper placement on 1038 board. Verify that jumpers on the bottom of the board are positioned for the failed off. correct drive type (DSD or HPV). • RUN, MC or BRK auxiliary contact not making properly. Contact GAL for instructions. Hydro • Faulty wiring to the SD or SC terminal on the 1038/1064 board. • Faulty wiring to the Down valve. • Faulty SD output or SDi input. Replace output and input chip. Traction • Faulty DNR output. Replace the DNR output chip. • Faulty DNRi input. Replace DNRi input chip. • Incorrect jumper placement on 1038 board. Verify that The DNR input or output has jumpers on the bottom center of the board are positioned for the correct drive type (DSD or HPV). If necessary move the failed on. jumpers to the correct drive type. Hydro • Faulty SDi input (replace input chip). • Faulty SD output (replace output chip). Faults Description • Loss of voltage on terminal CS. • MC contact in series with the drive run relay opened. • The drive faulted on start and dropped the run contact . Check the drive fault log. • Faulty run relay in the drive. • Faulty DON input on the controller. Replace the DON input chip. • The run relay in the drive is not programmed properly. Check the default drive setup for the Configure C3, Relay Coil 2= Speed Reg Rls parameter for a Magnetek drive. Check do.83=DRO on a KEB drive. DON I/O Failed On • Improper wiring of the brake BRK coil. Refer to prints for wire connections. The DON input or the drive • Faulty BRKi input. Replace BRKi input chip on 1038 board. output has failed on. When • Faulty BRK output. Replace BRK output chip on 1038 board. the drive is turned off, the • Fault on 1028 Safety Processor Board. The Safety Processor Board can disable the run control to the BRK output chip. run relay on the drive will Check if the PIC or PAL inhibit LED turns on when the car drop out turning off DON. attempts to run. Check the elevator service, faults, and inputs/outputs on the Safety Processor Board LCD display Door Close Fault The door did not reach the • Door Close Limit (DCL) not adjusted properly. Door Close Limit within the • Faulty Door Close Limit (DCL). Replace DCL input chip. door close protection time. • Trash in door track preventing door from closing. Door Lock Safe Fault Door lock safe fault • After Controller was safe with doors, gate switch and locks made and ready to run, a door lock inputs turned OFF. Door Low Voltage Flt Door Line Voltage Low • Voltage Sensor Board Related. Voltage being monitored for Door Operator dropped below the setting for parameter 'Low Door Volt ' Door Motor Overload Door Motor Overload • Door Motor Overload signal tripped. Check Input chip for DMO signal Door Open Fault The door did not reach the • Door Open Limit (DOL) not adjusted properly. Door Open Limit within the • Faulty Door Open Limit (DOL). Replace DOL input chip. door open protection time. P a g e | 239 Section 11 – Main CPU Faults The DON input or the drive run relay contact has failed off. The run relay on the drive turns on the DON DON I/O Failed Off input (Drive ON) indicating that the regulator is released and the drive is controlling the motor. Possible Cause/Suggested Fix Faults Description Possible Cause/Suggested Fix The auxiliary door zone input failed on. • DZA output on selector board GALX-1011 failed on. (Replace DZA output on selector driver board). • One or both of the DZA sensors on the selector sensor board failed. Replace selector sensor board. • DZA input on the 1037/1040 board failed. Replace DZA input on 1037/1040 board. The door zone input failed off. • DZ output on selector board GALX-1011 did not turn on. (Replace DZ output on selector driver board). • One or both of the DZ sensors on the selector sensor board failed. Replace selector sensor board. • DZ input on the 1040 board failed. Replace DZ input on 1037/1040 board. The door zone input failed on. • DZ output on selector board GALX-1011 did not turn off. (Replace DZ output on selector driver board). • One or both of the DZ sensors on the selector sensor board failed. Replace selector sensor board. • DZ input on the Main I/O board failed on. Replace DZ input on Main I/O board. DoorZone Aux Off Flt The auxiliary door zone input failed off. • DZA output on selector board GALX-1011 did not turn on. (Replace DZA output on selector driver board). • One or both of the DZA sensors on the selector sensor board failed. Replace selector sensor board. • DZA input on the 1040 board failed. Replace DZA input on 1037/1040 board. Down Directional Fault Car unexpectedly hit the Down Normal Limit while running down. • Faulty wiring for the DN limit. • The power common to the limit switches (CS) was lost. Check safety string prior to the CS terminal. DPM Input Fault The DPM input fault occurs • DPM Cam not setup properly on the door operator. when door opens and the • Faulty DPM input. Replace DPM input chip. DPM input did not turn off. DPM Off/GS or DL On DPM Off with Gate Switch or Door Lock On. The Door Protection Module input must go on before gate switch or door lock inputs go on. Door Zone Aux On Flt Door Zone Off Fault Door Zone On Fault • The DPM switch on the door operator is not setup properly. • There is no DPM input on the door operator. Jump the DPM input to the GS (Gate Switch) terminal. • Fault DPM input. Replace the DPM input chip. Faults Description Possible Cause/Suggested Fix Drive Com 8259 Error Drive Communications 8259 Error. This error is used to detect a hardware failure on • Hardware failure on the CPU board or 1036 board. If this the controller error occurs, contact G.A.L. communications port to the drive. Controller has a communications error with drive. The controller has Drive Com Rcv Error not received a valid message from the drive for more than one second. • Faulty communications cable connection. Check the drive twisted pairs connected from the drive to the 1036 board. • Noise on the communication cable. Verify that the shield on the communications cable to the drive is connected to earth ground on one end. • Faulty communication chip. Replace the 75176 driver chips on the 1036 board. Drive Com Trm Error Drive Communications Transmit Error. This error is used to detect a hardware • Hardware failure on the CPU board or 1036 board. If this failure on the controller error occurs, contact G.A.L. communications port to the drive. Drive Com Tx Stop Er Drive Communications Transmit Stop Error. This error is used to detect a hardware failure on the controller communications port to the drive. • Missing jumper on J7 of the 1036 board (COM1 IRQ6). Install the jumper. • Hardware failure on the CPU board or 1036 board. If this error occurs and the jumper J7 is in place, contact G.A.L. Drive Communications Transmit Stop Error. This Drive Com TxEmpty error is used to detect a hardware failure on the Er controller communications port to the drive. • Missing jumper on J7 of the 1036 board (COM1 IRQ6). Install the jumper. • Hardware failure on the CPU board or 1036 board. If this error occurs and the jumper J7 is in place, contact G.A.L. P a g e | 241 Section 11 – Main CPU Faults Drive Communications Interrupt Enable Error. This error is used to detect a • Hardware failure on the CPU board or 1036 board. If this Drive Com Int Error hardware failure on the error occurs, contact G.A.L. controller communications port to the drive. Faults Description Possible Cause/Suggested Fix Drive has a communications error. The controller has received a message from the Drive has Com Error drive that it has communication receive errors. • Faulty communications cable connection. Check the drive twisted pairs connected from the drive to the 1036 board. • Noise on the communication cable. Verify that the shield on the communications cable to the drive is connected to earth ground on one end. • Faulty communication chip. Replace the 75176 driver chips on the 1036 board. Drive Ready Fault • The drive has or had a fault. Check the drive fault log. • Faulty RDY input. (Replace the RDY input). DT Count Fault DT Failed On Fault The drive has a fault • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without The verification position overshooting the floor or stopping short of the floor. This count for the DT input refers to the CPU speed feedback. switch was off by more than • The power common to the limit switches (CS) was lost. 10 inches when the switch Check safety string prior to the CS terminal. was activated. This position • Incorrect counting of pulse counts. Check encoder count refers to the pulse connection to motor and encoder wiring. count recorded during a • Hoistway not learned properly. Perform a hoistway learn hoistway learn. procedure. • DT switch not adjusted properly. Check at slow speed if switch is breaking, making and then breaking again. Switch needs to be closer to the cam. DT input Failed On Fault. The car was at the bottom floor and the DTS input was low true (DTS switch open) but the DT input was high (DT not made). • The DTS switch is not wired or the DTS switch is not used. If the DTS switch is not used, jump the DT and DTS inputs together. • The DT did not break at the bottom terminal landing. Adjust or replace the DT switch. • Faulty DT input. Replace the DT input chip. Faults DT1 Count Fault DT3 Count Fault Possible Cause/Suggested Fix • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without The verification position overshooting the floor or stopping short of the floor. count for the DT1 input switch was off by more than • The power common to the limit switches (CS) was lost. 10 inches when the switch Check safety string prior to the CS terminal. was activated. This position • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. count refers to the pulse • Hoistway not learned properly. Perform a hoistway learn count recorded during a procedure. hoistway learn. • DT1 switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without The verification position overshooting the floor or stopping short of the floor. count for the DT2 input switch was off by more than • The power common to the limit switches (CS) was lost. 14 inches when the switch Check safety string prior to the CS terminal. was activated. This position • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. count refers to the pulse • Hoistway not learned properly. Perform a hoistway learn count recorded during a procedure. hoistway learn. • DT2 switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without The verification position overshooting the floor or stopping short of the floor. count for the DT3 input switch was off by more than • The power common to the limit switches (CS) was lost. 18 inches when the switch Check safety string prior to the CS terminal. was activated. This position • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. count refers to the pulse • Hoistway not learned properly. Perform a hoistway learn count recorded during a procedure. hoistway learn. • DT3 switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. P a g e | 243 Section 11 – Main CPU Faults DT2 Count Fault Description Faults DT4 count Fault DT5 count Fault DT6 count Fault Description Possible Cause/Suggested Fix • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without The verification position overshooting the floor or stopping short of the floor. count for the DT4 input switch was off by more than • The power common to the limit switches (CS) was lost. 24 inches when the switch Check safety string prior to the CS terminal. was activated. This position • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. count refers to the pulse • Hoistway not learned properly. Perform a hoistway learn count recorded during a procedure. hoistway learn. • DT4 switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without The verification position overshooting the floor or stopping short of the floor. count for the DT5 input switch was off by more than • The power common to the limit switches (CS) was lost. 32 inches when the switch Check safety string prior to the CS terminal. was activated. This position • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. count refers to the pulse • Hoistway not learned properly. Perform a hoistway learn count recorded during a procedure. hoistway learn. • DT5 switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without The verification position overshooting the floor or stopping short of the floor. count for the DT6 input switch was off by more than • The power common to the limit switches (CS) was lost. 42 inches when the switch Check safety string prior to the CS terminal. was activated. This position • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. count refers to the pulse • Hoistway not learned properly. Perform a hoistway learn count recorded during a procedure. hoistway learn. • DT6 switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. Faults DTS count Fault Description Possible Cause/Suggested Fix DTS input Failed On Fault. The car was at the bottom floor and the DT input was DTS Failed On Fault low true (DT switch open) but the DTS input was high (DTS not open). • The DT switch is not wired or DT input was lost. • The DTS did not break at the bottom terminal landing. Adjust or replace the DTS switch. • Faulty DTS input. Replace the DTS input chip. Emergency brake test EBAi Input Off Fault contacts in BA1,BA2 failed off • Possible bad NC contact on BA1 or BA2 relays • Check wiring on emergency brake relays • Replace EBAi input on expansion i/o board Emergency brake test EBAi Input On Fault contacts in BA1,BA2 failed on • Make sure BA1 and BA2 relays are being cycled • Replace EBAi input on expansion i/o board Emergency brake test EBBi Input Off Fault contacts in BB1,BB2 failed off • Possible bad NC contact on BB1 or BB2 relays • Check wiring on emergency brake relays • Replace EBBi input on expansion i/o board Emergency brake test EBBi Input On Fault contacts in BB1,BB2 failed on • Make sure BB1 and BB2 relays are being cycled • Replace EBBi input on expansion i/o board EBK1 Input Failed OFF • Locate EBK1 and visually determine if output is turning ON and OFF Faulty EBK1i input chip. Replace the EBK1i input chip. • Faulty EBK1 output Chip. Replace the EBK1 output chip. • Make sure the blue jumper connecting the input EBK1 to the output EBK1i is in place. Emergency Brake EBK1i failed off fault P a g e | 245 Section 11 – Main CPU Faults • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. Down Terminal Slowdown • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without Limit Count Fault. The verification position count overshooting the floor or stopping short of the floor. for the DTS input switch was • The power common to the limit switches (CS) was lost. off by more than 10 inches Check safety string prior to the CS terminal. • Incorrect counting of pulse counts. Check encoder when the switch was connection to motor and encoder wiring. activated. This position • Hoistway not learned properly. Perform a hoistway learn count refers to the pulse procedure. count recorded during a • DTS switch not adjusted properly. Check at slow speed if hoistway learn. switch is breaking, making and then braking again. Switch needs to be closer to the cam. Faults Description Possible Cause/Suggested Fix Emergency Brake EBK1 failed on fault • Locate EBK1 and visually determine if output is turning ON and OFF Faulty EBK1i input chip. Replace the EBK1i input chip. • Faulty EBK1 output Chip. Replace the EBK1 output chip. • Make sure the blue jumper connecting the input EBK1 to the output EBK1i is in place. Emergency Brake EBK2 failed off fault • Locate EBK2 and visually determine if output is turning ON and OFF Faulty EBK2i input chip. Replace the EBK2i input chip. • Faulty EBK2 output Chip. Replace the EBK2 output chip. • Make sure the blue jumper connecting the input EBK2 to the output EBK2i is in place. EBK2 Input Failed ON Emergency Brake EBK2 failed on fault • Locate EBK2 and visually determine if output is turning ON and OFF Faulty EBK2i input chip. Replace the EBK2i input chip. • Faulty EBK1 output Chip. Replace the EBK2 output chip. • Make sure the blue jumper connecting the input EBK1 to the output EBK1i is in place. EE Ram Failed EE Ram (Flash Memory) • Call factory to verify memory size on 1036 board. Replace Fault. Valid flash memory is memory chip with larger size. not found or memory chip is • Faulty 1036 board. Replace 1036 board not large enough EE Tst EE1 Failed OFF Electric Eye Test. Freight door electric eye input EE1 failed off. • Verify that the electric eye input EE1 pulses on during the electric eye test. • Possible faulty electric eye device. • Possible faulty EE1 input - replace the input. EE Tst EE1 Failed ON Electric Eye Test. Freight door electric eye input EE1 failed on. • Verify that the electric eye input EE1 is off before the electric eye test. • Possible faulty electric eye device. • Possible faulty EE1 input - replace the input. EE Tst EE2 Failed OFF Electric Eye Test. Freight door electric eye input EE2 failed off. • Verify that the electric eye input EE2 pulses on during the electric eye test. • Possible faulty electric eye device. • Possible faulty EE2 input - replace the input. EBK1 Input Failed ON EBK2 Input Failed OFF Description Possible Cause/Suggested Fix EE Tst EE2 Failed ON Electric Eye Test. Freight door electric eye input EE2 failed on. • Verify that the electric eye input EE2 is off before the electric eye test. • Possible faulty electric eye device. • Possible faulty EE2 input - replace the input. EE Tst EER1 Faild OFF • Verify that the electric eye input EER1 pulses on during the Electric Eye Test. Freight electric eye test. rear door electric eye input • Possible faulty electric eye device. EER1 failed off. • Possible faulty EER1 input - replace the input. EE Tst EER1 Faild ON • Verify that the electric eye input EER1 is off before the Electric Eye Test. Freight electric eye test. rear door electric eye input • Possible faulty electric eye device. EER1 failed on. • Possible faulty EER1 input - replace the input. EE Tst EER2 Faild OFF • Verify that the electric eye input EER2 pulses on during the Electric Eye Test. Freight electric eye test. rear door electric eye input • Possible faulty electric eye device. EER2 failed off. • Possible faulty EER2 input - replace the input. EE Tst EER2 Faild ON • Verify that the electric eye input EER2 is off before the Electric Eye Test. Freight electric eye test. rear door electric eye input • Possible faulty electric eye device. EER2 failed on. • Possible faulty EER2 input - replace the input. • Improper wiring of the brake EBRKC coil. Refer to prints for After the controller turns on wire connections. EM Brake Input OFF the output EBKC, EBKi never • Faulty EBKi input. Replace EBKi input chip on i/o board. came on • Faulty EBKC output. Replace EBKC output chip on i/o board The EBKi input or EBKC EM Brake Input ON output has failed on. EM Brake Switch OFF • Improper wiring of the brake Emergency Brake coil. Refer to prints for wire connections. • Faulty EBKi input. Replace EBKi input chip on i/o board. • Faulty EBKC output. Replace EBKC output chip on i/o board. Emergency brake switch • Improper wiring of Emergency brake switch. EBKS failed off once the car • Faulty EBKS input. Replace EBKS input chip on i/o board. stopped P a g e | 247 Section 11 – Main CPU Faults Faults Faults Description Possible Cause/Suggested Fix EM Brake Switch ON Emergency brake switch • Improper wiring of Emergency brake switch. EBKS failed off once the car • Faulty EBKS input. Replace EBKS input chip on i/o board. stopped • Check adjustment of Emergency brake switch. EM BRK CAN Com Error • Faulty CAN communication wire connection. Verify proper twisted pair wires to the CANH and CANL terminals on the Emergency Brake Board Can brake board. Communication Error. • Noise on the CAN Bus. Verify that the shield wire is connected according to the job print. • Controller may have seen car overspeed, unintended motion or lost governor input (GOV). See last page of this Section for more detailed information: Determining "Gripper/EBK fault" Device. Emergency Brake Trip Emergency Brake Trip fault Emergency Exit Flt • The Safety string opened while the car was running. Check An emergency stop occurred the safety circuit. • The LC input is off. Check the LC fuse. If the LC fuse is blown while moving. check for short from LC to GND. Enc Can Bus Ack Err Encoder CAN Bus acknowledge error Enc Can Bus Idle Err Encoder CAN Bus idle Can Open Encoder is not pulling the acknowledge line when data is being transmitted to it. Verify the following: • The Encoder is properly wired according to the schematic. • The Controller's encoder can baud rate matches that of the encoder: Adjustable Variables->System Options->Encoder Baud • Proper voltage is supplied to the encoder. Encoder CAN bus is floating for too many bit times so an idle bus is detected. Verify the following: • The Encoder is properly wired according to the schematic. • The Controller's encoder can baud rate matches that of the encoder: Adjustable Variables->System Options->Encoder Baud • Proper voltage is supplied to the encoder. Faults Description Possible Cause/Suggested Fix Enc Can Packet Fault Can Open Encoder did not respond with the expected packet. This could be caused by noise on the encoder cable. Make sure the encoder cable is properly shielded. Encoder CAN Bus packet fault Encoder Busy Error Encoder busy fault Can Open Encoder appears as busy and it is not taking signals from controller. Check encoder to see if it failed. Check wiring and shield connections as well as voltage from the GALX- 1100 CPU Board. Encoder communication error. Encoder board • Verify Connections on Encoder Board. Possible Noise on detected Comm error while Encoder cable. Check Encoder Voltage. Check that the shield is Encoder Com Error talking to the CAN Open wired on GALX-1100 CPU Board. encoder Encoder Count Error Encoder Count Error. An error is announced when the encoder count value is greater than 4 inches in 3 milliseconds. This is based on PPR (Pulses Per Inch) and the encoder is sending too many pulses. Encoder Dir Fault Encoder direction fault. Controller is in motion with an encoder velocity of more • Check for proper Voltage on Encoder. Verify Connections on than 50 feet per minute and Encoder Board. Possible Noise on Encoder cable. Check that the direction of the encoder the shields are wired on encoder Isolation Board. feedback is opposite to the direction run command • Faulty encoder connection. Verify the encoder connection to the 1022 encoder isolation board. • Faulty 4I30 encoder board. Replace the 4I30 board. • Faulty 1022 encoder isolation board. Replace the encoder isolation board. • Bus address problem on the PC/104 bus. Contact GAL regarding this fault. P a g e | 249 Section 11 – Main CPU Faults Enc Can Bus Off Err Encoder CAN Bus off Controller detected more than 255 transmit errors on CAN bus to the encoder. The CAN bus device is re-initialized to reestablish communications to the encoder. Verify the following: • The Encoder is properly wired according to the schematic. • The Controller's encoder can baud rate matches that of the encoder: Adjustable Variables->System Options->Encoder Baud • Proper voltage is supplied to the encoder. Faults Description Possible Cause/Suggested Fix Encoder Init Encoder initialization fault. • Verify Connections on Encoder Board. Encoder board failed to • Possible Noise on Encoder cable. Check Encoder Voltage. initialize CAN open Encoder • Check that the shields are wired on GALX- 1100 CPU Board. Encoder PPR Error PPR setting error from CAN Open encoder • Controller attempted to set PPR on the CAN Open Encoder but when we read it back, it did not change. • Possible Noise on Encoder cable. Check Encoder Voltage. • Check that the shields are wired on GALX- 1100 CPU Board. Encoder Preset Flt Encoder Preset error generated because controller could not establish position from Can open encoder. • Can Open Encoder / Encoder Board lost track of car position. • Possible Noise on Encoder cable. Check Encoder Voltage. • Check that the shields are wired on GALX- 1100 CPU Board. EP Recall Car 1 OT • Car 1 was out of service while elevators were in an Emergency Power Recall Car Emergency Power Recall Sequence Out of Service Car 1 • Check faults for car 1 • Car 2 was out of service while elevators were in an Emergency Power Recall Car Emergency Power Recall Sequence EP Recall Car 2 OTS Out of Service Car 2 • Check faults for car 2 EP Recall Car 3 OTS • Car 3 was out of service while elevators were in an Emergency Power Recall Car Emergency Power Recall Sequence Out of Service Car 3 • Check faults for car 3 EP Recall Car 4 OTS • Car 4 was out of service while elevators were in an Emergency Power Recall Car Emergency Power Recall Sequence Out of Service Car 4 • Check faults for car 4 EP Recall Car 5 OTS • Car 5 was out of service while elevators were in an Emergency Power Recall Car Emergency Power Recall Sequence Out of Service Car 5 • Check faults for car 5 EP Recall Car 6 OTS • Car 6 was out of service while elevators were in an Emergency Power Recall Car Emergency Power Recall Sequence Out of Service Car 6 • Check faults for car 6 Faults Description Possible Cause/Suggested Fix • Car 7 was out of service while elevators were in an Emergency Power Recall Car Emergency Power Recall Sequence EP Recall Car 7 OTS Out of Service Car 7 • Check faults for car 7 • Car 8 was out of service while elevators were in an Emergency Power Recall Car Emergency Power Recall Sequence EP Recall Car 8 OTS Out of Service Car 8 • Check faults for car 8 EPRecall Car1 Timot EPRecall Car2 Timot EPRecall Car3 Timot EPRecall Car4 Timot EP Recovery power lost while moving • Controller failed to turn on Normal Power Drive and Emergency Power Drive outputs (NPD and EPD) while in motion. Condition should not occur. Emergency Power Recall Time-out Car 1 • Car 1 timeout while it was in Emergency power recall mode • Make sure the field variable "Recall Timeout" is set properly to allow the car enough time to recover if it is between floors and away from Emergency Power Floor • If you have a blind shaft, consider increasing the Recovery Speed (default 25fpm) Emergency Power Recall Time-out Car 2 • Car 2 timeout while it was in Emergency power recall mode • Make sure the field variable "Recall Timeout" is set properly to allow the car enough time to recover if it is between floors and away from Emergency Power Floor • If you have a blind shaft, consider increasing the Recovery Speed (default 25fpm) Emergency Power Recall Time-out Car 3 • Car 3 timeout while it was in Emergency power recall mode • Make sure the field variable "Recall Timeout" is set properly to allow the car enough time to recover if it is between floors and away from Emergency Power Floor • If you have a blind shaft, consider increasing the Recovery Speed (default 25fpm) Emergency Power Recall Time-out Car 4 • Car 4 timeout while it was in Emergency power recall mode • Make sure the field variable "Recall Timeout" is set properly to allow the car enough time to recover if it is between floors and away from Emergency Power Floor • If you have a blind shaft, consider increasing the Recovery Speed (default 25fpm) P a g e | 251 Section 11 – Main CPU Faults EPR Pwr Lost Moving Faults EPRecall Car5 Timot EPRecall Car6 Timot EPRecall Car7 Timot EPRecall Car8 Timot Description Possible Cause/Suggested Fix Emergency Power Recall Time-out Car 5 • Car 5 timeout while it was in Emergency power recall mode • Make sure the field variable "Recall Timeout" is set properly to allow the car enough time to recover if it is between floors and away from Emergency Power Floor • If you have a blind shaft, consider increasing the Recovery Speed (default 25fpm) Emergency Power Recall Time-out Car 6 • Car 6 timeout while it was in Emergency power recall mode • Make sure the field variable "Recall Timeout" is set properly to allow the car enough time to recover if it is between floors and away from Emergency Power Floor • If you have a blind shaft, consider increasing the Recovery Speed (default 25fpm) Emergency Power Recall Time-out Car 7 • Car 7 timeout while it was in Emergency power recall mode • Make sure the field variable "Recall Timeout" is set properly to allow the car enough time to recover if it is between floors and away from Emergency Power Floor • If you have a blind shaft, consider increasing the Recovery Speed (default 25fpm) Emergency Power Recall Time-out Car 8 • Car 8 timeout while it was in Emergency power recall mode • Make sure the field variable "Recall Timeout" is set properly to allow the car enough time to recover if it is between floors and away from Emergency Power Floor • If you have a blind shaft, consider increasing the Recovery Speed (default 25fpm) Faults Possible Cause/Suggested Fix Traction • The “P” input did not drop from MC, BRK or RUN contactors being energized. • The drive on (DON) input did not energize or dropped out while running. • The BRK contactor did not energize or dropped out while running. • BRKI input did not turn on or dropped out while running. Hydro An emergency stop occurred • The DEL contactor did not energize or dropped out while while moving or attempting running • The DEL input did not turn on or dropped out while running. to move. • An emergency power recall was initiated while the car was running up. Both Traction and Hydro • The stop switch was pulled while running. • The car was not safe usually from clipping a door lock. See Car Safe Fault. • The stall protection timer timed-out. • The pulse count stopped counting. • After Controller was safe with doors, gate switch, door contacts and locks made and ready to run, a door contact input turned OFF. FDoor Close Cont Flt Door Close Contact safe fault FETST OFF Fault Front Door Electric Eye Test Failed OFF. Output is turned • FETST output or FETST input failed in the off state. on cause the electric eye • Replace the FETST output chip. outputs to controller input • Replace the FETST input chip. EE1 and EE2 to pulse. FETST ON Fault Front Door Electric Eye Test Failed ON. Output is turned • FETST output or FETST input failed in the on state. on cause the electric eye • Replace the FETST output chip. outputs to controller input • Replace the FETST input chip. EE1 and EE2 to pulse. Field Vars Deflt Ini Field Variables Default Initialization. Field • Job related parameters are invalid. This error occurs on the adjustable variables are first time the 1036 board is being powered up. being initialized for the first time. P a g e | 253 Section 11 – Main CPU Faults Estop Fault Description Faults Description Possible Cause/Suggested Fix Field Vars Relocated Field Variables Relocated. In software version 5.08 the adjustable field variables were relocated to a new location in flash memory to allow for additional future field variables. • The software has been updated to a version 5.08 or higher from a previous version. This is normal and should only occur once. If an older version software (earlier than 5.08) is later installed, the job parameters may be lost. Fire Fighter Stop switch is Fire Fighter Stop Sw pulled while the car is in motion. • Fire Fighter Stop switch is pulled. • Faulty wire connection in the Fire Fighter stop switch circuit. Fld Var Partial Init Field variables partial table initialized. Controller did not see extended memory • The software has been updated. This is normal and should initialized before. It should only occur once. If fault constantly occurs please contact GAL. occur once when updating controller software Front Det Edge Fault Front Detector Edge Timeout FST I/O Failed Off The FST input on the 1038 • Faulty FST output chip. Replace output chip. board did not pick up when • Faulty FSTI input chip. Replace input chip. expected. FST I/O Failed On The FST input on the 1038 board did not drop out when expected. • The Electric Eye signal stayed on continuously for longer than the parameter 'EE Time-out' is set to. • Faulty FST output chip. Replace output chip. • Faulty FSTI input chip. Replace input chip. The FSTP input on the 1038 • Faulty FST1 output chip. Replace output chip. FSTP I/O Failed Off board did not pick up when • Faulty FSTI input chip. Replace input chip. expected. FSTP I/O Failed On The FSTP input on the 1038 • Faulty FST1 output chip. Replace output chip. board did not drop out up • Faulty FSTI input chip. Replace input chip. when expected FVARS Backup Init Older software did not backup the field variables. When new Field Variables Backup Init. software replaces the older software this error will be Field variables backed up for displayed. If this error occurs every time the CPU powers up, the first time. then the CPU may be faulty and should be replaced. Description Possible Cause/Suggested Fix FVARS Backup Tbl Cksm Field Variables Backup Table Checksum Error. The verification checksum for the backup field variable table has failed. During power outages or brown-outs, enough noise can be generated on the 5V DC supply to cause an error in reading the field variables table on power up. For this reason we keep the data in two separate tables. If only one table checksum error occurs, then valid data will be restored. No action is required. FVARS Backup Tbl Err Field Variables Backup Table Error. The field variables from the backup MRAM table does not match the variable read into memory from the main MRAM table. Most likely, if this error occurs, other FVARS errors will also occur. A once-in-a-while occurrence of this error can be ignored if it is not accompanied by the following errors: FVARS Both Tbl Chksum error or FVARS Tbl Chksum Error. If either error occurs with this error, the main CPU board should be replaced. FVARS Both Tbl Chksum Field Variable data is stored in two separate MRAM tables and a checksum of each table is stored in a separate location. Field Variables Both Table When the system powers up, the checksum of each table is Checksum Table error. The verified. If one table fails verification, the field variables are verification checksum for copied from the table that passed verification and then both both the main field variable tables are updated with valid data. If both checksum table and backup table has verifications fail, data is copied from the main table and an failed. error code is displayed. • If this fault occurs, replace the main CPU board. FVARS Tbl Chksum Err Field Variables Table Checksum Error. The verification checksum for the main field variable table has failed. During power outages or brown-outs, enough noise can be generated on the 5V DC supply to cause an error in reading the field variables table on power up. For this reason we keep the data in two separate tables. If only one table checksum error occurs, then valid data will be restored. No action is required. Gate Switch Fault The Gate Switch failed on while the door was open. • Gate switch not adjusted properly. • GS input failed on. Replace GS input on 1038/1064 board. Gate/Lock Bypass Switch Fault The gate or lock bypass switch was on while the car was NOT on car top inspection. • Gate or Lock bypass switch on the controller 1038 board is in the on position. • Gate or Lock bypass input failed on. Replace GBP OR LBP input chip on 1038 board. Governor Switch Flt Governor Switch Tripped. • Verify that the governor switch is set properly. • Verify that the drive is setup properly and that the car does not overspeed. P a g e | 255 Section 11 – Main CPU Faults Faults Faults Description Possible Cause/Suggested Fix • Faulty wiring to the rope gripper. • Faulty GTS switch on rope gripper. Make sure that the The rope gripper did not Gripper did not Pick pick when the GR1 and GR2 switch opens and closes properly when the gripper is energized and dropped. relays were energized. • Faulty GTS input. Replace the GTS input chip. Gripper Trip Fault An overspeed or • Check if the governor has tripped from. uncontrolled motion caused • Make sure that the brake can hold the car. the rope gripper to trip. Group Comm Loss • Faulty wiring from TX+/TX- from car to car. • Faulty 75176 driver chip on the 1036 Comm/Memory board Car 2 (or another car) is not (next to the connector for the group comm). communicating with Car 1. • Noise on shield wire. Connect shield only on one end. • Noise on the communication wires. Run wires in separate conduit. Grp Comm Config Err • There as a device trying to get initialized that should not be Group Comm configuration on the bus. error. • Check detailed fault data for "dev" to identify board address GRT1 input Off Fault While testing the rope gripper relays, the contacts • Faulty GR1R or GR2R relays. Replace both GR1R and GR2R for GR1R or GR2R did not relays. close or the GRT1 input • Faulty GRT1 input. Replace the GRT1 input chip. failed off. GRT1 Input On Fault While testing the rope gripper relays, the contacts • Faulty GR1R or GR2R relays. Replace both GR1R and GR2R for GR1R or GR2R did not relays. open or the GRT1 input • Faulty GRT1 input. Replace the GRT1 input chip. failed on. GRT2 input Off Fault While in a door zone the DZ and DZ1 contacts used in the rope gripper circuit were not closed or the GRT2 input failed off. • Faulty DZ or DZ1 relays. Replace both DZ and DZ1 relays. • Faulty GRT2 input. Replace the GRT2 input chip. • Faulty LE or LE1 outputs. When a DZ input is turned on from the selector DZ output, LE and LE1 outputs control the DZ and DZ1 relays respectively. Replace the LE and LE1 output chips. Faults Description Possible Cause/Suggested Fix • Faulty DZ or DZ1 relays. Replace both DZ and DZ1 relays. • Faulty GRT2 input. Replace the GRT2 input chip. • Faulty LE or LE1 outputs. When a DZ input is turned on from the selector DZ output, LE and LE1 outputs control the DZ and DZ1 relays respectively. Replace the LE and LE1 output chips. Input failure on one of the GS & GS-1 Opposite Gate Switch (GS) inputs. • GS or GS-1 input failed on. Replace GS or GS-1 input chip. Check status of input from Input and Output menu on the LCD interface. Emergency Brake: GTS input • Check wiring for emergency brake did not turn on while doing • Check emergency brake relays during safety check GTS Input Off Fault the safety check for PFC and • Faulty GTS input chip. Replace input chip. SFC relays. Emergency Brake: GTS input • Check wiring for emergency brake did not turn off while doing • Check emergency brake relays during safety check GTS Input On Fault the safety check for PFC and • Faulty GTS input chip. Replace input chip. SFC relays. Hall Call Light Fuse Hall Call Light Fuse Blown • Check for short on the Hall Call Light circuit. HC Com Device Reset Serial Hall Call board reset unexpectedly. Usually caused by loss of power to the individual board. • Usually caused by loss of power to the individual board. • Faulty power connection to board. • Faulty hall call board. Not receiving packets from the bottom station • Cable is bad or disconnected • Cables going to wrong port (i.e., switched TO ABOVE and TO BELOW) • Transmitter from device above or below is bad, check faults for that device. • Receiver on driver board is bad – replace device HC DrvBd Rx from Bot P a g e | 257 Section 11 – Main CPU Faults The DZ and DZ1 contacts used in the rope gripper GRT2 input On Fault circuit did not open during a run or the GRT2 input failed on. Faults Description Possible Cause/Suggested Fix Can't internally read information from HC DrvBd Tx to Bot Transmitter to bottom station • Cable connecting two devices could be flip- flopped (i.e., gray wire goes from pin 1 on one end to pin 8 on the other end Car Options->Leveling Fault = ' is set so it trips the Rope Gripper/Emergency Brake Lev Flt Set Gripper Gripper set from leveling fault • A leveling fault occurred and the parameter 'Adjustable Options->Car Options->Leveling Fault = ' is set so it trips the Rope Gripper/Emergency Brake P a g e | 269 Section 11 – Main CPU Faults Keb drive not in run mode. We need to verify that the drive is in Run Mode before we do every Run. Faults Description Leveling stop fault occurred from incorrect count. As the Level Stop Cnt Fault car was leveling off the pulses, UL or DL turned off. Leveling Fault Leveling Fault. When the car attempted to drop the brake, the car moved out of the dead level. The leveling fault count was incremented. If this occurs more times than the adjustable variable “Level Fault Cnt” then this error is declared. Leveling Tim-out Flt Leveling Time-out Fault Limit Opp Dir Flt Car hit limits in wrong direction. In a single Run every Limit switch signal should only change state once or not change at all. If car was travelling down and an Up Terminal Slowdown switch goes LOW after we go in motion we will detect that as a fault. Load Weigh Var Init Load weigher init Possible Cause/Suggested Fix • Floor offset value set too high • Increase dead zone when the car is configured to stop on the pulses instead of just the magnet • Ensure outer sensors are set no more than 7.5" apart • Brake is dropping too slowly. Adjust the drop of the brake. • The drive is not holding zero speed. Run the car on inspection at 5fpm and while running change the inspection speed to zero. The car should stop and hold zero. • The response is not high enough on the drive. • Brake contactor is not dropping properly. • Car overshot floor and continue leveling. • Car targeted floor too soon and was creeping to the floor in leveling. • Check for causes of invalid pulse counts or invalid floor positions • Invalid floor position preset • Faulty encoder connection • Faulty encoder wiring • If Controller is not really faulting, check that Slowdowns are not at the same position as the dead level position. In Gearless jobs roll back could cause this extra change of state and therefore generate the fault. In that event reposition Terminal Slowdown by a couple of inches. • Invalid load weigher table on power up. The load weigher table will be re-initialized to zero and the load weigher must be re-setup. • If this error persist, the MRAM on the CPU board is faulty. Replace the CPU board. • Ignore this error if the load weigher is not being used. Faults Description Lobby Hall Call Fuse Lobby Call common fuse Possible Cause/Suggested Fix • Lobby Common fuse blown. Check Input chip for LHC The load weigher device should be re-calibrated according to the manufacturer's instructions. MCA I/O Failed Off The MCA input or output has failed off. • Faulty MCAi input chip. Replace input chip. • Faulty MCA output chip. Replace output chip. MCA I/O Failed On The MCA input or output has failed on. • Faulty MCAi input chip. Replace input chip. • Faulty MCA output chip. Replace output chip. MCC I/O Failed Off The MCC input or output has failed off. • Faulty MCCi input chip. Replace input chip. • Faulty MCC output chip. Replace output chip. MCC I/O Failed On The MCC input or output has failed on. • Faulty MCCi input chip. Replace input chip. • Faulty MCC output chip. Replace output chip. Middle Door Lock Fault • Faulty door lock. • Jumper on door lock circuit. • Door lock not adjusted properly. The Middle Door Lock failed • Faulty wiring to DLM input. on while the door was open. • Faulty DLM and DLM-1 inputs (For this to occur both DLM and DLM-1 inputs must fail on). • DOL input failed. Replace DOL input chip. • Door operator open limit DOL is not adjusted properly Section 11 – Main CPU Faults LW Calibration Error Load Weigher Calibration Error. The Load Weigher attempted to do an automatic calibration and could not be calibrated. GTS input opened unexpectedly during a run. Motion Exit GTS Flt GTS Motion emergency exit • Faulty GTS switch on the rope gripper. Replace or correct the switch activation Motion Exit Ins Flt Emergency motion exit from Car was in motion before going in inspection Mode. Check for inspection inspection inputs faulting out or Automatic input going low. MRAM Hardware Fault MRAM Fault The MRAM is tested on power up and has failed the test. Replace the CPU board. P a g e | 271 Faults Description Possible Cause/Suggested Fix MRAM Write Error. After parameter data RAM has been modified through the user interface, the data is automatically written to • This error should not occur. If it does occur, the problem is either a fault CPU board or MRAM chip. Replace the CPU MRAM Write Error MRAM for non-volatile storage. After the data is board. stored it is compared with the original parameter data. If it does not match a fault is recorded. NV Ram Failed NV Ram (Battery Backed) Fault. Valid battery backed • Call factory to verify memory size on 1036 board. Replace ram memory is not found or memory chip with larger size. memory chip is not large • Faulty 1036 board. Replace 1036 board enough Overspeed Fault Car overspeed fault. If the car goes 15% over contract speed the fault will be logged and the car will do an emergency stop. P input off Fault • Not enough current draw through all three contacts. Place a 10K 3W resistor from the normally closed contact of RUN to The normally closed contacts on MC, BRK or RUN GND. • Faulty normally closed contacts on MC, BK (traction only) or contactors did not drop. RUN. Replace auxiliary contacts. P Input On Fault The “P” input did not drop out while the car was running. This input should drop out when MC, BRK and Run contactors are energized. Traction • Faulty contactor or auxiliary contacts on MC, BRK or RUN. Replace auxiliary contacts or entire contactor. Hydro • Faulty Soft-Starter Fault contactor failed to pick. Verify that the fault contactor has power from MST output. Refer to schematic and check voltage for Soft-Starter overload. PC/104 Bus Error PC/104 Bus Error. During two consecutive reads to the encoder board the count value was different. • This error detects a hardware error on the PC/104 bus. Contact GAL regarding this error. • Encoder PPR incorrectly set. Set to match the Drive’s Encoder Pulses. • Encoder RPM incorrectly set. Set to match the Motor’s RPM. • The drive is not controlling the hoist machine motor. Check the response setting on the drive. Faults Description Possible Cause/Suggested Fix • Faulty PFC output chip. Replace output chip. PFC relay did not pick up as • Faulty PFC relay on main I/O Board (1038 or 1064). Replace PFC Relay Failed Off expected PFC relay. • Faulty PFC output chip. Replace output chip. • Faulty PFC relay on main I/O Board (1038 or 1064). Replace PFC relay. PFC-SFC Test Lost DZ Lost DZ input when performing a SFC/PFC test. • DZ output on selector board did not turn on. (Replace DZ output on selector driver board). • One or both of the DZ sensors on the selector sensor board failed. Replace selector sensor board. • DZ input on the 1040 board failed. Replace DZ input on 1037/1040 board. • Check leveling magnet. Pit Door Switch Flt Pit Door Switch Open • Verify that the pit door switch is closed. • Faulty wiring on the pit door switch circuit. Pit Switch Fault Pit Switch Input Open • Verify that the pit switch is closed. • Faulty wiring on the pit switch circuit. Pls Er 75% Top Speed Pulse Error occurred while car is running greater than 75% of contract speed. The pulse counts have to change a minimum distance by the time the car reaches 75% of top speed. • This error occurs if the car loses its pulse feedback from the encoder. Make sure that the encoder is not slipping. Check the encoder cable from the drive to the controller. Also check the ribbon cable from the encoder isolation board (1022N) to the encoder board (4I30) on the PC/104 CPU stack. • Possible faulty encoder isolation board (1022N), faulty ribbon cable or faulty encoder board (4I30). Position Fault • Car is out of step from faulty selector inputs. Check that the The Terminal limits do not DZ, UL and DL selector inputs work properly at each floor. match the car position (UT • UT or DT input lost from the safety string being opened. • Improper adjustment of UT or DT limit switches. or DT is hit but the car position is not at the top or Hydro • Car missed a slowdown input magnet. Check that the US bottom floor). and DS selector inputs work properly prior to each landing. P a g e | 273 Section 11 – Main CPU Faults PFC relay did not drop as PFC Relay Failed On expected when performing a SFC/PFC test. Faults Description The controller CPU lost the car top stop switch input CTS, but has the SS and GTS Possible DRV/1028 inputs ON indicating that Err the drive or Safety Processor (1028) board has opened the safety string. Possible Cause/Suggested Fix • View the faults on the Safety Processor board display and debug from the fault code listed. • Traction Only - View the drive faults log or led status and debug as directed from the drive manual. Power Up Reset Whenever power is cycled on the controller this error will indicate that the controller CPU was reset. • This error code is normal for a power loss. If power was not lost and the CPU re-boots, verify the +5VDC on the CPU power connector reads in the range of 4.90 and 5.1 VDC. If out of range, adjust the 5VDC supply pot for the correct voltage. Pulse Error > 75 fpm Pulse count shows a travel distance less than 2 inches while the car demand velocity is greater than 75 fpm. Insufficient number of pulses from the encoder. • Make sure that the encoder is not slipping. Check the ribbon cable from the encoder isolation board (1022N) to the encoder board (4I30) on the PC/104 CPU stack. • Possible faulty encoder isolation board (1022N), faulty ribbon cable or faulty encoder board (4I30). PWL UPS Comm Fault Power loss: Controller cannot establish comm to UPS • Check wiring and shielded pairs • Defective comm board • Possible bad UPS unit PWL UPS Low Bat Flt Power loss: ups battery fault • UPS Battery voltage has dropped below 18V • Replace unit PWL UPS Low Bat Volt • Defective battery inside UPS unit Power loss: ups batter fault • Make sure the UP is charging. • Replace UPS PWL UPS On Bat Power Power loss: ups on battery power • No Line voltage on UPS. Unit running on battery power PWL UPS Turned Off Power loss: ups turned off • Power loss on UPS. Power has been turned off Description Possible Cause/Suggested Fix RCM / Lock Flt Retiring Cam/Lock fault. Job has door contacts and door lock inputs as well as retiring cam output. Door locks are not coming on when trying to leave the floor. • Door Contacts were already closed and the controller attempted to energize the retiring cam (RCM) several times and the door locks did not turn on. After 4 attempts, it will declare this fault. Check locks or retiring cam device. RDoor Close Cont Flt Rear Door Close Contact safe fault • After Controller was safe with doors, gate switch, door contacts and locks made and ready to run, a door contact input turned OFF. Rear Bottom Door Lock Fault • Faulty door lock. • Jumper placed on door lock circuit. The Rear Bottom Door Lock • Rear door lock not adjusted properly. failed on while the door was • Faulty wiring to DLB input. open (door on the rear door • Faulty DLB and DLB-1 inputs (For this to occur both DLB and DLB-1 inputs must fail on). open limit). • DOLR input failed. Replace DOLR input chip. • Rear door operator open limit is not adjusted properly Rear Det Edge Fault Rear Detector Edge Timeout Rear Door Close Fault The rear door did not reach • Rear Door Close Limit (DCLR) not adjusted properly. the Rear Door Close Limit • Faulty Rear Door Close Limit (DCLR). Replace DCRL input. within the door close • Trash in door track preventing door from closing. protection time. Rear Door Open Fault The rear door did not reach the Rear Door Open Limit • Rear Door Open Limit (DOLR) not adjusted properly. within the door open • Faulty Rear Door Open Limit (DOLR). Replace DOLR input. protection time. Rear Gate Switch Fault The Rear Gate Switch failed • Rear Gate switch not adjusted properly. on while the door was open. • RGS input failed on. Replace RGS input. • The Rear Electric Eye signal stayed on continuously for longer than the parameter 'EE Time-out' is set to. P a g e | 275 Section 11 – Main CPU Faults Faults Faults Description Possible Cause/Suggested Fix Rear Middle Door Lock Fault • Faulty door lock. • Jumper placed on door lock circuit. • Rear door lock not adjusted properly. The Middle Door Lock failed • Faulty wiring to RLM input. on while the door was open. • Faulty RLM and RLM-1 inputs (For this to occur both RLM and RLM-1 inputs must fail on). • DOLR input failed. Replace DOLR input chip. • Rear door operator open limit is not adjusted properly • Faulty door lock. • Jumper placed on door lock circuit. • Rear door lock not adjusted properly. The Rear Top Door Lock • Faulty wiring to DLT input. Rear Top Door Lock failed on while the door was • Faulty DLT and DLT-1 inputs (For this to occur both DLT and Fault open. DLT-1 inputs must fail on). • DOLR input failed. Replace DOLR input chip. • Rear door operator open limit is not adjusted properly Reset Fault Any time the system detects one of the following faults a reset fault is logged: • Power is cycled • Controller finds itself out of the door zone. • This fault is logged under normal conditions. Check the fault • Binary input fault. log for error that would indicate a fault condition prior to the • Terminal limits do not reset fault. match the current position. • Car has been switched off of inspection. • After an open safety string has been closed. RETST OFF Fault Rear Door Electric Eye Test Failed OFF. Output is turned • RETST output or RETST input failed in the on state. on cause the electric eye • Replace the RETST output chip. outputs to controller input • Replace the RETST input chip. EER1 and EER2 to pulse. RETST ON Fault Rear Door Electric Eye Test Failed ON. Output is turned • RETST output or RETST input failed in the on state. on cause the electric eye • Replace the RETST output chip. outputs to controller input • Replace the RETST input chip. EER1 and EER2 to pulse. Description Possible Cause/Suggested Fix RGS & RGS-1 Opposite Input failure on one of the Rear Gate Switch (RGS) inputs. • Faulty RGS or RGS-1 input. Replace input chip. RLM & RLM-1 Opposite Input failure on one of the Rear Lock Middle (RLM) inputs • Faulty RLM or RLM-1 input. Replace input chip. RPM Input Fault RPM Input Fault. The Rear Door Protection input stayed on when the rear door reached full open. • RPM switch not setup properly on the door operator. • Faulty RPM input. Replace RPM input chip. RPM Off with Rear Gate Switch or Door Lock On. RPM Off/RGS or DL The Rear Door Protection Module input must go on On before rear gate switch or door lock inputs go on. Run Fault: Shutdown • The RPM switch on the door operator is not setup properly. • There is no RPM input on the door operator. Jump the RPM input to the RGS terminal. • Faulty RPM input. Replace the RPM input chip. Run Fault: Shutdown. If the car attempts to run 4 consecutive times and incurs a specific type of emergency stop without making a successful run, the car is shut down and this error code is shown. The specific types of emergency stops to cause this fault are as follows: 1. The car has picked the • Verify that the brake is lifting properly. brake and is in the run mode • Verify that the encoder pulses increment and decrement for more than 2 seconds and when running up or down. the position pulse has not changed. 2. The car is demanding a velocity greater than 75 fpm and change in position count is less than 3 inches. 3. The run stall protection timer has expired (Adjustable Varibles->Car Timers->Stall Time). P a g e | 277 Section 11 – Main CPU Faults Faults Faults Description RUN I/O Failed On Traction • Faulty wiring to RN1 terminal. • Faulty RUNi input. Replace the RUNi input chip. • Faulty RUN output. Replace the RUN output chip. The RUN input or output has Hydro failed on (has not dropped). • Faulty wiring at the SC terminal. Verify that the valve common SC terminal on the 1038 board is connected properly. • Faulty RUNi input. Replace the RUNi input chip. • Faulty RUN output. Replace the RUN output chip. Run Inhibit Rset Cnt Run inhibit from reset count Possible Cause/Suggested Fix • Once the car is in Reset mode, the controller attempted 5 times to come off reset but it keeps being sent back in reset. RUN O/RUN I Failed RUN output failed off or run • Faulty RUNi input chip. Replace input chip. input failed on • Faulty RUN output chip. Replace output chip. RUN O/RUNA I Failed RUN output failed off or RUNAi input failed on • Faulty RUNAi input chip. Replace input chip. • Faulty RUN output chip. Replace output chip. The RUNA input or output has failed off. Traction • Fault on Safety Processor Board. This board can disable the run control to the RUNA output chip. Check if the PIC or PAL inhibit LEDs are on or if they turn on when the car attempts to run. Check the elevator service, faults, and inputs/outputs on the Safety Processor Board LCD display. • Faulty RUNAi input. Replace the RUNAi input chip. • Faulty RUNA output. Replace the RUNA output chip. Hydro • Faulty wiring at the SC terminal. Verify that the valve common SC terminal on the 1038 board is connected properly. • Faulty RUNAi input. Replace RUNAi input chip. • Faulty RUNA output. Replace RUNA output chip. • Faulty RUN output. Replace RUN output chip. RUNA I/O Failed Off Faults RUNA I/O Failed Off Description The RUNA input or output has failed off. Possible Cause/Suggested Fix Traction • Faulty RUNAi input. Replace the RUNAi input chip. • Faulty RUNA output. Replace the RUNA output chip. Hydro • Faulty wiring at the SC terminal. Verify that the valve common SC terminal on the 1038 board is connected properly. • Faulty RUN output. Replace RUN output chip. • Faulty RUNAi input. Replace RUNAi input chip. • Faulty RUNA output. Replace RUNA output chip. RUNA I/O Failed On The RUNA input or output has failed on RUNA O/RUN I Failed RUNA output or RUNI input • RUNA output failed off. Replace the RUNA output chip. Or failed • RUNI input failed off. Replace the RUNI input chip. Safety String Fault Safety string fault occurs from the following conditions: • The safety string is open (SS input is off). • The safety string is open (SS input if off). Refer to the job • The drive ready input is prints and check all circuits ahead of the SS input. not energized from the drive. • The potential to run input “P” is off. P a g e | 279 Section 11 – Main CPU Faults Traction • Fault on Safety Processor Board. This board can disable the run control to the RUNA output chip. Check if the PIC or PAL inhibit LEDs are on or if they turn on when the car attempts to run. Check the elevator service, faults, and inputs/outputs on the Safety Processor Board LCD display. • Faulty RUNAi input. Replace the RUNAi input chip. • Faulty RUNA output. Replace the RUNA output chip. Hydro • Faulty wiring at the SC terminal. Verify that the valve common SC terminal on the 1038/1064 board is connected properly. • Faulty RUNAi input. Replace RUNAi input chip. • Faulty RUNA output. Replace RUNA output chip. • Faulty RUN output. Replace RUN output chip Faults Description Serial Expansion Board CAN Communications Error. One of the Serial Expansion SEB CAN Com Error boards is not communicating with the main CPU. Selector Count Fault Selector Preset Flt Possible Cause/Suggested Fix • From the LCD user interface, select the Diagnostic menu and then the Car Com Status menu. The device that is not communicating will be shown with the online status equal 0. Check the terminal connection for the twisted pair wires and check power to the board. A 5V LED should be on solid and the MCU & COM LEDs should blink on and off at the same rate. Selector Count Fault. If the hoistway has been learned and the selector count init flag (tapeless selector) is not set then this error is declared. • The governor encoder has lost battery power. • The encoder was disconnected from the governor. • Faulty encoder connection to the governor • Loss of communications from the Safety Processor Board to the encoder. Selector preset position fault • Controller could not establish position from selector pulse count or tapeless encoder. It tried to establish position but pulse count did not match floor tables. • Check pulses on Safety processor board, encoder comm and 485 encoder. • Faulty SFC output chip. Replace output chip. • Faulty SFC relay on main I/O Board (1038 or 1064). Replace SFC relay did not pick up as SFC relay. SFC Relay Failed Off expected. • Verify the software version on the safety processor board (1028) is 3.07 or higher. SFC relay did not drop as SFC Relay Failed On expected when performing a SFC/PFC test. • Faulty SFC output chip. Replace output chip. • Faulty SFC relay on main I/O Board (1038 or 1064). Replace SFC relay. • Verify the software version on the safety processor board (1028) is 3.07 or higher. Side Emerg. Exit Flt Side Emergency Exit Fault • Verify that the side emergency exit is properly shut and the switch is closed. • Faulty wiring in the side emergency exit circuit. Slip Detect Fault SPB Velocity difference fault. There is a speed difference between the CPU and the safety processor board possibly because of Rope Slippage • This is a Slip detection mechanism required for 2010 code. The parameter Adjustable Variables->Car Options->Slip Vel Diff determines how many feet per minute the two speeds could be apart when Adjustable Variables->Car Options->Slip Det Dis is set to zero. Faults Description Possible Cause/Suggested Fix • Check the terminal connection for the twisted pair wires. • Verify that the bus termination jumper is placed on the Safety Processor Board CAN Safety Processor Board (1028 or 1066). Communications Error. The • Verify that the bus termination jumper is place on the 1036 Comm/Memory board. SPB CAN Com Error Safety Processor Board is not communicating to the • Disconnect the CAN wires to the traveling cable. If the SPB (1028 or 1066) starts communicating, verify that the bus main CPU. termination jumper is placed on the TOC board (1037 or 1040). Replace the traveling cable CAN wires. • Speed was greater than 100 foot per minute while the Safety Processor detected velocity in the opposite direction of the controller run command. • Possible Noise on Encoder cable. Check Encoder Voltage. • Check for wires shield connections on GALX- 1102 Board. • Make sure AdjVar->Enc Dir is set correctly in the Safety Processor. SPB SFC Off Fault Safety Processor Board SFC fault. CPU detected SFC (Secondary Fault Controller) turn off while the ready input (RDY) was still on • Check faults in safety processor board • Replace SFC (EQR) input chip • If no voltage at SFC terminal and no faults in safety processor, replace output chip for SFC on the main i/o board SPB Unintend Motion Safety Processor Board unintended motion • Safety processor detected unintended motion of elevator with the doors open. Speed Control Exit • The Electrical Safety String was open during a run. Check the safety string inputs. • The Drive dropped the SFD relay causing the RDY input to drop. Check the drive for faults. Speed Control Exited from a • The S10 input turned off. Possible short in traveling cable or fault condition. bad S10 input. Correct short condition or replace S10 input on 1064 board. • GTS input turned off during run. Rope Gripper turned off. • Inspection Switch applied during run. P a g e | 281 Section 11 – Main CPU Faults Safety Processor encoder opposite direction fault in tapeless encoder jobs. Car SPB Enc Opp Dir Flt moving up while CPU is giving a Down command or vice versa. Faults Description Possible Cause/Suggested Fix Stalled Fault Stall Fault occurs if the motion run timer exceeds the stall protection time. • Increase Stall Timer on the controller under Adjustable The motion run timer is Variables and Car Timers. incremented while the car is trying to run. Stop Switch Fault Stop switch is pulled while the car is in motion. Target Fault at DT When going down, the target count should always be below the position count. • This fault should never occur. Please call the factory if this This fault is logged if the fault occurs. target count is above the position count when the DT slowdown limit is hit. • Stop switch is pulled (in car stop switch). • Faulty wire connection in the stop switch circuit. This fault is logged if the target count is above the Target Fault at DT1 position count when the DT1 slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. This fault is logged if the target count is above the Target Fault at DT2 position count when the DT2 slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. This fault is logged if the target count is above the Target Fault at DT3 position count when the DT3 slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. This fault is logged if the target count is above the Target Fault at DT4 position count when the DT4 slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. Faults Description Possible Cause/Suggested Fix • This fault should never occur. Please call the factory if this fault occurs. This fault is logged if the target count is above the Target Fault at DT6 position count when the DT6 slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. This fault is logged if the target count is above the Target Fault at DTS position count when the DTS slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. Target Fault at UT When going up, the target count should always be above the position count. • This fault should never occur. Please call the factory if this This fault is logged if the fault occurs. target count is below the position count when the UT slowdown limit is hit. This fault is logged if the target count is below the Target Fault at UT1 position count when the UT1 slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. This fault is logged if the target count is below the Target Fault at UT2 position count when the UT2 slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. This fault is logged if the target count is below the Target Fault at UT3 position count when the UT3 slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. P a g e | 283 Section 11 – Main CPU Faults This fault is logged if the target count is above the Target Fault at DT5 position count when the DT5 slowdown limit is hit. Faults Description Possible Cause/Suggested Fix This fault is logged if the target count is below the Target Fault at UT4 position count when the UT4 slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. This fault is logged if the target count is below the Target Fault at UT5 position count when the UT5 slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. This fault is logged if the target count is below the Target Fault at UT6 position count when the UT6 slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. This fault is logged if the target count is above the Target Fault at UTS position count when the UTS slowdown limit is hit. • This fault should never occur. Please call the factory if this fault occurs. TOC CAN Com Error Top of Car Board Communication Error. • Faulty CAN wire connection. Verify the traveling cable connections from the 1036 Comm/Memory board, to the Safety Processor Board (GALX-1028 or GALX-1066) and to the TOC board (1037 or 1040). • Jumper for bus termination resistors not placed. Verify that the bus termination resistor jumpers are placed on the TOC (1037 or 1040), on the 1036 Comm/Memory Board, and on the Safety Processor Board (GALX-1028 or GALX-1066). • Noise on the communication cable. Verify that the traveling cable shield wires are connected only at one end or is not connected at all. • Faulty communication chip. Replace the CAN bus drive chip 82C251. • Faulty 5V isolated supply for CAN driver on TOC board (1037 or 1040). Measure DC voltage between pins 2 and 3 on the 82C251 CAN driver chip. Call GAL for instructions. Faults Description Possible Cause/Suggested Fix • Faulty door lock. • Jumper on door lock circuit. • Door lock not adjusted properly. The Top Door Lock failed on • Faulty wiring to DLT input. Top Door Lock Fault • Faulty DLT and DLT-1 inputs (For this to occur both DLT and while the door was open. DLT-1 inputs must fail on). • DOL input failed. Replace DOL input chip. • Door operator open limit DOL is not adjusted properly Top Emergency Exit Fault Top Final Limit Flt Top Final Limit Open. • Car traveled onto the top final limit. • Faulty wiring of the final limit circuit. UF I/O Failed On The UF input or output has failed on. Traction • Faulty UF or B1 output. Replace the UF or B1 output chip. • Faulty UFi or B1i input. Replace UFi or B1i input chip. • Incorrect jumper placement on 1038 board. Verify that jumpers on the bottom center of the board are positioned for the correct drive type (DSD or HPV). If necessary move the jumpers to the correct drive type. Hydro • Faulty SUFi input (replace input chip). • Faulty SUF output (replace output chip). UL & UL-1 Opposite Input failure on one of the Up Level sensor input • Faulty UL or UL-1 input (replace input chips). UL and DL Fault • Faulty adjustment of the selector head. • Worn selector guides. Replace selector guides. Both UL and DL level sensors • Faulty Door Zone Magnet. If this fault occurs at one are off when car is at a floor. particular floor, replace the door zone magnet at the floor. • Faulty sensor board. Replace the selector sensor board. P a g e | 285 Section 11 – Main CPU Faults Top Emerg. Exit Flt • Verify that the top emergency exit is properly shut and the switch is closed. • Faulty wiring in the top emergency exit circuit. • Faulty wiring in the side emergency exit circuit. Faults UL Failed On Fault Description Possible Cause/Suggested Fix UL Failed On Fault. The UL leveling sensor did not go off during a run. • UL hall effect sensor is bad on selector sensor board. Replace sensor board. • UL Output Driver failed on. Replace output on selector driver board. • UL traveling cable wire is shorted to 120 VAC. Remove input wire to 1038 or 1064 board and verify that LED goes out. Correct short condition. • UL inputs failed on. Short on 1038 or 1064 main I/O board. Replace main I/O board. UL, DL & DZ sensors off at floor. The car thinks it UL,DL & DZ Off at FL should be at a floor or is at a floor and all the floor sensors have turned off. • Loss of power on the selector. • Faulty cable from the selector driver board to the sensor or sensor board. • Faulty wiring from the selector driver board to the main I/O board (1038 or 1064). • Dead Zone was estimated to be greater than eight inches. • Make sure the car is running at correct speed before learning Pulses per inch are incorrect the hoistway. UL,DL Learn Cnt Flt from the Encoder RPM/ PPR • The recommended distance between UL and DL sensors in settings tapeless system is 7.5 inches (center of UL to center of DL) if the controller is configured to stop on pulses. UL and DL Direction Fault. Once the car is in Motion, controller verifies the order for the leveling signals. UL, UL/DL Dir Seq Fault DZ and DL should come in the right sequence depending in the direction of travel. Unintended Motion Unintended Motion fault Flt • During Setup, the leveling signals may be wired incorrectly. Once in service this fault should not occur. If detected, Check Detailed Fault data to determine direction of travel as well as possible inputs causing error. • Unintended motion occurred. Car moved out of door zone with doors open or it had a speed feedback when not running from main encoder. Please keep Encoder feedback to the Safety Processor away from power wires to prevent induced voltages. If Adjustable Variables->Car Options->Griper/EBK Trip is SET then Safety processor speed could cause fault as well. Faults Description Possible Cause/Suggested Fix Car unexpectedly hit the Up • Faulty wiring for the UN limit. Up Directional Fault Normal Limit while running • The power common to the limit switches (CS) was lost. up. Check safety string prior to the CS terminal. The UP input or output has failed off Traction • Faulty UP output. Replace the UP output chip. • Faulty UPi input. Replace UPi input chip. • Incorrect jumper placement on 1038/1064 board. Verify that jumpers on the bottom center of the board are positioned for the correct drive type (DSD or HPV). Hydro • Faulty SUi input. Replace SUi, input chip. • Faulty SU output. Replace SU output chip. UP I/O Failed On The UP input or output has failed on. Up Normal SW Setup • Up Normal (UN) switch turned off before controller detected Up Normal must turn off top landing. The up normal switch must be mounted to break after reaching the top floor above the top landing. If problem persists, look at hoistway dead level. tables to detect possible defective magnets. P a g e | 287 Section 11 – Main CPU Faults UP I/O Failed Off Traction • Fault on Safety Processor Board. This board can disable the run control to the UP output chip. Check if the PIC or PAL inhibit LED turns on when the car attempts to run. Check the elevator service, faults, and inputs/outputs on the SPB LCD display. • Faulty UP output or UPi input. Replace the UP output and UPi input chips. • No 24VDC from the drive. Refer to Schematics. • Incorrect jumper placement on 1038/1064 board. Verify that jumpers on the bottom of the board are positioned for the correct drive type (DSD or HPV). • RUN or MC auxiliary contact not making properly. Contact GAL for instructions. Hydro • Faulty wiring to the SU or SC terminal on the 1038/1064 board. • Faulty wiring to the Up valve. • Faulty SUi input. Replace SUi input chip. • Faulty SU output. Replace SU output chip. Faults UPF I/O Failed Off Description Possible Cause/Suggested Fix Traction • Fault on Safety Processor Board. This Board can disable the run control to the UPF/B1 output chip. Check if the PIC or PAL inhibit LED turns on when the car attempts to run. Check the elevator service, faults, and inputs/outputs on the Safety Processor Board LCD display. • Faulty UPF/B1 output. Replace the UPF/B1 output chip. • Faulty UPFi/B1i input. Replace UPFi/B1i input chip. • No 24VDC from the drive. Verify the 24VDC between terminals 10 and 12 on the drive. • Incorrect jumper placement on 1038 board. Verify that jumpers on the bottom center of the board are positioned for The UPF input or output has the correct drive type (DSD or HPV). If necessary move the jumpers to the correct drive type. failed off. • RUN, MC or BRK auxiliary contact not making properly. Contact GAL for instructions. Hydro • Fault on 1028 Safety Processor Board. The Safety Processor Board can disable the run control to the UPF output chip. Check if the PIC or PAL inhibit LED turns on when the car attempts to run. Check the elevator service, faults, and inputs/outputs on the Safety Processor Board LCD display. • Faulty wiring to the SC common on the 1038 board. • Faulty wiring to the SUF terminal on the 1038 board. • Faulty wiring to the Up Fast valve. UPS Low Bat Capacity Power loss ups battery capacity low fault. Battery Capacity went below the threshold set by the parameter Adjustable Variables->System Options->Low Bat Cap Lev. User Variable Init User variable initialization User related parameters such a password and telephone numbers are being initialized. This error occurs on the first time the GALX-1100 CPU board is being powered up. Description Possible Cause/Suggested Fix UT Count Fault The verification position count for the UT input switch was off by more than 10 inches when the switch was activated. The car was lost due to a preset error or the controller has a faulty encoder signal for the pulse count. This position count refers to the pulse count recorded during a hoistway learn. • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without overshooting the floor or stopping short of the floor. • The power common to the limit switches (CS) was lost. Check safety string prior to the CS terminal. • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. • Hoistway not learned properly. Perform a hoistway learn procedure. • UT switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. UT Failed On Fault UT input Failed On Fault. The car was at the top floor and the UTS input was low true (UTS switch made) but the UT input was high (UT not made). • The UTS switch is not wired or the UTS switch is not used. If the UTS switch is not used, jump the UT and UTS inputs together. • The UT did not break at the bottom terminal landing. Adjust or replace the UT switch. UT1 Count Fault The verification position count for the UT1 input switch was off by more than 10 inches when the switch was activated. The car was lost due to a preset error or the controller has a faulty encoder signal for the pulse count. This position count refers to the pulse count recorded during a hoistway learn. • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without overshooting the floor or stopping short of the floor. • The power common to the limit switches (CS) was lost. Check safety string prior to the CS terminal. • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. • Hoistway not learned properly. Perform a hoistway learn procedure. • UT1 switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. P a g e | 289 Section 11 – Main CPU Faults Faults Faults Description Possible Cause/Suggested Fix UT2 Count Fault The verification position count for the UT2 input switch was off by more than 14 inches when the switch was activated. The car was lost due to a preset error or the controller has a faulty encoder signal for the pulse count. This position count refers to the pulse count recorded during a hoistway learn. • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without overshooting the floor or stopping short of the floor. • The power common to the limit switches (CS) was lost. Check safety string prior to the CS terminal. • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. • Hoistway not learned properly. Perform a Hoistway learn procedure. • UT2 switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. UT3 Count Fault The verification position count for the UT3 input switch was off by more than 18 inches when the switch was activated. The car was lost due to a preset error or the controller has a faulty encoder signal for the pulse count. This position count refers to the pulse count recorded during a hoistway learn. • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without overshooting the floor or stopping short of the floor. • The power common to the limit switches (CS) was lost. Check safety string prior to the CS terminal. • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. • Hoistway not learned properly. Perform a hoistway learn procedure. • UT3 switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. The verification position count for the UT4 input switch was off by more than 24 inches when the switch was activated. The car was lost due to a preset error or the controller has a faulty encoder signal for the pulse count. This position count refers to the pulse count recorded during a hoistway learn. • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without overshooting the floor or stopping short of the floor. • The power common to the limit switches (CS) was lost. Check safety string prior to the CS terminal. • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. • Hoistway not learned properly. Perform a hoistway learn procedure. • UT4 switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. UT4 count Fault Description Possible Cause/Suggested Fix UT5 count Fault The verification position count for the UT5 input switch was off by more than 32 inches when the switch was activated. The car was lost due to a preset error or the controller has a faulty encoder signal for the pulse count. This position count refers to the pulse count recorded during a hoistway learn. • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without overshooting the floor or stopping short of the floor. • The power common to the limit switches (CS) was lost. Check safety string prior to the CS terminal. • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. • Hoistway not learned properly. Perform a hoistway learn procedure. • UT5 switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. UT6 count Fault The verification position count for the UT6 input switch was off by more than 42 inches when the switch was activated. The car was lost due to a preset error or the controller has a faulty encoder signal for the pulse count. This position count refers to the pulse count recorded during a hoistway learn. • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without overshooting the floor or stopping short of the floor. • The power common to the limit switches (CS) was lost. Check safety string prior to the CS terminal. • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. • Hoistway not learned properly. Perform a hoistway learn procedure. • UT6 switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. UTM Contact/GTS Flt UTM contact/GTS input pick GTS input did not come on. Gripper (or UTM Relay) is set and fault GTS did not come on or turned OFF momentarily. P a g e | 291 Section 11 – Main CPU Faults Faults Faults UTS count Fault Description Possible Cause/Suggested Fix Up Terminal Slowdown Limit Count Fault. The verification position count for the UTS input switch was off by more than 10 inches when the switch was activated. The car was lost due to a preset error or the controller has a faulty encoder signal for the pulse count. This position count refers to the pulse count recorded during a hoistway learn. • The car was lost due to a preset error. Check the guides on the selector. Check the fault log for binary preset errors. • The controller has a faulty encoder signal for the pulse count. Check that the car can make long runs without overshooting the floor or stopping short of the floor. • The power common to the limit switches (CS) was lost. Check safety string prior to the CS terminal. • Incorrect counting of pulse counts. Check encoder connection to motor and encoder wiring. • Hoistway not learned properly. Perform a hoistway learn procedure. • UTS switch not adjusted properly. Check at slow speed if switch is breaking, making and then braking again. Switch needs to be closer to the cam. UTS input Failed On Fault. The car was at the top floor • The UT switch is not wired or UT input was lost. and the UT input was low • The UTS did not break at the top terminal landing. Adjust or UTS Failed On Fault true (UT switch open) but replace the UTS switch. the UTS input was high (UTS switch made). Velocity Diff Fault • Controller detected a difference between demand and Velocity difference between feedback speed greater than the setting under 'Velocity Diff'. Make sure speed is tracking properly in acceleration and demand and encoder deceleration. Set Adjustable Variables->Car Options->Velocity feedback. Diff based on Speed of the car. Faults Description Possible Cause/Suggested Fix This fault refers to CPU pulses. If Motor Encoder speed feedback: • Check the jumper on the encoder isolation board. If this car has been previously running properly, the encoder isolation board could be faulty. If during initial setup, change the jumpers for A and A not. P a g e | 293 Section 11 – Main CPU Faults Wrong Dir Pls Run Dn If CAN Open Encoder speed feedback: Check “Encoder Dir” in the Car Motion menu. Run the car in the up direction. If the controller pulse count increments then the “Encoder Dir” bit is fine, else if the count decrements, change the “Encoder Dir” parameter to the opposite value. Check for roll back of the car. The controller will allow for some counts in the wrong direction on start but if the roll back becomes excessive, the fault may occur. If this job is not in Wrong Direction Pulses setup and has been running with an older mechanical Turck while car running down. encoder, the encoder could be faulty. The mechanical Turck The pulse counts should be encoders use reed switches in the encoder to latch higher counting down while the car order digits of the absolute value. If this encoder is placed is running down. near a magnetic source or if the reed switch is faulty, the count can appear to jump in the opposite direction. Please also check for accompanying fault messages. Faults Description Possible Cause/Suggested Fix This fault refers to CPU pulses. Wrong Dir Pls Run Up If CAN Open Encoder speed feedback: Check “Encoder Dir” in the Car Motion menu. Run the car in the up direction. If the controller pulse count increments then the “Encoder Dir” bit is fine, else if the count decrements, change the “Encoder Dir” parameter to the opposite value. Check for roll back of the car. The controller will allow for some counts in the wrong direction on start but if the roll back becomes excessive, the fault may occur. If this job is not in Wrong Direction Pulses setup and has been running with an older mechanical Turck while car running up. The encoder, the encoder could be faulty. The mechanical Turck pulse counts should be encoders use reed switches in the encoder to latch higher counting up while the car is order digits of the absolute value. If this encoder is placed running up. near a magnetic source or if the reed switch is faulty, the count can appear to jump in the opposite direction. Please also check for accompanying fault messages. If Motor Encoder speed feedback: • Check the jumper on the encoder isolation board. If this car has been previously running properly, the encoder isolation board could be faulty. If during initial setup, change the jumpers for A and A not. XBK Low DC Bus Volts • Incorrect Setting of Line to Line Brake voltage in Adjustable Variables Aux Brake board low dc bus • Incorrect dip-switch setting for Three Phase or Single Phase voltage fault • Low Line Voltage • Rectifiers Blown or have bad Connection XBK No Currnt w/Volt • No Brake Connected Aux Brake board no current • Bad Current Sensor fault with voltage applied • Check if board is low current or high current board. XBK No DC Bus Volts Aux Brake board no dc bus voltage fault XBK No Output Volts Aux Brake board not output • IGBT Not Gating voltage fault • No AC Voltage Coming into AC1-AC2-AC3 • Rectifiers Blown or have bad Connection Description Possible Cause/Suggested Fix XBK Over Current Flt Aux Brake board over current fault • IGBT Shorted • Free Wheeling Diode Shorted • Gating Circuitry Shorted ON XBK Over Voltage Flt Aux Brake board over voltage fault • IGBT Shorted • Gating Circuitry shorted ON XBK Rq Volt > DC Bus Aux Brake board demand • Incorrect Setting of Pick/Hold/Re-level Voltage in Adjustable voltage greater than dc bus Variables voltage fault • Low Line Voltage Zero Velocity Deceleration Roll. The controller • This fault should never occur. Please call the factory if this Zero Vel Decel Roll calculated a velocity value of fault occurs. zero during the roll in to constant deceleration. P a g e | 295 Section 11 – Main CPU Faults Faults Determining “Gripper/EBK Fault” Device This section explains how to determine what might be causing “Gripper/EBK Fault” status by looking at the device number. The device number can be found in the detailed faults screen of the 1021/1101 LC Screen: go to Fault Log->View Fault Log and press “Enter” when you find: “Gripper Trip Fault” or “Emergency Brake Trip”, press “Enter” again to see the detailed faults. For each detailed fault you will see a list of all the flags that were set at the time when the fault occurred. Look for what the “dev” (old CPU) or “PF1” (new CPU) is equal to and compare that to the table below. dev / PF1 # 1 2 3 4 5 6 Fault Description Encoder velocity is over 125% compared to car speed set in the cons file. You may want to check the parameter "Adjustable Variables->Car Motion->Overspeed Trip" and set the percentage properly. This also relates to of the car but it occurs when the field adjustable variable "Adjustable Variables->Car Options->Gripper/EBK Trip" is set to +2 for over speeding. Gripper fault with this device will only occur if field adjustable variable "Adjustable Variables->Car Options->Gripper/EBK Trip" is set to +1 (SPB) or +4 (ENC) or both added together. Mainly you should check the Safety Processor or the Encoder. Gripper fault with this device will only occur if the GOV input is low and LC input is high and field adjustable variable "Adjustable Variables->Car Options->GOV Gripper/EBK" is set to "0". Faults with this device number only occur when you are on Car Top or Machine Room inspection mode and both car gate and hoistway doors are open and you are not on a door zone. When on Automatic, both car gate and hoistway doors are open and car moves from door zone will cause the fault with this DEV/PF1 number. NOTE: If emergency brakes are enabled you would get an "Emergency Brake Trip" fault, otherwise you would get "Gripper Trip Fault". 11.1 Detailed Faults Section 11 – Main CPU Faults SRV Service Flag 0 = Out of Service 1 = Automatic 2 = Independent 3 = Load Weighing Bypass 4 = Attendant 5 = Code Blue 6 = Fire Phase 2 7 = Emergency Power 8 = Earthquake Emergency 9 = Fire Phase 1 Main Egress 10 = Fire Phase 1 Alternate Egress 11 = Homing 12 = Reset Run Up 13 = Reset Run Down 14 = Low Oil Operation 15 = Return to Lobby 16 = Load Overload 17 = Massachusetts Medical Emergency 18 = Calibrate load weigher 19 = CS Elevator Off 20 = HS Elevator Off 21 = Low Pressure Operation 22 = Hospital Service Operation 23 = VIP Service Operation 24 = Security Recall 25 = Sabbath service 26 = TUG Service operation PRC Process Flag 1 = Reset 2 = Inspection 3 = Motion: hsf=1, dir=1, Up Fast hsf=0, dir=1, ul=0 Up Transition hsf=0, dir=1, ul=1, Up Leveling hsf=1, dir=2, Down Fast hsf=0, dir=2, dl=0, Down Transition hsf=0, dir=2, dl=1, Down Leveling 4 = Motion Mode 1 – Soft Start 5 = Motion Mode 2 – Constant Acceleration 6 = Motion Mode 3 – Roll Over to Max Velocity 7 = Motion Mode 4 – Constant Velocity 8 = Motion Mode 5 – Roll Over to Deceleration 9 = Motion Mode 6 – Constant Deceleration 10 = Motion Mode 7 – Targeting Floor P a g e | 297 11 = Motion Mode 8 – Emergency Slowdown 12 = Safety String 13 = Turned Off 14 = Parked 15 = Waiting Assignment 16 = Doors Operation 17 = Elevator Stalled (or Low Oil for Hydro) 18 = Elevator Resetting Hydro Jack 19 = Elevator on Low Oil Pressure mode 20 = Elevator is in Automatic Learn Hoistway DRF Front Door Flag 0 = Door Closed 1 = Door Opening 2 = Door Dwelling 3 = Door Closing 4 = Door Nudging Closed RDF Rear Door Flag 0 = Door Closed 1 = Door Opening 2 = Door Dwelling 3 = Door Closing 4 = Door Nudging Closed DPR Direction Preference Flag 0 = None 1 = Up 2 = Down DIR Car Direction Flag 0 = None 1 = Up 2 = Down EMP Emergency Power Flag 0 = Not on Emergency Power 1 = On Emergency Power Waiting 2 = On Emergency Power Waiting with Doors Open 3 = On Emergency Power Returning Home 4 = On Em. Power Returned Home with Doors Open 5 = On Em. Power Returned Home with Doors Closed 6 = On Emergency Power and Selected to Run 7 = On Emergency Power waiting with Doors Closed MED Medical Emergency 0 = No Medical Emergency Service 1 = Recall Car to Medical Emergency Recall Floor 2 = At Return Floor with Door Open (Return Complete) 4 = On EMS Car Call Service 5 = On EMS Car Hold Service (key off but not at the recall floor) Section 11 – Main CPU Faults CBL Code Blue Flag 0 = No Code Blue 1 = Recall to Emergency Floor 2 = At Code Blue Floor 3 = At Code Blue Floor with Door Open 4 = Finished Code Blue EQU Earthquake Flag 0 = Not on Earthquake Operation 1 = Earthquake Sensor Activated 2 = Counterweight Derailment Sensor Activated 3 = Recover Away From the Counterweight 4 = Stopped at a Floor FIR Fire Flag 0 = Not on Fire Service 1 = Phase 1 Main Egress Return 2 = Phase 1 Alternate Egress Return 3 = Phase 1 Completed 4 = Phase 2 Door Hold 5 = Phase 2 Constant Pressure Door Open 6 = Phase 2 Constant Pressure Door Close 7 = Phase 2 Door Hold RFI Rear Fire Flag 0 = Not on Fire Service 1 = Phase 1 Main Rear Egress Return 2 = Phase 1 Alternate Rear Egress Return 3 = Phase 1 Completed 4 = Phase 2 Rear Door Hold 5 = Phase 2 Constant Pressure Rear Door Open 6 = Phase 2 Constant Pressure Rear Door Close 7 = Phase 2 Rear Door Hold HSF High Speed Flag 0 = No High Speed 1 = High Speed P a g e | 299 STF Start Flag 0 = Not valid Start 1 = Start of Run CAL Direction of Calls 0 = No Call 1 = Above Call 2 = Below Call 3 = Above and Below Calls ESP Emergency Stop Flag 1 = Emergency Stop NST Need to Stop Flag 1 = Car need to stop at next floor RLV Re‐level Flag 1 = Car in re‐leveling STE Step Flag 1 = Step to the next position (non‐distance feedback) PDO Pre‐open Door Flag 1 = Pre‐open door STO Next Stop Floor Floor number of next stop INS Inspection Status Flag. (Status bit set to “1” when switch is on) Bit 0: Car Top Inspection Bit 1: Machine Room Inspection Bit 2: Access Bit 3: In Car Inspection Bit 4: Lock Bypass Bit 5: Gate Bypass Bit 6: Not in Automatic (AUTO==0) NDS Next Car Up Sequence 0 = Initiate Next Up Door Open 1 = Opening Next Up Door 2 = Door full open on Next Up 3 = Allow door close for onward call 4 = Allow door close while on next up DEV – Boards not communicating. (p.306) PF1 – Internal GAL use PF2 – Internal GAL use DV2 – Internal GAL use STATUSF Control Status Flag. (Status bit set to “1” when status active) Example: 00000400 = BIT10: Stop Switch open (Third set of bits -- BIT 8=Binary 1 / Bit 9=Binary 2 / Bit 10=Binary 4 / Bit 11=Binary 8) Section 11 – Main CPU Faults Bit 0: NO LC power Bit 1: NO HC power Bit 2: NO SS input Bit 3: Drive not ready Bit 4: Gripper error Bit 5: I/O error during redundancy check Bit 6: Inspection or lock bypass fault Bit 7: Binary Position Input Error Bit 8: Position Error Bit 9: No automatic Doors Bit 10: Stop switch open Bit 11: Door Zone fault Bit 12: Gate or Door lock fault Bit 13: No Potential “P” Input Bit 14: No DCL Bit 15: No gate or lock Bit 16: Brake lift switch error Bit 17: Top of Car Communications Error Bit 18: Drive Communications Error Bit 19: Safety Processor Board Comm Error Bit 20: DB Resistor Temp. Error Bit 21: Shutdown (too many fault runs) Bit 22: Annual Safety Test Bit 23: Waiting for Car to be safe Bit 24: UT, UTS, DT or DTS limit error Bit 25: GTS input off Bit 26: UL, DL and DZ off at floor Bit 27: Brake Board Can Error Bit 28: Fire Fighter Stop Switch Bit 29: Selector Can error Bit 30: UL or DL fault Bit 31: Leveling fault IO0 to IOD (p.308) DPP Position counts in pulses P a g e | 301 TG Target Count in pulses DMD Velocity in feet per minute ENC Encoder Velocity in fpm SPB Position Count in pulses Service – Safety Processor Service (Section 13) Example: 11h = UNMOTION 0 = AUTO 1 = CT INS 2 = GATE BYP 3 = LOCK BYP 4 = ACCESS 5 = MR (Motor Room Inspection) 6 = IC INS (In Car Inspection) 7 = INS ERR 8 = BYP ERR 9 = Inspection VEL ERR 0A = UP ERR 0B = DNR ERR 0C = DNR/UP 0D = EEP ERR 0E = NO UTS 0F = NO DTS 10 = PLS ERR 11 = UNMOTION SPB Vel – Safety processor Velocity in fpm Status – Safety Processor Status. Example: 5h = Bit0 + Bit2 = Secondary Fault + Leveling Speed Control Bit 0: Secondary Fault Control Bit 1: PIC Enable (On is normal) Bit 2: Leveling Speed Control Bit 3: Comm Fault Bit 4: Velocity Fault Bit 5: Position Count Initialized Bit 6: Active Fault Bit 7: Position Count Updated Decoding IO0 - IOD IO1 = 2C h 1 2 3 4 5 6 7 0001 0010 0011 0100 0101 0110 0111 8 9 A B C D E F 1000 1001 1010 1011 1100 1101 1110 1111 1 UT3 1 UT2 0 UT1 0 UTS IO1 0 RLM 0 DLT 1 DLM 0 DLB In the example above we are illustrating IO1=2Ch. The h signifies that the number is in hexadecimal notation, the actual hexadecimal number is 2C and the h can be ignored. The 2C is converted to binary using the chart above (green) and the binary values transferred to the appropriate IO line, IO1 in our example (blue). In binary notation we count from the right - LSB – (Least Significant Bit) to the left – MSB - (Most significant Bit), which is why binary 1 is written as 0001 – it begins at the right. A binary 1 indicates a high input or output, meaning it is ON . A binary 0 indicates the input or output is low, meaning it is OFF . In our example above we can see that UTS, UT1, DLB, DLT and RLM are all low, or OFF, and UT2, UT3, and DLM are all ON. Decoding Statusf Satusf is 32 bits long and each digit in =0000 0000 is four bits. Example: Statusf=0000 D000 = 0000 0000 0000 0000 1101 0000 0000 0000 8th Digit Statusf = 0000 D000 4th Digit 1st Digit 0 1 2 3 4 5 6 7 0000 0001 0010 0011 0100 0101 0110 0111 8 9 A B C D E F 1000 1001 1010 1011 1100 1101 1110 1111 1 No Gate or Lock STATUSF Control Status Flag 8th Digit → 0000 0000 ← 1st Digit 4th Digit 1 0 No DCL No Potential "P" Input 1 Gate or Door Lock Flt Starting from the right it can be seen that there is a Gate or Door Lock Fault , a No DCL fault, and a No Gate or Lock fault. Safety Processor Status and Inspection Status work similarly. P a g e | 303 Section 11 – Main CPU Faults 0 0000 0 0000 8 1000 1 0001 9 1001 2 0010 A 1010 3 4 5 6 0011 0100 0101 0110 B C D E 1011 1100 1101 1110 INS Inspection Status Flag 2nd Digit → 00 ← 1st Digit Only updated when ON inspection - If on AUTO this shows last Inspection status 1st Digit = ICI (In Car Insp) ACCESS Not Used NOT AUTO MRI (Motor Room Insp) 2nd Digit = GBP (Gate Bypass) 7 0111 F 1111 CTI (Car Top Insp) LBP (Lock Bypass) STATUSF Control Status Flag 8th Digit → 0000 0000 ← 1st Digit 1st Digit = Drive Not Ready NO SS Input NO HC Power NO LC Power 2nd Digit = Binary Position Err Ins or Lock Bypass Error IO Error - Redundancy 3rd Digit = Gripper Error Door Zone Fault Stop Sw Open No Automatic Doors 4th Digit = Position Error No Gate or Lock No DCL No Potential "P" Input 5th Digit = Gate or Door Lock Flt Safety Proc Comm Err Drive Comm Error TOC Comm Error 6th Digit = Brake Lift Sw Err Waiting For Safe Annual Safety Test Too Many Flt Runs 7th Digit = DB Resistor Temp Err Brake Board CAN Err Leveling Fault UL, DL, DZ Off At Floor GTS Input Off 8th Digit = UL or DL Fault Selector Can Err UT, UTS, DT, DTS Lim Err Fire Fighter Stop Sw 1 2 3 4 5 6 7 0000 0001 0010 0011 0100 0101 0110 0111 8 9 A B C D E F 1000 1001 1010 1011 1100 1101 1110 1111 SPB Stat - Safety Processor Status 2nd Digit → 00 ← 1st Digit Secondary Fault Control (SFCO) 0=Normal Operation PIC Enable 1=Normal Operation 1st Digit = Comm Fault Position Count Updated Leveling Speed Ctrl PIC Enable 2nd Digit = Active Fault Pos Count Initialized Secondary Fault Velocity Fault P a g e | 305 Section 11 – Main CPU Faults 0 Car Com Device Reset – HC Com Device Reset Look for DEV=xxh in the detailed fault log, find the HEX number below, in the RED column. The board address to the right of the HEX number refers to the DIP switch address of the I/O board (if the board has a dip switch – the car top board for example has a permanent address of “9” and no DIP switch). Device (HEX) Description of the Device 02h Can start index 02h Encoded Tape Selector 03h Emergency Brake 04h Brake Board 05h Safety processor board 06h Selector board 07h Front Door board 08h Rear Door Board 09h Load Weigher 0Ah Voltage Sensor 0Bh Serial I/O Expansion board address 1 0Ch Serial I/O Expansion board address 2 0Dh Serial I/O Expansion board address 3 0Eh Serial I/O Expansion board address 4 0Fh Serial I/O Expansion board address 5 10h Serial I/O Expansion board address 6 11h Serial I/O Expansion board address 7 12h Serial I/O Expansion board address 8 13h Serial I/O TOC Top of Car Board address 9 14h Serial PI and Lantern (global address for all pi and lantern devices) 14h Serial I/O Expansion board address 10 (Uses special address) 15h Serial I/O Expansion board address 11 16h Serial I/O Expansion board address 12 17h Serial I/O Expansion board address 13 18h Serial I/O Expansion board address 14 19h Serial I/O Expansion board address 15 1Ah Serial I/O Expansion board address 16 1Bh Serial I/O Expansion board address 17 1Ch Serial I/O Expansion board address 18 1Dh Serial I/O Expansion board address 19 1Eh Serial I/O Expansion board address 20 1Fh Serial I/O Expansion board address 21 20h Serial I/O Expansion board address 22 20h Last can device 29h Special address for SEB 10 since it conflicts with PI address 32h ID to swap to standard address for pi/lantern board 20 FFh Global can address Serial Hall Calls – Secondary Device For serial hall calls the dev=XX (previous page) indicates which serial driver board and dv2=XX indicates which hall station has communications errors. The possible faults are: hcb dev reset hcb dn led brd hcb up led brd hcb led short red up hcb led short green up hcb led short blue up hcb led short blue dn hcb led short green dn hcb led short red dn hcb led open red up hcb led open green up hcb led open blue up hcb led open blue dn hcb led open green dn hcb led open red dn hcb fet short red up hcb fet short green up hcb fet short blue up hcb fet short blue dn hcb fet short green dn hcb fet short red dn hcb fet open red up hcb fet open green up hcb fet open blue up hcb fet open blue dn hcb fet open green dn hcb fet open red dn hcb low supply voltage hcb up input overload hcb dn input overload hcb xu input overload Section 11 – Main CPU Faults hcb tx dn hcb tx up hcb rx dn hcb rx up hcb stuck up hcb stuck dn hcb led open dn hcb led open up hcb led short dn hcb led short up hcb fet open dn hcb fet open up hcb fet short dn hcb fet short up hcb inv fl hcb no com Serial RGB Car Stations – Secondary Device & Specific I/O For Serial RGB Car Stations dev=XX (previous page) indicates which driver board has comm issues (bear in mind that Serial RGB drives have three board addresses: example Address 18, 19 & 20 for first serial RGB driver board), dv2=XX indicates which board in the local bus and pf1-XX indicates which I/O is declaring an error. The possible faults are: ccb led short red ccb fet short green ccb led short green ccb fet short blue ccb led short blue ccb fet open red ccb led open red ccb fet open green ccb led open green ccb fet open blue ccb led open blue ccb led board ccb fet short red ccb stuck button P a g e | 307 0 1 2 3 4 5 6 7 0000 0001 0010 0011 0100 0101 0110 0111 8 9 A B C D E F 1000 1001 1010 1011 1100 1101 1110 1111 DT1 DTS DT DN UT3 UT2 UT1 UTS RLM-1 DLT-1 DLM-1 DLB-1 ALT MES MRS HWS 4U RTL/3U UT5/2U UT4/1U AD IND LBP GBP DPM DL DZ UL ICI CS ID IU RDY GTS FST P/RTL MCAI MCCI RUNAI RUNI UFI UPI DFI DNI BP8 BP4 BP2 BP1 SE EE DCL DOL P6 NUD DC DO IO0 = UT UN DT3 DT2 IO1 = RLM DLT DLM DLB IO2 = TAD BAU BAD ACC IO3 = SS HC FS BP IO4 = 5D 4D DT5/3D DT4/2D IO5 = DL-1 UL-1 BKS DEL IO6 = INS LC GS-1 GS IO7= AUTO MRID MRIU MRI IO8 = DON BRKI GTR2 GTR1 IO9 = LVC SECF/SVSD RGS-1 RGS IOA = PS GOV RDPM CTS IOB = DS US DZA BP16 IOC = LWD LWB OVL LWA IOD = CLF FB/NB FL CDL Section 12 Combined Field Adjustable Variables This section contains the combined field adjustable variables: Main CPU Adjustable Variables Section 12 – Combined Field Adjustable Variables Safety Processor Adjustable Variables NTS Processor Adjustable Variables P a g e | 309 Table 1: Car Motion Field Variable Min Max Initial Units Acceleration 50 300 92 fpm/s Access Speed 0 75 35 fpm Adv Pre Torque 0 0 0 Balanced Load 0 100 40 Decel Jerk 50 480 125 Decel Rate 50 300 92 Dist Feed Fwd 0 1.3 0 Description Acceleration Rate. The constant acceleration rate to reach top speed. Access Speed. Car velocity while running on access. Advance Pretorque. When set, the controller will pick the motor contactor and pretorque the motor when the door closes to the DLM limit. It is enabled to improve floor to floor times when pretorque is used. 0=Off 1=On % Balanced Load. Percent load of the counterweight. Deceleration Jerk Rate. fpm/s/s Maximum jerk rate to roll from top speed to constant deceleration. Deceleration Rate. fpm/s The constant deceleration rate from top speed to leveling speed when stopping for a floor. Distance Feed Forward. During the final approach to the floor, when using a tape selector, the number of pulses to calculate the velocity is 64 pulses per foot. So during this time, if the CPU does not see a distance change, it calculates the distance the car should move over the next ten millisecond period and then uses that value to calculate next velocity value. This value is a multiplier for what percentage of the velocity calculation to uses. When the next pulse comes in, the CPU calculates the velocity value as normal. Table 1: Car Motion Field Variable Min Max Initial Units Description 0 1 1 ‐ Drv Speed Mult 0.25 2.000 1.000 ‐ Drive Speed Multiplier. Used for KEB drive to adjust the speed of the elevator. EM Decel Lev 50 300 100 Emergency Deceleration Leveling Rate. fpm/s The rate at which the elevator will go from decel to leveling while on Emergency Slowdown. Emergency Deceleration Rate. fpm/s The rate at which the elevator will decelerate when it is doing an emergency slowdown. Em Decel Rate 80 360 180 Encoder Dir 0 1 0 ‐ Encoder PPR 60 3200 2048 PPR Encoder Pulses Per Revolution. The number of pulses the motor encoder generates per revolution. Encoder Revolutions Per Minute. The number of revolutions per minute the motor makes at top speed. Encoder Direction for CAN Bus Encoder. Set to zero or one during Setup to get correct direction of pulses for the CAN encoder. Encoder RPM 1 3000 105 RPM Field Weaken 60 110 110 Field Weakening Velocity. % vel Percent of velocity above which the motor field is weakened to allow the car to reach top speed. Floor Targ Dis 1.2 25 12 Floor Target Distance. inches Distance to start leveling mode into the floor. Increasing this distance will lower the jerk rate. P a g e | 311 Section 12 – Combined Field Adjustable Variables DON Start Ctrl Drive ON Start Control. 0 = Off 1 = The controller starts the pattern delay after the drive on signal (DON) from the drive. Table 1: Car Motion Field Variable Min Max Initial Ins Decel Stop 50 480 300 Inspect Speed 0 150 40 fpm Inspection Speed. Maximum car speed while running on inspection. Leveling Speed 1 15 5 fpm Leveling Speed. Maximum car speed while leveling into the floor. Motor RPM 0 3000 500 rpm Motor RPM. Used for KEB drive only. Overspeed Trip 80 125 110 % Pattern Delay 0 3 0 sec Pls Cnt Upd Ere Pls Err Delay 0 1 2 10000 Units Description Inspection Deceleration Stop Rate. fpm/s The rate for the elevator to decelerate from inspection speed to zero. Over Speed Trip. Percentage of contract speed at which the controller will drop the rope gripper. Pattern Delay. Delay time before the speed profile will start. 1 Position Count Update Error. If the pulse count is off by more than this value and the update inches flag is enabled, the position pulse count is updated. If this value is set to zero and the update flag is enabled, then the pulse count is updated every time the DZ is hit at high speed. 5000 Position Count Update Error Delay. This number is the time delay from when DZ is hit until the 1/sec input is read. The time delay parameter, times the current speed of the car, is used to estimate the number of pulses the count will change during the turn on time of the DZ input. Table 1: Car Motion Field Variable Pos Count Upd Min 0 Max 7 Initial Units Description Preopen Delay 0 3200 0.5 sec Preopen Delay. Delay time to preopen the door starting from when the car reaches 3 inches from dead level and the door can safely be opened. Recovery Speed 15 100 25 fpm Recovery Speed. Recovery Speed to the nearest floor. Relev Pat Dly 0 3 0 sec Relevel Pattern Delay. Delay time before speed profile will start on a relevel. sec Relevel Start Velocity Hold Time. If relevel start speed is set to a non zero value, the controller will use that value for the speed before going in relevel velocity This parameter controls how long we stay in Relevel Start Velocity. Relev St Time 0 2 0 Relev Strt Spd 0 15 0 fpm Re‐level Start Speed. Maximum starting velocity for a re‐level. Car will stay in relevel Start speed for a time set by parameter ' Relev St Time ' and then switch to relevel Speed Relevel Speed 1 15 6 fpm Re‐level Speed. Maximum car speed during re‐leveling operation. Roll Over Jerk 50 480 125 fpm/s/s Rollover Jerk Rate. Maximum roll jerk rate while rolling into top speed. P a g e | 313 Section 12 – Combined Field Adjustable Variables 0 Position Count Update Flag. The pulse count is checked every time the DZ input is hit. +1=Update the DPP floor count as the elevator passes by a landing and hits DZ. +2=Interrupt the CPU when DZ hit otherwise the update is done during the loop time (roughly 1 msec). +4=Update every time the DZ is hit and the car is at constant speed regardless of the pulse count update error value. Table 1: Car Motion Field Variable Min Max Initial Units Description Rope Comp Torq 0 50 0 Rope Compensation Torque. Used primarily on gearless machines that do not have any compensating chains. This parameter adds torque to the offset pretorque value to compensate for weight of the elevator cables holding the car. The value is calculated from the position of the car in the hoistway. Soft Start Jerk 50 480 125 Soft Start Jerk Rate. fpm/s/s Maximum jerk rate to roll into constant acceleration from a dead stop. Soft Stop Time. Soft Stop Time 0.2 30 1 sec Stop Decel Rate 5 225 50 fpm/s Stop On Pos Cnt 0 Top Speed Contract 25 Speed Torque Amount 0 1 100 Hydraulic Elevators – time the motor is kept running after the valve is turned off. Traction Elevators – time that zero speed is held until the brake is set. Stop Deceleration Rate. Rate to bring the velocity from leveling speed to zero speed. 0 Stop On Position Count. Enable to stop the elevator on position pulse count. Used only for tapeless application. It requires cons file setting to be enabled and readjustment of leveling sensors for it to work. 0= Off 1=On 0 fpm Top Speed or Contract Speed of the Car. If set to zero, or set to a value greater than top speed, it will use top speed in cons file. gain Torque Amount. Multiplier for the amount of torque proportional to the load. A value of 100 will give 100percent torque with 100 percent load or 60 percent torque with an empty car. 0 Table 1: Car Motion Field Variable Torque Down Amt 0 0 Max 100 1 Initial 0 0 Units Description gain Torque Down Amount. Torque Amount for down direction of travel. Multiplier for the amount of torque proportional to the load. A value of 100 will give 100 percent torque with 100 percent load or 60 percent torque with an empty car. If this value is set to zero then the Torque Amount parameter above will be used for both up and down direction. sec Torque Ramp Time. The amount of time for the torque to ramp up prior to the elevator leaving the floor during pattern delay. P a g e | 315 Section 12 – Combined Field Adjustable Variables Torque Ramp Tim Min Table 2: Car Brake Field Variable Min Max Initial Units Description Brake DropDelay. Delay time to drop the brake after the car has stopped and is dead level at the floor. BrakeDropDel 0 5 0.1 sec BrakeHold Volt 10 400 160 volts BrakeOptoDly 0 Brake OptoDelay. The SCR Brake board trigger circuit uses optocoupler devices that have a turn on delay of roughly 1 millisecond but can vary from 7372 5500 3686/msec part to part and vary from different input filtering. This parameter is used to compensate for different turn on delays to start of triggering of the SCRs. Only change this value at the advice of a G.A.L.Technician. BrakePick Del 0 5 0 sec Brake PickDelay. Delay time to pick the brake after the run relay is energized. 0.1 6 3 sec Brake PickTime. Duration of applied brake pick voltage before changing to the hold voltage. BrakePick Time Brake Hold Voltage. Voltage to hold the brake for the remainder of the run. BrakePick Volt 10 400 230 volts Brake PickVoltage. DC Voltage to pick the brake. Brake voltage will start at start voltage and then ramp to pick voltage. Brk ACL‐L Volt 80 300 240 volts Brake AC Line to LineVoltage. AC input voltage to the brake board. BrkDropRate 0 5 0 sec BrkDropStart 0 1 0 ‐ Brake Drop RateTime. Time value for brake to ramp from start voltage to zero. Brake Drop Timing During Leveling. 0 = Normal brake drop 1 = Early drop selected Table 2: Car Brake Field Variable Min Max Initial Units Description Brake Initial Drop Voltage. DC Voltage to start the brake drop. Brake voltage will start at this value ramp down to zero volts. BrkDropVolt 0 200 0 volts Brk Pick Rate 0 2 0 sec Brake Pick Rate Time. Time value for brake to ramp from start voltage to pick voltage. Brk Pick Start 0 400 0 volts BrkRelev Rate 0 2 0 sec Brake Relevel Rate Time. Time value for brake to ramp from relevel start voltage to relevel voltage. volts Brake Relevel Start Voltage. Initial DC Voltage to pick the brake on a relevel. Brake voltage will ramp to relevel voltage. BrkRelev Start 0 400 0 BrkRelev Volt 10 400 230 volts Brake Relevel Voltage. Brake voltage applied on the brake coil during a relevel. This parameter is useful to have a partial brake lift on relevel. Relevel brake voltage will start at relevel start voltage and then ramp to relevel voltage. Brk Resistance 0.1 500 283 Ohms Brake Resistance. Resistance value measured on the brake coil in ohms. EmBkDropDly 0 360 0 sec Emergency Brake Drop Delay. Delay time to drop the brake after the car has stopped and is dead level at the floor. EmBkDropRate 0 1.5 0 sec Emergency Brake Drop Rate Time. Time value for brake to ramp from start voltage to zero. P a g e | 317 Section 12 – Combined Field Adjustable Variables Brake Pick Start Voltage. Initial DC Voltage to pick the brake. Brake voltage will ramp to pick voltage. Table 2: Car Brake Field Variable Min Max Initial Units Description EmBkHold Volt 0 400 160 volts Emergency Brake Hold Voltage. Voltage to hold the emergency brake for the remainder of the run. EmBkL‐L VAC 80 300 240 volts Brake AC Line to Line Voltage. AC input voltage to the brake board. 0 Emergency Brake Opto Delay. The SCR Brake board trigger circuit uses optocoupler devices that have a turn on delay of roughly 1 millisecond but can vary from 7372 5500 3686/msec part to part and vary from different input filtering. This parameter is used to compensate for different turn on delays to start of triggering of the SCRs. Only change this value at the advice of a G.A.L. Technician. EmBkOptoDly EmBkPick Rate EmBkPick Tim EmBkPick Volt Pwl BkOffTim 0 0 10 0 2 10 400 5 0 3 230 0 sec Emergency Brake Pick Rate Time. Time value for emergency brake to ramp from start voltage to pick voltage. Only used if two brake boards are installed. sec Emergency Brake Pick Time. Duration of applied emergency brake pick voltage before changingto the hold voltage. Only used if two brake boards are installed. volts Emergency Brake Pick Voltage. DC Voltage to pick the emergency brake. Brake voltage will start at start voltage and then ramp to pick voltage. Only used if two brake boards are installed. sec Power Loss Brake Off Time. When Pwl Bk On Tim and Pwl Bk Off Tim are set to a non zero values, the timers are used to pulse the brake contactor output on and off while recovering the car with Power loss brake option. Table 2: Car Brake Field Variable Min Max Initial Units Description 0 5 1 sec RelevBrk Delay 0 5 0 sec Relevel Brake Delay. Time delay to lift the brake during a relevel. RelevBrk LowV 0 1 0 ‐ Relevel Brake Low Voltage. Set to a 1 to relevel the car with the hold voltage to create a partialpickof the brake. Not used with electronic brakeboard. 0=Off 1=On P a g e | 319 Section 12 – Combined Field Adjustable Variables Pwl BrkOnTim Power Loss Brake On Time. When Pwl Bk On Tim and Pwl Bk Off Tim are set to a non zero values, the timers are used to pulse the brake contactor output on and off while recovering the car with Power loss brake option. Table 3: Modified Motion Field Variable Min Max Initial Units Description EP Accel Rate 50 300 92 fpm/s Emergency Power Accel Rate EPDecelJerk 50 480 125 fpm/s/s Emergency Power Decel Jerk Rate EPDecelRate 50 300 92 fpm/s Emergency Power Decel Rate EP Recov Speed 10 100 25 EP Roll Jerk 50 480 125 fpm/s/s Emergency Power Roll Jerk Rate EPSoftStJerk 50 480 125 fpm/s/s Emergency Power Soft Start Jerk EPTargetDist 1.2 25 12 EPTopSpeed 10 ShFlAccel Rate 50 300 92 fpm/s ShFlDecelRate 50 300 92 Short Floor Deceleration Rate. fpm/s The constant deceleration rate from top speed to leveling speed when stopping for a floor. 480 Short Floor Soft Start Jerk Rate. 125 fpm/s/s Maximum jerk rate to roll into constant acceleration from a dead stop. ShFlSoftStJrk 50 Contract 100 Speed fpm Emergency Power Recovery Speed. Recovery speed during emergency car recovery. Used when the emergency power recovery source can only provide enough powerto to bring the car to the floor in the direction of the load. inches Emergency Power Floor Target Distance fpm Top Speed for Emergency Power Short Floor Acceleration Rate. The constant acceleration rate to reach top speed. Table 3: Modified Motion Field Variable ShortFlCntrl Min Max 0 7 Initial Units 0 ‐ Description Short Floor Distance. Any floor less than this distance is considered a short floor.The inches short floor flag gets set and if preopening is enabled, it can be specifically disabled for the short floorrun. ShortFlDist 10 72 30 ShrtFlDeclJrk 50 480 Short Floor Deceleration Jerk Rate. 125 fpm/s/s Maximum jerk rate to roll over from top speed to constant deceleration. ShrtFlRoll Jrk 50 480 125 fpm/s/s ShrtFlTargDis 1.2 25 8 Short Floor Rollover Jerk Rate. Maximum roll jerk rate while rolling into top speed (acceleration). Short Floor Target Distance. inches Distance to start leveling mode into the floor. Increasing this distance will lower the jerk rate. P a g e | 321 Section 12 – Combined Field Adjustable Variables Short Floor Control. 0=Default. The car relevels to the shortfloor. +1=Car will make a run between very short floors instead of re‐ leveling. +2= Short floor slowdown magnets between short floors (non‐ distancefeedback). +4=Mid Short floor slowdown magnets between short floors (non‐ distancefeedback). Table 4: Car Timers Field Variable AdvDoorEnTim AttBuz Delay Min Max Initial Units Description 0 0 240 900 0 Advanced Door Enable Time. Door open advance enable time to open the opposite door when operating with non‐simultaneous doors. If there is a request for both sec doors, instead of waiting for the first open door to close completely before opening the second door, the second door starts to open after the advance door enable time while the first door is closing. 60 Attendant Buzzer Delay. If this parameter is enabled, Service options> HC Acknwldg Buz will not work. sec Buzzer sounds if a hall call is entered and the car has not started moving within this delay time. This function is disabled when set to zero. AttBuzOffTime 0 30 0 Attendant Buzzer Off Time. Cycle off time to turn attendant buzzer on and off once attendant sec delaytime function has been met (See ATT Buz Delay). Buzzer will stay on continuously if this timer set to zero. AttBuzOnTime 1 30 5 Attendant Buzzer On Time. sec Cycle on timer to turn attendant buzzer on and off once attendant delaytime function has been met (See ATTBuzDelay). AutoSwgDODly 0 10 1.0 sec Auto Swing Door Open Delay. Delay time to enable the auto swing door open output. CarCallDwell 1 900 2 sec Car Call Dwell. Door open dwell time when answering a car call only. 3200 60 Code Blue Door Time. sec Door time for Code blue operation once elevator is at the emergency floor before EMS is energized. 2 0.2 sec 320 5 CBDoorTime 1 ChimeonCCTime 0.1 CL Pulse Time 0 Chime on Car Call Time. Handicap buzzer on Car Call. Length of beep time. sec Car Lantern Pulse Time. Table 4: Car Timers Field Variable Min Max Initial Units Description Door Delay Time. sec Delay time between DO and DC to switch when opening or closing the door. 10 3200 25 Door Fail Time. sec Time with power on the door without getting the door open limit. 0 2 sec Electric Eye Test Time for Automatic Freight Doors. 0 DoorFailTime EETestTime 1.5 2 EETime‐ out 0 3200 40 Electric Eye Time‐out Time. If the Electric Eye or detector edge is on continuously for this amount sec of time, it will be flagged as timed‐out and the controller will ignore the EE input and close the door on nudging. When set to zero, this feature is disabled. FaultTime 0 10 2 Fault Time. sec Delay time before allowing the car to run after a fault occurs. FR DCTime‐ out 1 3200 1 Freight Door Close Time‐out. sec The amount of time prior to closing the doors on automatic freight door operation. 1 Freight Door Power Door Open Time. sec The amount of time to turn on the power door open relay on automatic freight door operation. FR PwrDOTime 0 30 Gen/Lt/FanTime 30 3200 360 Generator Run/Cab Light/Fan Time. sec Length of time to leave the generator running or the Cab light and fan on after there is no longer a demand to run. Grip/EBK Rset T 0 sec 20 4 Gripper/Emergency Brake Reset Time. The amount of time it takes for the rope gripper to reset on power‐up. P a g e | 323 Section 12 – Combined Field Adjustable Variables 0 DoorDelayTime Table 4: Car Timers Field Variable HallCallDwell Min Max Initial Units Description 1 60 4 HallLantDly 0 15 0 Handicap Dwell 1 120 25 Hall Call Dwell. Door open dwell time when answering a hall call or both a hall and car sec call. Hall Lantern Delay Time. By default, when set to zero, hall lanterns go off as soon as the car starts to slow down to arrive at a floor. When set to a nonzero value, this will be used as a timer for the hall lantern to go off prior to sec arriving at the floor.For example, if set to three seconds, hall lanterns will turn on approximately three seconds before the car arrives to the floor regardless of the speed of the car. We recommend to set this parameter for high speedcars. Handicap Dwell. sec Extended door time from pressing the ED button in the car. HEOF Auto Reset Time. When the hall elevator off function is activated from the HEOF sec inputbeing turned on, the car will be taken out of service until the input is turned off. Once the input is off, the car will stay out of service until the auto reset timer times out. HEOFAuto Rst T 0 3200 0 LantOffTime 0 2 0.2 Lantern Off Time. sec Used for double stroke gongs. The lantern off time is the delay time after the lantern first turns on until it turns off. 0.7 Lantern On Time. Used for double stroke gongs. The lantern will turn on, turn off and sec then turn on again. The Lantern on time is the delay time from when the lantern first turns on until it turns on the second time. LantOnTime 0 2 Table 4: Car Timers Field Variable Min Max Initial Units Description 1 3200 30 LobbyDwell 1 60 5 sec 0 Manual Door Buzzer Delay. On a car with manual doors, sound the buzzer if the door is left open sec and a call is entered after this time delay. This function is disabled when set to zero. ManDoor BuzDly 0 900 Lobby Dwell. Door open dwell time for a car at the lobby. MaxDoorHldT 0 3200 0 Maximum Door Hold Time. Hold time to be allowed when the extended dwelling input (ED) is pressed. If set to zero, there will be no limit on how long the car will sec be held on ED. When set to a value, this will be the maximum allowedtime for the car to held by ED input, then the car will go on regular dwelling timers (car or hall call dwelling timers). Non InterferT 1 60 2 sec Non‐Interference Time. Time between when you stop and when you can run again. Nudging Time 20 3200 60 sec Nudging Time. Delay time for a door to be held before going into nudging. OSERBTFlrTim 0 900 60 Out of Service Between Floors Time. sec Timer to control the OSERL output. Used with OSERL Control option 1 for 'between floors for over a minute' set to 2. OSERNcall Tim 0 900 600 Out of Service Not Responding to Calls Time. sec Timer to control the OSERL output. Used with OSERL Control option 1 for 'not responding to calls' set to 1. P a g e | 325 Section 12 – Combined Field Adjustable Variables LearnHW Stall Automatic Hoistway Learn Stall Time. The time required for a hoistway learn is calculated by the numberof floors at an average height of 12.5 feet. This stall time value is added to the calculated value for the maximum time allowed for the sec autohoistway learn to run. If floor heights are taller or if there is a blind shaft, this timer may need to be increased to the additional floor height times1.2 (multiplier for car running at 30fpm). For a blind shaft of 50 feet use a timer value of 50 * 1.2 = 60.0 seconds. Table 4: Car Timers Field Variable Min Max Initial Units Description OSERSopenTim 0 900 60 Out of Service Safety String Open Time. sec Time to control the OSERL output. Used with OSERL control option 1 for ' SS open' set to 4. PasChimeTime 0.2 2 0.5 Floor Passing Chime Time. sec Length of time the floor passing chime will sound when a floor is passed. 0.5 Retiring Cam Drop Fail Time. sec Retiring cam drop fail safe delay for manual doors. Time it waits when car arrives to the floor before it drops the output. RCdropfailTim 0.5 5.5 RC Pick Delay 0 7 0 Retiring Cam Pick Delay. sec The amount of delay time for the retiring cam to pick once the doors are closed. RelevDlyTim 0 2 1 Relevel Delay Time. sec The amount of delay time before the car will re‐level. This would be used for jobs that have excessive rope stretch. ResetTime 0 10 5 sec Reset Time. Delay time in the reset mode before allowing the car to run. RTLDwellTime 1 60 8 Return To Lobby Dwell Time. If Return To Lobby is set to cycle doors at the lobby, use this timer to sec control how long they will dwell before closing in return to lobby mode. RunCycleTime 0 300 0 Run Cycle Time. hours Used to initiate a run when the elevator has been sitting idle for a period of time. Used for jobs that have high friction bearing machines. Table 4: Car Timers Field Variable SabbBuzz Delay SecDisableTim 1 1 0 10 60 3200 10 Sabbath Door Dwell Time. The Car will wait this amount of time on every floor forSabbath sec operation except at the lobby where it will follow the handicap dwell door time (separate timer). 0 Security Disable Time. This timer is used with a security disable input button at the sec lobby.When the button is pressed, the car call security is disabled for the time value set from this parameter. 1 Short Door Dwell Time. sec Door open dwell time when the doors re‐open on a door open button, electric eye, safety edge or door hold button. ShortDwellTim 0 StallTime 20 3200 60 sec VIPDoorTime 1 20 VIP Door Time. sec The amount of time the car will park at the VIP recall floor prior to returning to automatic service. 1.5 Y‐Delta Time. Transfer time to change motor from Y start to Delta run. This timer is sec also used for DEL or MCX turn on time with controllers without y‐delta starters. YDeltaTime 1 60 5 Sabbath Door Buzzer Timer Prior To Doors Closing. In jobs where the light curtain is disabled in Sabbath operation it is sec required to ring a buzzer prior to the door closing sequence.This timer warns people when the light curtains are about to been eabled (output name: SABUZ). 3200 5 Stall Time. Maximum time a run is requested but the car is not moving. P a g e | 327 Section 12 – Combined Field Adjustable Variables SabbathDwell Min Max Initial Units Description Table 5: Car Options Field Variable Min Max Initial Units Description Arrival Lant 0 1 0 ‐ Arrival Lantern 0=Disable 1=Activate lant/gong without onward call BehindCCCanc 0 1 0 ‐ Behind Car Call Cancel. When enabled the elevator will not latch any car calls in the opposite direction of travel. ‐ Binary Preset. 0=Update the car position count based on the binary preset when the car recovers into afloor. 1=Always update the car position count based on binary preset when the position doesn’t match. ‐ Brake Lift Switch. If set to 1 or 2 a brake lift switch fault isdetected. 0=The Brake switch is ignored. 1=The car is prevented from running if the brake does not drop or if the brake did not pick on the previous run. The car is allowed to run after the brake drops. 2=The rope gripper will set if the brake does not drop and then can only be reset by placing the car on inspection and back to automatic. ‐ Cab Lantern Control. The default is for the cab lanterns to go off when the door is fully open. This allows the cab lanterns to go off earlier. +1 Ring cab lanterns as soon as door starts to open. +2 Ring the cab lanterns when the door reaches DPM point. ‐ Car Call Security on Sabbath. When this parameter is enabled, sabbath car calls will not latch on floors that have been secured using car call lockouts security. ‐ Close Gate (Swing Door) When No Onward Preference. The gate on a swing door normally stays open until a call is placed. This bit causes the gate to close while the car is sitting at the floor. Binary Preset BrakeLiftSw CabLantCtrl CCSonSabbath Cl Gate No Pref 0 0 0 0 0 1 2 2 1 1 0 1 0 0 0 Table 5: Car Options Field Variable COP/RemoteCC DCBCancDwell DO NoActvDOL DOBOverNudg DoorOpen LCtrl 0 0 0 0 0 0 Max Initial Units Description 7 14 1 1 1 16 0 0 0 ‐ COP/Remote Car CallSelect. 0=Both: COP and Remote Car Call Station used to enter calls. +1=Separate: COP only or Remote CC only used to enter car calls. +2=C‐R: Car calls entered on the COP sets the acknowledgment light on the Remote station. +4=R‐C: Car calls entered on the Remote station sets the acknowledgment light on the COP. ‐ COP/Remote Disable. +1=Up Direction DisableCOP +2=Down Direction Disable COP +4=Up Direction Disable Remote Panel +8=Down Direction Disable Remote Panel ‐ Door Close Button Cancel Dwell Time. 0= The DCB cancels door dwell time. 1= DCB does not cancel the door dwell time. This parameter basically disables DCB to shorten door dwell time. 0 Door Open Output When No Active DOL. When the door is fully open and hits the DOL, the DO is turned off and stays off even if the door drifts off DOL. With this bit set, the DO output will turn on any time the DOL is lost. 0 DOB Over Nudging. If set the door open button will open the door when the door is nudging closed. 0 Door Open Light Control. The way 'DoorOpenL Ctrl' parameter works is as below: +1=Set OPENL on phase 1 completed +2=Set OPENL on RTL return to lobby +4=Set OPENL on EMP returne home with doors open, also sets OPENL on EMP and selected to run +8=Set OPENL on when Lobby Floor +16=Set OPENL all the time. ‐ P a g e | 329 Section 12 – Combined Field Adjustable Variables COP/RemoteDis Min Table 5: Car Options Field Variable DoubleStroke DriveRdy Flts DZ gripper ctl EECancelDwell Min 0 1 0 0 Max Initial Units Description 1 10 1 1 1 5 0 0 ‐ Double Stroke Gong Selection. Select 1 or 2 gongs for down hall calls. 0=1 Gong 1=2 Gongs. Drive Ready Fault Reset Count. count Number of times the drive can be reset in a 20 minute time period. ‐ DZ Gripper Trip Control. 0=The gripper will trip when the car is out of the door zone, only DZ needs to go low. +1=The gripper will trip when both DZ and DZA go low which changes the trip zone from 2 inches to 6 inches. ‐ Electric Eye Cancel Dwell. By turning this parameter on you disable the short dwelling door time from the electric eye signal (EE). By default the short dwelling time is enabled. EM Brake Sw 0 1 0 ‐ Emergency Brake Switch Control. 0=Don't start if brake switch does notpick. 1=Ignore brake switch on start. Enc DirFltDis 0 1 0 ‐ Encoder Direction Fault Disable. 0=Enable Fault. 1=Disable Fault. ‐ Governor Switch Gripper/Emergency Brake Trip Control. 0=Sets and latches a gripper fault immediately when the governor switch is opened. 1=Latches the gripper fault only if the governor switch is opened while the car is traveling at contract speed or above 150 fpm. When the gripper fault is latched it must be reset from the LCD interface for the car to run. GOVGripper/E BK 0 1 0 Table 5: Car Options Field Variable Griper / EB K Buz Min 0 Max Initial Units Description 1 0 ‐ Gripper/Emergency Brake Buzzer. Turn on buzzer if you have an active rope gripper or emergency brake fault. 0 3 3 ‐ HB/PIDisNVFl 0 1 0 ‐ Handicap Buzzer/PI Display Control. 1=Do not sound HB or update floor PI when passing an invalid floor. Hndcap TimeFlr Bottom Top Floor loor 1 Handicap Time Floor. If the job is configured to have an extended door input at a hall floor station, this parameter configures the floor number when parameter will change door timing. Follows fvexdt timer. It will operate for EDHL (Extended Door Hold) only. IInvertBLS 0 1 0 ‐ Invert Brake Lift Switch. 1=Inverts the logic for the brake lift switch to use a normally closed switch instead of normally open. InvertCLF 0 1 1 ‐ Invert The Logic For The Car Light/Fan. 0=Car light fan is normally open. 1=Car light fan is normally closed. ‐ Invert In Service Output. 1=The in service light output is turned off when the car is in service instead of turned on. 2=The ISER output will function as an elevator in use light. 4=This output functions as out of service from a shutdown and doesnot include independent, inspection or recovery mode. InvertISER 0 7 0 P a g e | 331 Section 12 – Combined Field Adjustable Variables Gripper/E BKTrip Gripper/Emergency Brake Trip. 0=Off +1=Safety Processor Speed +2=Overspeed Table 5: Car Options Field Variable LantPref Dly LevelFaultCnt Leveling Fault Lim DirFltDis LobbyLan NCU/IR LowDoorVolt LowLineVolt Min 0 3 0 0 0 0 0 Max Initial Units Description 3 10 1 1 1 600 600 0 3 0 0 0 sec Lantern Preference Change Delay. When the direction preference for the elevator changes, we clear the lanterns and wait for this amount of time before the lanterns are turned on again. Level Fault Count. Maximum count of consecutive re‐level tries when a re‐level error count is detected. A relevel error is detected when the brake is dropped and the car moves out the level zone. ‐ Leveling Fault Effect. 0=Drop everything 1=Set emergency brake or gripper when a leveling fault occurs. The fault will have to be manually reset. ‐ Limit Direction Fault Disable. Controller confirms the car direction of travel as it hits the terminal limits. 0=Enable Fault. 1=Disable Fault. ‐ Lobby Lantern NCU/IR. 0=Light the lanterns on IR service at each floor. The lantern will notlight at the lobby if next up operation is selected because the IR car will not be selected to be the next upcar. 1=The IR car will light the lantern at all the floors and the lobby even with the system on next up operation. 198 Low Door Voltage. Settings for Line Voltage Monitor Board. Vrms This parameter sets the value of voltage for 'Door Low Voltage Fault' to be triggered. 198 Low Line Voltage. Settings for Line Voltage Monitor Board. Vrms This parameter sets the value of voltage for a 'Low Line Voltage Fault' to be triggered. Table 5: Car Options Field Variable MinDoorTimEn Min 0 Max Initial Units Description 1 0 ‐ Minimum Door Time Enable. 1=The minimum door time for a car call or a hall call is set from the car or hall call dwell timers and cannot be shortened by the Door Close button. 0 3 0 ‐ NCUPref Ctrl 0 1 0 ‐ Next Up Preference Control. 1=Allows direction preference to change before the door starts to close, after the next up door time. No HCDoorReop 0 3 0 ‐ No Hall Call Button Door Reopen. 1=Do not reopen the door from an at floor hall call. ‐ Non‐Simultaneous Doors. 0=Both front and rear doors will open at the same time if there is a demand at both the front and rear openings. 1=The front doors will open first before the rear doors open if there is a demand to open. 2=The rear doors will open first before the front doors open if there is a demand to open. Non‐SimulDoors 0 2 0 NudgeDisCtl 0 7 0 ‐ Nudging Disable Control. +1=Do not turn on the NUD output when doors are in nudging close mode, basically you are disabling nudging output. +2=When doors are in nudging close mode and SE input is ON, keep doors open and also keep FB/NB output latched. +4=Sound the nudging buzzer but do not close the doors on nudging. Nudge No Calls 0 1 0 ‐ Nudge With No Calls. 1=The doors will close on nudging even if the elevator has no onward calls. P a g e | 333 Section 12 – Combined Field Adjustable Variables NCULantCtrl Next Up Direction Lantern Control. +1=Turn off hall lantern after next uptime. +2=Turn off cab lantern after next uptime. Table 5: Car Options Field Variable OSERLOutCtrl1 OSERLOutCtrl2 Preopen Doors RadPos Ind RCFoutenable RCMControl Min 0 0 0 6 0 0 Max Initial Units Description 7 1 3 48 1 3 0 0 0 6 0 0 ‐ Out of Service Light Control. +1=Not responding to calls. +2=Between floors for over a minute. +4=SS open. When this parameter as well as OSERL OutCtrl 2 is set to zero,the output will just operate as an Out of Service light. ‐ Out of Service Light Control 2. +1=Alarm. When this parameter as well as OSERL OutCtrl 2 is set to zero,the output will just operate as an Out of Service light. ‐ Preopen Doors. +1=Will enable preopening of the doors. If retiring cam used with auto door, RCM will also turn on at the preopening point. +2=Exclude short floors. Radial Position Indicator. Used for radial Position indicator output. This parameter adjusts inches the range for the distace from the floor where the poistion indicator outputs should turn on and off. ‐ Retiring Cam for Freight Output Enable. When you turn on this parameter it creates a retiring cam output in the controller, RCF, that mirrors the signal from RCM. You need to reboot CPU everytime you change this parameter for the change to take effect. ‐ Retiring Cam Control. 1=Hold the retiring cam up at the floor if there is no pilot to open the door (manual doors). The retiring cam will drop after 5 minutes. 2=RCM output turns on when DZ is hit to advance the RCM ahead of the door open (auto door with retiring cam) otherwise the default is that RCM turns on when dead level. If preopening is set RCM and DO turn on when DZ is hit. Table 5: Car Options Field Variable SabbathEnCtl Sabbath Mode SecndRisr Lant SlipDetDis 0 0 0 0 0 Max Initial Units Description 7 3 1 1 1 0 0 0 0 0 SlipVelDiff 0 300 150 SPB DirFltDis 0 1 0 ‐ Sabbath Enable Control. 0=Disables all options. +1=Allow IR momentarily to override Sabbath operation. +2=Lobby Dwell time in Sabbath follows handicap door dwell time instead of the lobby dwell time. +4=Wait until car is at lobby to turn off Sabbath operation. ‐ Sabbath Enable Control 2. +1=When the car is placed on Sabbath operation, it waits to go to the lobby before switching to Sabbath Operation. +2=Use the cab lanterns as directional arrows. This allows people on the hallways to know direction of travel for the elevator. ‐ Sabbath Collective Mode. 0=Down collective car calls 1=Up collective car calls. ‐ Second Riser Lantern. Turn on cab lantern only when IR call answered. If this parameter is set cab lanterns will only turn on when answering second riser calls. ‐ Slip Velocity Difference Disable. 0=Enable Fault. 1=Disable Fault Can only be disabled with code previous to A17.12010. Slip Velocity Difference Fault Trip Value. fpm This parameter determines Maximum allowable difference between Safety processor speed and controller speed. ‐ SPB Direction Fault Disable. 0=Enable Fault. 1=Disable Fault. P a g e | 335 Section 12 – Combined Field Adjustable Variables SabbathEnCtl2 Min Table 5: Car Options Field Variable ULDLDirFltDis VelDiffDis Velocity Diff Min 0 0 50 Max Initial Units Description 1 1 300 0 0 150 ‐ UL/DL Direction Fault Disable. Controller confirms the car direction of travel when it passes the UL and DL door zone limits. 0=Enable Fault. 1=Disable Fault. Velocity Difference Fault Disable. fpm 0=Enable Fault. 1=Disable Fault. Velocity Difference. Maximum velocity difference between Encoder feedback and fpm demand velocity. When the difference exceeds this setting, 'Velocity DiffFault' will occur. Table 6: Service Options Field Variable Access BotFl AccessDoorCls Att Buz ctrl Max Initial Bottom Top Floor Floor 0 1 Bottom Top Floor Floor 0 1 1 Units floor 0 ‐ 2 floor 1 Description Access Bottom Floor. Floor for bottom access. Access Door Close. When on access operation the car runs with the Door Lock and GS open. By turning this parameter on, the car needs to have the gate switch signal ON in order to run. It should be used on hoistways where the car door will physically hit something if moved on access operation. Access Top Floor. Floor for top access. ‐ Attendant Buzzer Control. 0=Hall Calls only. 1=Hall Calls and Car Calls. Att CCfromHC 0 1 0 ‐ Attendant Car Call from Hall Call. When set to 1 and the car is on Attendant service the respective car call will register when a hall call is registered. CB Buzzer Ctrl 0 1 0 ‐ Code Blue Buzzer Control. 1=Turn buzzer on while in code blue recall. CB OverInd 0 1 0 ‐ Code Blue Override Independent. 1=Wait for timer to expire and then recall the car. ‐ Code Blue Single Car Call. 0=Car on Code Blue operation allows multiple car calls on Hospital Service. 1=Allow only a single call once placed on Hospital Service. CB singlecall 0 1 0 P a g e | 337 Section 12 – Combined Field Adjustable Variables Access TopFl Min Table 6: Service Options Field Variable CCPBS onGp Sec CEOFControl CEOFControl2 Min 0 0 0 Max Initial 1 7 15 0 0 0 Units Description ‐ CCPBS On Group Car Call Security. This variable enables Car Call Push Button Security with group car call lockout switches.The configuration (CONS) file setting for security type and car call push button security must also be set. ‐ Car Elevator Off Options. +1=Recall. +2=Keep Door Open. +4=Turn off CLF. ‐ Car Elevator Off Options 2. +1=Keep doors Closed (do not cycle on reversal). +2=Do not blink Elevator Off Light. +4=Elevator Off Auto Reset With Timer. +8=Enable Elevator Off Light to indicate the car finished recall of elevator off mode. DOBOverSec 0 5 0 ‐ DoorHold Msg 0 1 0 ‐ DOB Override Security. This parameter allows the car to open the door at a secured floor when the car is secured from the followingconditions: 1=The DOB will be allowed to open the door at any secured floor. 2=The DOB can open the door at floors secured from group security floor mask table. 3=Allows the DOB to open the front door at floors secured by car call lockout security (switches or cardreader). 4=Allows the DOB to open the rear door at floors secured from rear car call lockout security. 5=Allows the DOB to open the door at floors locked out by group security floor mask tables when the car is also on Independent. Door Hold Message. Set to enable Extended Door Time Message Indicator in CE Driver board. Table 6: Service Options Field Variable Elev OffRet Fl EMS/HSafterCB EP Recovery Dir Max Initial Units Description Top Floor 0 floor Elevator Off Return Floor. Related to HEOF input. This setting is to be used in conjunction with 'Elev Off Ctl =+1'. If the elevator is configured to recall, this parameter will determine what floor the car should be recalled to in elevator off mode. If Parameter is set to zero, car will be returned to the lobby. Bottom Top Floor Floor 1 floor Emergency Power Recall Floor. 0 0 0 1 1 0 0 ‐ EMS (Emergency Medical Service) / HS (Hospital Service) after Code Blue. This is a Code Blue bypass control. 0=Car goes from Auto to Hospital service, by passing the code blue sequence when EMS switch is turned on. 1=Hospital service only activates after a code blue recall. ‐ Emergency Power Recovery Direction. Recover to the nearest floor on emergency power. 0=Based on movement of the car when brake is picked. 1=Based on load weighing device. Used when the emergency power recovery source can only provide enough power to bring the car to the floor in the direction of the load. EPS SelNo Grp 0 2 0 ‐ Emergency Power Selection Switch Operation with no Group Active. 0=Run Automatic. 1=Recall first and then run Automatic. 2=Recall only; do not run after recall. FlashCBLight 0 1 0 ‐ Flash Code Blue Light. 1=The code blue light inside the car station will flash. % Handicap Load (Car Capacity). Percent of load, when above this value, the car may not have enough room for a person in a wheelchair. Cars with loadsbelow this value would be given a preference to get an assignment at a floor requested by a handicap person. Handicap Load 0 100 40 P a g e | 339 Section 12 – Combined Field Adjustable Variables Em Power Floor Min Table 6: Service Options Field Variable HCAcknwldg Bzz HEOFControl Min 0 0 Max Initial 1 7 0 0 Units ‐ Description HC Acknowledge Attendant Buzzer ‐ Buzz Once (for one second every time a call comes in). Car Timers->Att Buz Delay must be set to “0”. 0=Disable. 1=Enable. ‐ Hall Elevator Off Control. +1=Recall car when key switch activated. +2=Keep door open at the shutdown floor. +4=Allow the cab light and fan to time‐out even though the door is open but the car is shutdown. HEOFControl2 0 15 0 ‐ Hall Elevator Off Options 2. +1=Keep doors Closed (do not cycle). +2=Do not blink HEOFL. +4=Auto Reset when input off and timer expires. +8=Use HEOFL to indicate car finished recall. HEOFControl3 0 1 0 ‐ Hall Elevator Off Options 3. +1=Only activate if doors are closed. See other Hall Elevator Off Options as well. HEOFOverInd 0 1 0 ‐ Hall Elevator Off Override Independent. 1=Wait for timer to expire and then recall the car. HSV DoorClCC 0 1 0 ‐ Hospital Service Close Door Car Call. Close the doors from a car call when the car is on Hospital Service. IND DoorClCC 0 1 0 ‐ Independent Door Close Car Call. 1=Enable to close the doors from a car call when the elevator is on independent. ‐ Independent Overrides Security. 1=Allow independent service to override security car call lockouts. 2=Override Security Floor Mask configurations. 4=Override remote car call station. Ind OverSec 0 7 0 Table 6: Service Options Field Variable Min Max Initial IND Rclto Lby 0 1 INDRcl2Lby tmr 10 60 Description 0 ‐ Independent Recall to Lobby. 1=Forces the car to recall to the lobby when on independent and no calls are made. 20 sec Independent Recall to Lobby Timer. Recall delay for car in independent when 'IND Rcl to Lby' is set. InsDoorClose 0 1 0 ‐ Inspection Door Close. 1=The door close output will turn on when the up or down inspection run button is pressed. INSECOutpCtl 0 1 0 ‐ INSEC ‐ In Security Output Invert. Output located on the car call security board. % Load Anti‐nuisance. Percent of load, when below this set point will cause the car to drop its car calls.This function is disabled when set to zero. % Load Bypass. Percent of load, when above this set point will cause the car to bypass hall calls.This function is disabled when set to zero. % Load Dispatch. This set point is used as a trigger to activate Up Peak operations in the group. Each time the car leaves the lobby with a load greater than this value, the group will increment the Up Peak Trigger.This function is disabled when set to zero. LoadAntinuisan LoadBypass Load Dispatch 0 0 0 100 100 100 20 60 40 P a g e | 341 Section 12 – Combined Field Adjustable Variables Units Table 6: Service Options Field Variable LoadOverload LWAnti‐ nuisan Min 0 0 Max Initial 125 50 110 0 Units % Description Load Overload. Percent of load, when above this set point will cause the car to go on overload operation (sit at the floor with the door open and the overload light on). When the load goes below this value,the car will automatically return to service.This function is disabled when set to zero. Load Weighing Anti‐nuisance. Set to the maximum number of car calls that can be enentered before all car calls are cancelled without the load count switch LWA input on. Once the load switch is on, all car calls will stay latched. If set to 0, this function is disabled. ManualDirEn 0 4 0 ‐ Attendant Manual Direction Enable. 1=Works in conjunction with the ATTUP and ATTDN to determine direction of travel. 2=Reads the ATTUP input and use it as a START button. 4=Will not allow car calls to be registered until the door is fully closed. MedCCSOvrride 0 1 0 ‐ Medical Service Override Car Call Security. 1=Medical service car will override car call security. 0 ‐ Medical Service Door Reopen. When car is in medical Service, this parameter determines the door open sequence for re‐open: 0=Stop. 1=Constant pressure. 2=Momentary to DOL. 1 floor 0 ‐ MedDoorReopen MedEmFloor Med EmSwLoc 0 2 Bottom Top Floor Floor 0 1 Medical Emergency Return Floor. Medical Emergency Switch Location. Selects the switch location for the front or rear door. Table 6: Service Options Field Variable MedInd Ovrride 0 Max Initial 2 0 PI Service Message 1. Service When the car service matches this number, user message 1 is Number sent to the PI display. This will correspond to user P Idisplay message 17. 0 Max Service 0 PI Service Message 2. Service When the car service matches this number, user message 2 is Number sent to the PI display. This will correspond to user PI display message 18. 0 Max Service 0 PI Service Message 3. Service Used for Custom messages. Need to be programmed byCE Number electronics and GAL for special messages. 0 Max Service PI Serv Msg2 PI Serv Msg3 RTLDoorSelct Medical Service Overrides Independent Control. 0=Immediate. 1= After Delay. 2=No override. 0 10 ReturnToLobby ‐ Description No Passenger Run Count. When set to a number other than zero, the car call antinuisance feature is activated. This count is the number of count times the car will run from a car call without detecting that a passenger has broken the detector edge. Once the count is reached, all remaining car calls will be cancelled. 0 PI Serv Msg1 0 Units 0 0 7 2 0 0 ‐ Return to Lobby Option. +1=Cycle door at lobby. +2=Cancel car calls when activated. +4=Cycle door on reversal. ‐ Return To Lobby Door Select. This variable allows you to specify door open type on 'Return to Lobby' service. 0=The car will open only the front door. 1=The car will open only the rear door. 2=The car will open both front and rear doors. P a g e | 343 Section 12 – Combined Field Adjustable Variables No Psg Run Cnt Min Table 6: Service Options Field Variable Sec Reassign CC Sec Recall2 Security Floor Security Recall Min 0 0 0 0 Max Initial 3 2 Top Floor 15 0 0 1 0 Units Description ‐ Security Reassign Car Call. Re‐assign secured car call to opposite door. Used with security configuration, cons.dat file setting: cons[SecFlCfg]=2. 0=Disabled. +1=In case front CC are secured, reassign them as rear. +2=In case rear CC are secured, reassign them as front. ‐ Security Recall Control 2. 0=Out of group on first recall. 1=Out of group on all recalls. 2=No out of group recalls. floor ‐ Security Floor. The security recall floor. This is the floor where the security guard would be stationed. This floor would not be locked out when on security. Security Recall Selection. 0=No Recall. +1=Recall to Security Floor on activation of security. +2=Cycle front door once recalled to the Security Floor. +4=Cycle rear door once recalled to the Security Floor. +8 =Always recall to security floor after each run. Table 6: Service Options Field Variable Min Max Initial Units Description Service Light Control. When the configuration file parameter cons[servOUT] is set to 1 or 2, the service output SERVO will turn on when the car service matches the car service number in this parameter. The available options are: SR CCSecbyDir 0 0 30 2 0 0 Service Number ‐ Section 12 – Combined Field Adjustable Variables ServiceLTCTL 0: Out of Service 1: Automatic Service 2: Independent Service 3: Load Weighing Bypass 4: Attendant Service 5: Code Blue Service 6: Fire Service Phase 2 7: Emergency Power Service 8: Earthquake Service 9: Fire Phase 1 Main Return 10: Fire Phase 1 Alt Return 11: Homing 12: Reset Going Up 13: Reset Going Down 14: Stalled Out of Service 15: Return to Lobby 16: Load Weighing Overload 17: Medical Emergency Serv 18: Calibrate Load Weigher 19: Car Switch Elevator Off 20: Hall Switch Elevator Off 21: Low Pressure 22: Hospital Service 23: Priority Service 24: Security Recall 25: Sabbath Service 26: TUG Service 27: Hot Oil Operation 28: Riot Control 29: Car Switch Elevator Off 2 Second Riser Car Call Security by Direction. Allows calls in the one direction but disables them in the other. 1=Allow calls in the up direction (above the floor) but disable them going down. 2=Allow calls in the down direction (below the floor) but disable then going up. P a g e | 345 Table 6: Service Options Field Variable StopAt Lobby Vip LantCtrl VIP multicall Min 0 0 0 Max Initial 15 3 1 0 0 0 Units Description ‐ Stop at Lobby. 0=Do not automatically stop at lobby. +1=The car will stop at the lobby when the car is traveling up and the car is below the lobby floor. +2=The car will stop at the lobby when the car is traveling down and the car is above the lobby floor. +3=The car will stop at the lobby when traveling in either direction. +4=Stop at lobby with any onward call past the lobby. +8=Recall to the lobby. ‐ VIP Lantern Control. 0=Do not ring lanterns on VIP. 1=Ring up or down lantern at VIP floor when the door is fully open. 2=Ring up or down lantern at VIP floor before the door is opened. ‐ VIP Multiple Calls. 0=VIP feature works as single call. 1=The car will be allowed to make multiple VIP calls until no more car calls are entered and until the VIP sequence time‐ out timer is expired. Table 7: Fire Options Field Variable Min ALTFireFloor Max Initial Units Bottom Top Floor Floor 2 Description floor Alternate Fire Floor. 0 3 0 ‐ Aux.FireSw. 0 1 0 ‐ Auxiliary Fire Switch. 1=The controller expects an auxiliary hall fire switch to be used. CB overFS 0 1 0 ‐ Code Blue Over Fire Service. +1=Prevent Code Blue car from recalling in Fire Service. Cl DoorF1Rcl 0 1 0 ‐ Close Door After Fire Phase 1 Recall. 1=Elevator will close the doors after phase 1 recall and reopen from a hall call (Denver Fire service amendment). F1DCTime‐out 10 60 20 Fire Phase 1 Door Close Time‐out. The amount of time it will take before the car doors start to close sec while the car is on Independent or Attendant service prior to recalling the elevator on Fire Phase 1. F1DoorDwell 1 90 60 Fire Phase 1 Door Dwell Time. sec Fire Service Phase one complete dwell time when 'Cl Door F1Rcl' parameter is set. (Denver FS phase 1 dwell time). F2DOBovrDCB FireMain Floor 0 1 Bottom Top Floor Floor 0 1 ‐ Fire Phase 2 Door Open Button Overrides Door Close Button. 1=Allows the Door Open Button to override Door Close Button when on phase 2. (Miami Fire Service). floor Fire Main Floor. P a g e | 347 Section 12 – Combined Field Adjustable Variables Alt RclFSOff Alternate Floor Recall Fire Service Off. +1=Have the elevator recall back to the alternate floor when the lobby fire switch is turned to the off position and car recalled to the main fire floor. +2=Allows the car to return to the alternate landing even if sensor was reset. Table 7: Fire Options Field Variable Min FireOption FireOption2 0 0 Max Initial Units 3 3 0 1 Description ‐ Fire Option. Recall Reset Selection. 0=Reset fire service phase 1 after hall switch is turned off and car returns to fire floor. 1=Reset phase 1 immediately after hall switch is turned off. ‐ Fire Option 2. +1=Initiate a phase 2 recall only when the door is open (Chicago Fire Service). +2=Disable flashing FL on phase 2 (Chicago Fire service). FireSwLoc 0 4 0 ‐ Fire Switch Location. Location of Fire Hall Switch. 0=Main/Alt Front. 1=Main Rear/Alt Front. 2=Main Front/Alt Rear. 3=Main/Alt Rear. 4=Set from Dispatcher Car selection. FireLEmerPwr 0 1 1 ‐ Fire Light Control During Emergency Power. 1=Cause the fire light FL to turn off if the car is not selected to run. ‐ Fire Light Control for Out of Service Cars. 1=Enabling this parameter will turn off the fire light in the event the car cannot recall for being out of service. The cause could be due to Earthquake, low oil, stall,etc. ‐ NYC FS2 Door Reopen on Stop Switch. When the elevator is on FS2 and DCB is pressed, the doors will behave thus: 0=While the door is closing, if you hit the in car stop switch the doors continue to close. 1=While the door is closing and you hit the in car stop switch,the doors re‐open. FireLOTSRet FS2DoorReopen 0 0 1 1 0 0 Table 7: Fire Options Field Variable Min HallFireLight 0 4 1 0 0 Description ‐ Hall Fire Light. This variable controls the FLH output on the controller so it can be used for a hall fire light or a fire security override. 0=FLH turns on while the car is on phase 1 or phase 2 fire service. +1=FLH turns on while phase 1 is ineffect. +2=Flash FLH at 1 second intervals while activated. +4=FLH follows the Fire Light (FL) logic. ‐ Hoistway Fire Sensor Return Floor Selection. 0=Return to the Main fire floor. 1=Return to the Alternate fire floor. HWS2FireLoc 0 1 50 ‐ Fire Service Hoistway HWS2 Sensor Location. 0= Same hoistway. 1=Separate hoistway. HWS2FireRet 0 1 0 ‐ Second Hoistway Fire Service Sensor Return Option. 0=Main recall floor. 1=Alternate recall floor. ‐ Machine Room Fire Sensor Return Floor Selection. 0=Return to the Main fire floor. 1=Return to the Alternate fire floor. ‐ Recall From Fire Phase 1 Alternate Floor. 0=If the car has returned to the alternate floor from a smoke sensor and when two fire hall switches are used, both must be on to recall the car from the alternate floor to the main floor. 1=The car will recall from the alternate floor to the main floor from either hall fire key switch. (Set to 1 for Mass. fire service). ‐ Recall Reset Selection. 0=Reset fire service phase 1 after hall switch cycled through reset and turned off and car returns to fire floor. 1=Reset phase 1 immediately after hall switch is cycled through reset and then turned off. 2=Reset fire service without cycling fire switch through reset but turned off only if the smoke sensors were not activated. MachRm FireRet RclfromF1Alt Recall Reset 0 0 0 1 1 3 0 0 0 P a g e | 349 Section 12 – Combined Field Adjustable Variables Hoistw FireRet 0 Max Initial Units Table 7: Fire Options Field Variable Min Recall Reset 2 0 Max Initial Units 1 0 ‐ Description Recall Reset Selection 2. 0=Reset fire service phase 1 with car at any floor. 1=Reset phase 1 only if car at fire recall floor. Table 8: Group Dispatch Field Variable Min AltLobbyFloor Asgn Park FlDO AutoSVCtm‐out AutoSVCtotTM Dn Peak Contrl 1 0 0 10 0 Top Floor Top Floor 1 1 3200 1 Initial Units Description 1 Alternate Lobby Floor. Galaxy groups can be configured to have an alternate lobby. Switching between regular lobby and alternate lobby can be floor done by means of liftnet, Galileo, controller input or service timer. Oncethe alternate lobby is enabled, controllers will use this landing as the lobby floor for all dispatching purposes. 1 Alternate Parking Floor. Normally, during parking operation, one car is always parked at the lobby. With alternate parking floor operation, a free car is floor parked at the alternate parking floor instead of the lobby floor.This operation is controlled by an input or from a service timer. 0 ‐ Assign Parking Floor with Door Open. By default we only park cars that have the doors closed after a time delay. This parameter allows to re‐assign parking to cars with doors open as long as they do not have a direction to run. ‐ Auto Service Time‐out. When this parameter is enabled and 'Auto SVC tot TM' parameter time is set accordingly, each car is checked for answering assigned hall calls. If the car does not move to answer calls in the required time, it is put into AST service. Hall calls that are assigned to that car are reassigned to working cars in the group. The group then periodically assigns hall calls to the AST car to verify if it can beput back into the group for normal operation. 0=Disable. 1=Enable 0 120 0 Auto Service Time Out Time. This time, in seconds, is used in conjunction with 'Auto sec SVCtm‐out' and is the amount of time that the group will wait before setting a 'not moving/responding' car as timed out. ‐ Down Peak Control. 0=Normal down peak. 1=Heavy down peak. P a g e | 351 Section 12 – Combined Field Adjustable Variables Alt Parking Fl 1 Max Table 8: Group Dispatch Field Variable Min Max Initial Units Description Dn PkTrigCnt 1 100 12 Down Peak Trigger Count. Number of down hall calls above the lobby that are set within count the down peak trigger time to place the system on down peak operation. Dn PkTrigTime 0 3200 60 Down Peak Trigger Time. sec The time interval to count the number of down hall calls above the lobby to activate down peak operation. DownPeak Pool 0 Number Cars 0 car DownPeak Time 0 3200 Down Peak Pool. Number of cars to be utilized for down peak. 180 Down Peak Duration Time. sec The duration time for down peak operation once down peak is activated. ETA CoCCTime 0 60 15 ETA Coincident Car Call Time. Hall calls will be assigned to the car with the coincident car call sec unless the car without the coincident car call can reach the call faster then ETA Coincident Car Call Time. ETAMin Time 0 60 6 ETA Minimum Time. sec For a hall call to be assigned to a new car, the difference in ETA must be greater than the ETA Minimum Time. 0 Number Cars 0 Group Service Timer Park Cars. car This is the number of parking cars when parking is set from the Service Activation Timer for Group parking. GrpTimerPark Table 8: Group Dispatch Field Variable Min High PriortyFL LobbyFloor LobbyReq Cntrl LobbyRequest Top Floor Initial Units 0 High Priority Floor. When this parameter is set to a floor number other than zero the high priority operation is activated. If there is a call latched at the high priority floor and the timer set from the 'High PriorityTM' floor expires, the group will choose the best car by considering only car calls. It will remove all hall calls on that best car except for the priority floor hall call. The car will serve all car calls and then service the priority floor before being assigned another hall call from the group. High Priority Time. Works in conjunction with parameter 'High Priority Floor', it is sec the amount of time to wait before removing hall calls assigned to the selected best car. 6 254 60 Bottom Floor Top Floor 1 0 1 0 Number Cars Description 0 0 floor Lobby Floor. ‐ Lobby Request Control. If the lobby request variable is set to non‐zero, then that is how many cars are requested to the lobby all the time. 1=The lobby request is only used when next up is active. Next Up can be active all the time, from a dedicated input or from UpPeak. Lobby Request. car Number of Cars Requested to the Lobby floor. Used with Next Car Up operation. P a g e | 353 Section 12 – Combined Field Adjustable Variables High PriortyTM 0 Max Table 8: Group Dispatch Field Variable Min Max Initial Units Description Next Car Up. Set to 1 or 2 will activate the Next Car Up operation. +1=The Next Up car will open its door at the lobby and keep it open. The car is allowed to leave the floor after the Lobby Dwell time expires but will remain at the floor with the door open until an onward call is assigned to it. +2=The Next Up car will close its door after the Lobby Dwell time expires and go off on Next Up but will remain at the lobby. An up hall call at the lobby will cause the car to open its door and go on Next Up. +4=Next Up is activated on Up Peak detection only. Next Up can also be activated from an input. NextCarUp 0 7 0 ‐ ParkDelayTime 0 120 8 sec 1 Number of Cars to Park. One car is parked at the lobby. The remaining cars in the group car are parked at the most used floors of the building. If set to zero, no cars are parked. 0 Parking Floor 1. Floor to park the second idle car, the first idle car is parked at the floor Lobby. If set to zero, the group will use number of hall call history to decide where to park the car. The 'Parking' variable must be set to at least 1 for this function to work. See also Parking Type. 0 Parking Floor 2. Floor to park the third idle car, the first idle car is parked at the floor Lobby. If set to zero, the group will use number of hall call history to decide where to park the car. The parking variable must be set to at least 1 for this function to work. See also Parking Type. Parking Parking floor1 Parking floor2 0 0 0 Number Cars Top Floor Top Floor Parking Delay Time. Time delay an idle car waits before being parked. Table 8: Group Dispatch Field Variable Min Parking floor3 Parking floor5 Parking floor6 Parking floor7 0 0 0 0 Top Floor Top Floor Top Floor Top Floor Top Floor Initial Units Description 0 Parking Floor 3. Floor to park the fourth idle car, the first idle car is parked at the floor Lobby. If set to zero, the group will use number of hall call history to decide where to park the car. The parking variable must be set to at least 1 for this function to work. See also Parking Type. 0 Parking Floor 4. Floor to park the fifth idle car, the first idle car is parked at the floor Lobby. If set to zero, the group will use number of hall call history to decide where to park the car. The parking variable must be set to at least 1 for this function to work. See also Parking Type. 0 Parking Floor 5. Floor to park the sixth idle car, the first idle car is parked at the floor Lobby. If set to zero, the group will use number of hall call history to decide where to park the car. The parking variable must be set to at least 1 for this function to work. See also Parking Type. 0 Parking Floor 6. Floor to park the seventh idle car, the first idle car is parked at the Lobby. If set to zero, the group will use number of hall call floor history to decide where to park the car. The parking variable must be set to at least 1 for this function to work. See also Parking Type. 0 Parking Floor 7. Floor to park the eighth idle car, the first idle car is parked at the floor Lobby. If set to zero, the group will use number of hall call history to decide where to park the car. The parking variable must be set to at least 1 for this function to work. See also Parking Type. P a g e | 355 Section 12 – Combined Field Adjustable Variables Parking floor4 0 Max Table 8: Group Dispatch Field Variable Min Parking Type 0 Max 3 Initial Units 0 ‐ Description Parking Type. Determines the type of parking operation that is implemented by the group. 0=Park free cars to floors with the most hall calls for that 15-minute period. 1=Divide the hoistway by the number of cars and place a car in each zone starting with the lobby. 2=Park cars according to the adjustable variable 'Parking Floor'. Note that during parking, a car is always parked at the Lobby except when the option for alternate parking floor is selected through an input. Parking Width. floor The number of floors that a car is within to be considered parked at the parking floor. See also ParkingType. Parking Width 0 Top Floor Up Peak Contrl 0 1 0 ‐ Up Peak Pool 0 Number Cars 1 car 0 Up Peak Control. 0=Normal up peak. 1=Heavy up peak. Up Peak Pool. Number of cars to be utilized for up peak. Up Peak Duration Time. sec The duration time for up peak operation once up peak is activated. If set to zero, up peak operation will never turn on. Up Peak Time 0 3200 180 Up PkCCCount 1 40 3 Up Peak Car Call Count. count Number of car calls the car must have when leaving the lobby to count as an up peak trigger. 3 Up Peak Trigger Count. The number of up peak triggers that are set within the up peak count trigger time to activate up peak operation. Up peak triggers are counted when the car leaves the lobby with the load dispatch input set or with more car calls than the up peak car call count. Up PkTrigCnt 1 100 Table 8: Group Dispatch Field Variable Min Max Up PkTrigTime 3200 0 Initial Units 60 sec Description Up Peak Trigger Time. The time interval to count the number of up peak triggers. Section 12 – Combined Field Adjustable Variables P a g e | 357 Table 9: Group Options Field Variable 1st EP Run Car 1st Rcl EPSF2 1stRecall Car 1stRun EPSF2 2nd IRCar ATT Pref Time CB Button Loc Min Max 0 Number Cars 0 0 Number Cars Number Cars 0 Number Cars 0 Number Cars 0 0 60 2 Initial Units Description 1 First Emergency Power Run Car. car This is the first car selected to run. If this car cannot run, the next consecutive car is selected. 2 Frst Return Car Emergency Power Service Feeder 2. This will be the first car recalled in Emergency Power car (the rest are done sequentially in a loop) for power feeder 2. 1 First Recall Car. This is the first car allowed to recall during the car emergency power recall sequence. The recall sequence continues in consecutive order and then loops around until all cars are recalled. 2 First Run Car Emergency Power Service Feeder 2. This will be the first car selected to run on emergency car power (the rest are done sequentially in a loop) for power feeder 2. 0 2nd Inconspicuous Riser Car. car Set this option to have a second car answer the Inconspicuous Riser calls. 0 Attendant ETA Preference Time. When set to non‐zero, the car not on attendant service sec has this time added to its ETA time. This causes the attendant car to be given a preference for the hall call. 0 ‐ Code Blue Location. 0=CB onCB. 1=CB on HCB. 2=CB onIR. Table 9: Group Options Field Variable CBIRPenalty 0 0 Max 60 1 Initial Units 10 0 Description IR Car Code Blue Penalty Time. sec This is used to calculate and give preference to cars in fully automatic operation. ‐ Code Blue Recall Any Call. 0=Disable. 1=Enables dispatcher to recall any car If Code Blue Cars 1 and 2 are not available. If you want to select any car as your primary option, make Code Blue Car and Code Blue Car #2 equal to zero and enable this setting. CB Req Ind Car 0 1 0 ‐ Code Blue Request Independent Car. Code blue request for car on independent operation. Set to a 1 in dispatcher and in all cars so the car can be requested (flash EML) if the car is in independent mode. CB SelIRCar 0 1 0 ‐ Code Blue Over IR Car. CBSRiserCar 0 Number Cars 0 car Code Blue Second Riser Car Select. 0 Code Blue Car. When a code blue call is initiated, this will be the first car car to respond. If car is not available, see variables 'Code Blue Car# 2' and'CB Rcll Any Car' for more options. CodeBlue Car 0 Number Cars CodeBlue Car#2 0 Number Cars 0 Code Blue Car# 2. When a code blue call is initiated, this will be the second car car to respond. In the event that first 'Code Blue Car' is not available, seevariables 'Code Blue Car' and 'CB Rcll Any Car' for more options. Dis OppHC Time 10 30 10 Disable Opposite Hall Call Time. sec Specify amount of time the opposite hall call will be disabled. P a g e | 359 Section 12 – Combined Field Adjustable Variables CB Rcll Any Car Min Table 9: Group Options Field Variable DisableOppHC Dispatcher Car Em Power Cars Emerg Dispatch Min 0 Max 15 0 Number Cars 1 Number Cars 0 7 Initial Units 0 ‐ Description Disable Opposite Hall Call After Initial Hall Call Is Entered. When the first up or down hall call is hit, disable opposite call for the time set; +1=Front HC riser. +2=Rear HC riser. +4=IR Front HC riser. +8=IR Rear HC riser. 0 Dispatcher Car. If set to 1, this car is allowed to become the dispatcher. Innormal operation, this variable would be set to zero and car #1 would bethe dispatcher. If car #1 is shut car down, car #2 automatically becomes the dispatcher. During installation, it may be necessary to force car #3 or above to be the dispatcher until car #1 or #2 are brought online. 1 Number of Emergency Power Cars. car Number of cars that can run at the same time on the emergency power source. 0 ‐ Emergency Dispatch. This parameter is applied to both the car that is selected as the dispatcher and also the non‐dispatcher cars. If set to 1 and hall call is power lost, the dispatcher car will set down hall calls above the lobby and up hall calls at and below the lobby. For the non‐dispatcher cars, if set to a 1, and communications is lost to the dispatcher car, the car will dispatch itself to down hall calls above the lobby and up hall calls below the lobby. The front hall call and rear hall call bits settings are only used for the dispatcher car and when set, if communication is lost to a particular hall call board, hall calls are set for the affected floors. Table 9: Group Options Field Variable EMPATTcar 1st EmPwrPk Output EP ManSelEn EP RclOuten 0 0 0 0 0 Max 1 3 2 3 1 Initial Units 0 0 0 1 0 Description ‐ Emergency Power Attendant Car First. Select and Prioritize the attendant car for running on emergency power service. It won't be recalled. After recall is complete for the group, It recovers and goes back in service. ‐ Emergency Power Operation LED. This parameter controls the group outputs for emergency power status for each car. 0=Outputs are on for cars that are operational. 1=Outputs are on for cars on normal power. 2=Outputs are on for cars on emergency power. 3=Outputs are on for cars that are being recalled. ‐ Emergency Power Park LED. This parameter controls the group outputs for emergency power parked status for eachcar. 0=Cars are parked on emergency power. 1=Cars are parked or selected to run. ‐ Emergency Power Manual Select Enable. 0=The recall sequence is aborted and any moving car will stop at the next floor to allow the selected car torun. +1=Car is selected to run when the currently selected car completes its recall. +2=Makes the selected car wait for all the cars to recall before being selected to run. ‐ Emergency Cars Finished Recalling Output Enable. This enables an output in the hall call board for Emergency Power Complete (EPCOM). This setting is only read in power up so after changing this setting you need to reboot the controller. P a g e | 361 Section 12 – Combined Field Adjustable Variables EmPwrOpOutput Min Table 9: Group Options Field Variable EP Recall Delay EP Recover Tim GrpCCOvrride Grp CCSecOvrT Handicap Wait Min 0 1 0 1 0 Max 3200 60 1 240 255 Initial Units Description 15 Emergency Power Recall Delay Time. sec Time delay before the group starts the emergency power recall sequence. 20 Emergency Power Recover Time. When elevators are in Emergency Power recall, this is the time that the dispatcher will wait for each car to sec recover to a floor. If the car is in the middle of a blind shaft, you need to calculate the time each car may take to get to a floor in emergency power recovery speed. 0 ‐ Group Car Call Override. Normally visitor access allows the car call security to be overridden momentarily from a push button in an owner's apartment. 1=The security override works directly from a key switch input. 60 Group Car Call Security Override Timer. This is the amount of time that the car call security is sec overridden when a group car call security override button is pressed. 0 Handicap Car Wait Time. Special operation that when a passenger presses a handicap hall button, the group adds this time to the ETA of all cars that do not have enough capacity. See sec Handicap Capacity in 'Car Options'. Normally, if a car is at the floor of the handicap hall call, it will get the assignment regardless of the handicap capacity unless this value is set to 255. Table 9: Group Options Field Variable HC Asg SecType 0 0 Max 15 2 Initial Units 0 0 Description ‐ Hall Call Assignment Security Type. Use with Special Priority Service. Determines what hall calls should be given a special priority. 1=Up. 2=Down. 4=Up Rear. 8=Down Rear. ‐ Hall Call Security Control. Set what riser the hall call security inputs work with: 0=Only standard hall calls. 1=Standard hall calls and Second Riser hall calls. 2=Only Second Riser hall calls. Hall Call Cross Assignment Enable. 1=Front hall call cross assignment is enabled. 4=Rear hall call cross assignment. 5=Front and rear hall call cross assignment. The group will look for cross assignment calls as well as hall calls. HC X‐AssignEn 0 5 0 ‐ Power should be cycled on controller after this variable is modified so all communications to all devices are made. 2=Hall call cross cancellation is used and hall calls are are not cancelled when all cars are out ofservice. A setting of 3 for both hall call assignment and cancellation is not valid and may cause unpredictable results. HCX‐AssignETA 0 500 60 Hall Call Cross Assignment ETA Limit. If ETA for hall call assignment is greater than this ETA sec limit, the hall call will be cross‐assigned to the old group controller. P a g e | 363 Section 12 – Combined Field Adjustable Variables HCSecurtyctrl Min Table 9: Group Options Field Variable IRCar IRControl Number VipCars OTS NoHCCanc Recall Timeout Sabbath Restart Min Max 0 Number Cars 0 7 0 Number Cars 0 1 0 1 600 3200 Initial Units 0 0 car ‐ Description Inconspicuous Riser Car. This car is assigned all the IR hall calls. Inconspicuous Riser Control. This parameter alters how IR riser service is activated or deactivated. 0=IR active from ICR or RICR input. +1=IR activated when any IR call is activated. +2=Finish car calls then answer IR calls. +4=Finish car calls before going off IR. 1 Number of VIP Cars. Number of cars allowed to service VIP (priority service) calls at one time. 0 Out of Service No Hall Call Cancelled. Do not cancel hall calls if cars are out of service. This is used inaccordance with cross assignment feature. ‐ 60 Recall Time‐out. The time allowed for the car to reach the recall floor sec during the emergency power recall sequence. If this timer expires, the next car is selected to recall. 8 Sabbath Restart Delay Time. sec The amount of time after the elevator answered the last sabbath call to restart the process. Table 9: Group Options Field Variable SecndRisr Ctl Skip Car@RcFLDO SkipCarN@ RcFLDO 0 0 0 0 Max 3 5 1 1 Initial Units 0 0 0 0 Description ‐ Second Riser Control. Defines the second riser operation. 0=Car defined for second riser answer second riser call and standard hall calls. 1=Car defined for second riser answer only second riser calls. 2=Second riser call or’ed with standard riser calls if second riser operation not selected from input. ‐ Single Automatic Push Button Operation. 0=Manual Doors (this would be the normal operation for cars with manual doors). 1=Enable SAPB operation for simplex car with automatic doors. 2=Disable SAPB operation for cars with manual doors. 3=Invalid setting. 4=Allow only one car call to be entered at floor for cars with manual doors regardless of the door position. 5=Allow only one car call to be entered at floor for cars with automatic doors. This feature normally allows only hall calls and car calls to register when the doors are closed. ‐ Skip Car at Recall Floor with Door Open. While on Emergency Power Recall sequence, if enabled, out of service cars at the Emergency Power Recall floor with door open will be given a chance to run. 0=Override immediately. 1=Override after time delay. Time delay defined by variable 'EP RecoverTim'. ‐ Skip Car Not at Recall Floor with Door Open. While on Emergency Power Recall sequence, if enabled, out of service cars at the Emergency Power Recall floor with door open will be given a chance to run. 0=Override immediately. 1=Override after time delay. Time delay defined by variable 'EP RecoverTim'. P a g e | 365 Section 12 – Combined Field Adjustable Variables SingleAuto PB Min Table 9: Group Options Field Variable ThirdRisr Ctrl Min 0 Max 1 Initial Units 0 ‐ Description Third Riser Control. Defines the third riser operation. 0=Car defined for third riser answers third riser calls and standard hall calls. 1=Car defined for third riser answers only third riser calls. Vid PosCar1 1 Number Cars 1 Video Position Car 1. The column where the car is displayed, on the group screen, starts from left to right for positions 1 through 6 car (8 for high rise cars). Car 1 through 6 positions are defaulted to display positions 1 through 6 respectively. Changing the car’s video position changes the column where the car is displayed. Vid PosCar2 1 Number Cars 2 car Video Position Car 2. See Video Position Car 1 for an explanation. Vid PosCar3 1 Number Cars 3 car Video Position Car 3. See Video Position Car 1 for an explanation. Vid PosCar4 1 Number Cars 4 car Video Position Car 4. See Video Position Car 1 for an explanation. Vid PosCar5 1 Number Cars 5 car Video Position Car 5. See Video Position Car 1 for an explanation. Vid PosCar6 1 Number Cars 6 car Video Position Car 6. See Video Position Car 1 for an explanation. Vid PosCar7 1 Number Cars 7 car Video Position Car 7. See Video Position Car 1 for an explanation. Table 9: Group Options Field Variable Vid PosCar8 Vip Button Loc Min Max 1 Number Cars 0 2 Initial Units 8 0 0 3 0 X‐Assign Cars 0 Number Cars 0 Video Position Car 8. See Video Position Car 1 for an explanation. ‐ VIP Button Location. 0=VIP on VIP Board. 1=VIP on HC Board. 2=VIP on IR Board. ‐ VIP (Priority Call) Operation. +1=Cancel hall call if no cars available for VIP call. +2=Cancel car call upon initiation of being selected as the VIP car. Cross Assignment Cars. car Number of cars in the old group to assign calls using cross assignment system. P a g e | 367 Section 12 – Combined Field Adjustable Variables VIPOperation car Description Table 10: CC & COP Lights Field Variable Min Max Initial Units Description Enable Backlight Output Lights for RGB Style Output Lights in COP. Bit 0: Fire Bit 1: Medical color Bit 2: Emergecy Bit 3: OTS (Out Of service) Bit 4: Att Up/DnLight Bit 5: Non‐CC Backlight Lt 0 63 0 CC AttDnBlue 0 100 0 % Car Call Button Attendant Down Light Blue Intensity. CC AttDn Bright 0 100 100 % Car Call Button Attendant Down Light Brightness. Car Call Button Attendant Down Light Color. 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White CC AttDn Color 0 15 0 CC AttDnGreen 0 100 0 % Car Call Button Attendant Down Light Green Intensity. CC AttDnRed 0 100 100 % Car Call Button Attendant Down Light Red Intensity. CC AttUpBlue 0 100 0 % Car Call Button Attendant Up Light Blue Intensity. CC AttUpBright 0 100 100 % Car Call Button Attendant Up Light Brightness. Table 10: CC & COP Lights Field Variable Min Max Initial Units Description CC AttUp Color 0 15 0 CC AttUpGreen 0 100 100 % Car Call Button Attendant Up Light Green Intensity. CC AttUpRed 0 100 0 % Car Call Button Attendant Up Light Red Intensity. Section 12 – Combined Field Adjustable Variables Car Call Button Attendant Up Light Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White Flashing Car Call Lights. +1=Flash Car Call Security. +2=Flash Attendant Annunciator Sequence. CCLightCtl 0 3 0 CCOffBlue 0 100 50 % Car Call Off Blue Intensity. CCOffBright 0 100 20 % Car Call Output Off Brightness For LED. P a g e | 369 Table 10: CC & COP Lights Field Variable Min Max Initial Units Description Car Call Button Light Off Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White CCOffColor 0 15 15 CCOffGreen 0 100 100 % Car Call Off Green Intensity CCOffRed 0 100 62.5 % Car Call Off Red Intensity CCOnBlue 0 100 50 % Car Call On Blue Intensity CCOnBright 0 100 100 % Car Call Output On Brightness For LED Table 10: CC & COP Lights Field Variable Min Max Initial Units Description CCOnColor 0 15 15 CCOnGreen 0 100 100 % Car Call On Green Intensity CC OnRed 0 100 62.5 % Car Call On Red Intensity CCSecBlue 0 100 100 % Car Call Security Light Blue Intensity CCSecBright 0 100 100 % Car Call Security Light Brightness Section 12 – Combined Field Adjustable Variables Car Call Button Light On Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White P a g e | 371 Table 10: CC & COP Lights Field Variable Min Max Initial Units Description Car Call Button Security Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White CCSecColor 0 15 15 CCSecGreen 0 100 0 % Car Call Security Light Green Intensity CCSecRed 0 100 100 % Car Call Security Light Red Intensity EmerLtBlue 0 100 0 % Emergency Light Blue Intensity EmerLtBright 0 100 100 % Emergency Light Brightness Table 10: CC & COP Lights Field Variable Min Max Initial Units Description EmerLtColor 0 15 0 EmerLtGreen 0 100 100 % Emergency Light Green Intensity EmerLtRed 0 100 75 % Emergency Light Red Intensity FireLtBlue 0 100 50 % Fire Light Blue Intensity FireLtBright 0 100 100 % Fire Light Brightness Section 12 – Combined Field Adjustable Variables Emergency Light Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White P a g e | 373 Table 10: CC & COP Lights Field Variable Min Max Initial Units Description Fire Light Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White FireLtColor 0 15 0 FireLtGreen 0 100 100 % Fire Light Green Intensity Fire LtRed 0 100 62.5 % Fire Light Red Intensity MedLtBlue 0 100 100 % Medical Light Blue Intensity MedLtBright 0 100 100 % Medical Light Brightness Table 10: CC & COP Lights Field Variable Min Max Initial Units Description MedLtColor 0 15 0 MedLtGreen 0 100 0 % Medical Light Green Intensity MedLtRed 0 100 0 % Medical Light Red Intensity OTSLtBlue 0 100 0 % Out of Service Light Blue Intensity OTSLtBright 0 100 100 % Out of Service Light Brightness Section 12 – Combined Field Adjustable Variables Medical Light Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White P a g e | 375 Table 10: CC & COP Lights Field Variable Min Max Initial Units Description Out of Service Light Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White OTSLtColor 0 15 0 OTSLtGreen 0 100 40 % Out of Service Light Green Intensity OTSLtRed 0 100 100 % Out of Service Light Red Intensity Table 11: HC & IR Call Lights Field Variable Min Max Initial Units Description 0 100 20 % Hall Call Light Off Brightness. Select the brightness for LED hall call button when button is NOT pressed. Used only with GAL serial hall button fixtures. HCOnBrght 0 100 100 % Hall Call Light On Brightness for LED Hall Call Buttons. Used only with GAL serial hall button fixtures. HCDnOffBlue 0 100 50 % Hall Call Down Light Off Blue Intensity. Used only with GAL serial hall button fixtures. HCDnOffBrght 0 100 20 % Hall Call Down Light Off Brightness for LED Hall Call Buttons. Used only with GAL serial hall button fixtures. 15 Hall Call Down Light Off Color. Select what color LED to illuminate on hall call button when button is NOT pressed. Used only with GAL serial hall button fixtures. 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine color 7 Cyan 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White HCDnOffColor 0 15 HCDnOffGreen 0 100 100 % Hall Call Light Down Off Green Intensity. Used only with GAL serial hall button fixtures. HCDnOffRed 0 100 62.5 % Hall Call Light Down Off Red Intensit Used only with GAL serial hall button fixtures. P a g e | 377 Section 12 – Combined Field Adjustable Variables HCOffBright Table 11: HC & IR Call Lights Field Variable Min Max Initial Units Description HCDnOnBlue 0 100 50 % Hall Call Light Down On Blue Intensit Used only with GAL serial hall button fixtures. HCDnOnBright 0 100 100 % Hall Call Light Down On Brightness for LED Hall Call Button Used only with GAL serial hall button fixtures. 15 Hall Call Down On Light Color. Select what color LED to illuminate on hall call button when button is pressed. Used only with GAL serial hall button fixtures. 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine color 7 Cyan 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White HCDnOnColor 0 15 HCDnOnGreen 0 100 100 % Hall Call Light Down On Green Intensit Used only with GAL serial hall button fixtures. HCDnOnRed 0 100 62.5 % Hall Call Light Down On Red Intensity Used only with GAL serial hall button fixtures. HCUpOffBlue 0 100 50 % Hall Call Up Light Off Blue Intensity HCUpOffBrght 0 100 20 % Hall Call Up Light Off Brightness for LED Table 11: HC & IR Call Lights Field Variable Min Max Initial Units Hall Call Button Up Light Off Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White 0 15 15 HCUpOffGreen 0 100 100 % Hall Call Up Light Off Green Intensity HCUpOffRed 0 100 62.5 % Hall Call Up Light Off Red Intensity HCUpOnBlue 0 100 50 % Hall Call UP Light On Blue Intensity HCUpOnBright 0 100 0 % Hall Call Up Light On Brightness for LED Section 12 – Combined Field Adjustable Variables HCUpOffColor Description P a g e | 379 Table 11: HC & IR Call Lights Field Variable Min Max Initial Units 15 Description Hall Call Button Up Light On Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White HCUpOnColor 0 15 HCUpOnGreen 0 100 100 % Hall Call Up Light On Green Intensity HCUpOnRed 0 100 62.5 % Hall Call Up Light On Red Intensity IRColorCtrl 0 1 0 ‐ IR Light Color Control 0=IR Color. 1=HC Color until IR activated. IRDnOffBlue 0 100 50 % Hall Call IR Down Light Off Blue Intensity IRDnOffBrght 0 100 20 % Hall Call IR Down Light Off Brightness Table 11: HC & IR Call Lights Field Variable Min Max Initial Units Hall Call IR Down Light Off Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White IRDnOffColor 0 15 IRDnOffGreen 0 100 100 % Hall Call IR Down Light Off Green Intensity IRDnOffRed 0 100 62.5 % Hall Call IR Down Light Off Red Intensity IRDnOnBlue 0 100 50 % Hall Call IR Down Light On Blue Intensity IRDnOnBright 0 100 20 % Hall Call IR Down Light On Brightness Section 12 – Combined Field Adjustable Variables 15 Description P a g e | 381 Table 11: HC & IR Call Lights Field Variable Min Max Initial Units 15 Description Hall Call IR Down Light On Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White IRDnOnColor 0 15 IRDnOnGreen 0 100 100 % Hall Call IR Down Light On Green Intensity IRDnOnRed 0 100 62.5 % Hall Call IR Down Light On Red Intensity IRUpOffBlue 0 100 50 % Hall Call IR Up Light Off Blue Intensity IRUpOffBrght 0 100 100 % Hall Call IR Up Light Off Brightness Table 11: HC & IR Call Lights Field Variable Min Max Initial Units Description IRUpOffColor 0 15 15 IRUpOffGreen 0 100 100 % Hall Call IR Up Light Off Green Intensity IRUpOffRed 0 100 62.5 % Hall Call IR Up Light Off Red Intensity IRUpOnBlue 0 100 50 % Hall Call IR Up On Blue Intensity IRUpOnBright 0 100 100 % Hall Call IR Up On Brightness Section 12 – Combined Field Adjustable Variables Hall Call IR Up Light Off Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White P a g e | 383 Table 11: HC & IR Call Lights Field Variable Min Max Initial Units Description Hall Call IR Up On Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White IRUpOnColor 0 15 15 IRUpOnGreen 0 100 100 % Hall Call IR Up On Green Intensity IRUpOnRed 0 100 62.5 % Hall Call IR Up On Red Intensity Table 12: CB, VIP & Hsec Call Lights Field Variable Min Max Initial Units Description CB OffBlue 0 100 100 % Hall Call CB Light Off Blue Intensity CBOffBright 0 100 % Hall Call CB Light Off Brightness 20 CB OffColor 0 15 0 CBOffGreen 0 100 0 % Hall Call CB Light Off Green Intensity CB OffRed 0 100 0 % Hall Call CB Light Off Red Intensity CB OnBlue 0 100 100 % Hall Call CB Light On Blue Intensity CBOnBright 0 100 100 % Hall Call CB Light On Brightness Section 12 – Combined Field Adjustable Variables Hall Call CB Light Off Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White P a g e | 385 Table 12: CB, VIP & Hsec Call Lights Field Variable Min Max Initial Units Description Hall Call CB Light On Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White CB OnColor 0 15 0 CBOnGreen 0 100 0 % Hall Call CB Light On Green Intensity CB OnRed 0 100 0 % Hall Call CB Light On Red Intensity HC SecBlue 0 100 100 % Hall Call Light Security Blue On Intensity Used only with GAL serial hall button fixtures. HCSecBright 0 100 100 % Hall Call Security Brightness for Secured Floors Table 12: CB, VIP & Hsec Call Lights Field Variable Min Max Initial Units 0 15 15 Hall Call Security Color Select what color to illuminate the hall buttons when the system is on security. Used only with GAL serial hall button fixtures. 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine color 7 Cyan 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White HC SecCtl 0 7 0 ‐ Hall Call Button Security Light Control +1=Invert security. +2=Flash security. +4=Master Security Enabled. HCSecGreen 0 100 0 % Hall call Light Green Intensity When On Security. Used only with GAL serial hall button fixtures. HC SecRed 0 100 100 % Hall Call Light Red Intensity When On Security. Used only with GAL serial hall button fixtures. Vip OffBlue 0 100 0 % Hall Call VIP Light Off Blue Intensity VipOffBright 0 100 20 % Hall Call VIP Light Off Brightness P a g e | 387 Section 12 – Combined Field Adjustable Variables HCSecColor Description Table 12: CB, VIP & Hsec Call Lights Field Variable Min Max Initial Units Description Hall Call VIP Light Off Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White VipOffColor 0 15 0 VipOffGreen 0 100 40 % Hall Call VIP Light Off Green Intensity Vip OffRed 0 100 100 % Hall Call VIP Light Off Red Intensity Vip OnBlue 0 100 % Hall Call VIP Light On Blue Intensity VipOnBright 0 100 100 % Hall Call VIP Light On Brightness 0 Table 12: CB, VIP & Hsec Call Lights Field Variable Min Max Initial Units Description VipOnColor 0 15 0 VipOnGreen 0 100 40 % Hall Call VIP Light On Green Intensity Vip OnRed 0 100 100 % Hall Call VIP Light On Red Intensity Section 12 – Combined Field Adjustable Variables Hall Call VIP Light On Color 0 Based on Parameters 1 Red 2 Orange 3 Yellow 4 Chartreuse 5 Green 6 Aquamarine 7 Cyan color 8 Azure 9 Blue 10 Violet 11 Magenta 12 Rose 13 Rose White 14 Warm White 15 Cool White P a g e | 389 Table 13: System Options Field Variable Min Max Auto Fault Dpy CANBaud Rate CANSync Count COM1Baud Rate Com 1Port Sel Com 2Baud Rate 0 0 0 0 0 0 1 1 7 3 3 3 Initial Units 0 ‐ Description Automatic Fault Display. Enable to automatically display a fault on the LCD screen. 0 CAN Baud Rate. Set to zero and do not change. Special jobs uitilize a different baud ratefor CAN Bus. All devices need to be reconfigured for bps new rate. 0=115.2K 1=57.6K 4 CAN Sync Count. count Frequency to update CAN Bus devices. Units are 1/4 seconds. It sets Synchronization Count in 250 millisecond increments. 0 Com 1 User Interface Baud Rate. Selects the bit rate of the COM 1 serial port. 0=2400bps. bps 1=4800bps. 2=9600bps. 3=19200bps. 0 Com 1 Port Select. Selects the operation of COM 1 port. 0=Comm Diag. 1=Comm Debug 2=Galcom. 3=DL20. 0 ‐ COM 2 User Baud Rate. Selects the bit rate of the COM 2 serial port. 0=2400bps. bps 1=4800bps. 2=9600bps. 3=19200bps. Table 13: System Options Field Variable Min Max Com 2Port Sel DriveBaud Rate DriveModbus DrvUpdate Rate EEMemoryType 0 0 0 0 0 3 7 3 5 2 1 0 0 0 0 0 0 Description ‐ Com 2 Port Select. Selects the operation of COM 2 port. 0=Comm Diag. 1=Comm Debug. 2=Galcom. 3=DL20. ‐ CPU Timing Output. The CPU has three test point pins that output timing signals depending upon the setting of this parameter. These are 5 Volt signals that can be monitored by an oscilloscope. 0=Z6 LED 1 second pulse. 1=Inc time. 2=Grp IO. 4=10 msec. Drive Baud Rate. 0=19200 (HPV‐900, DSD‐412, HPV‐600 and QuattroDrives). bps 1=38400 (KEBDrives). 2=57600. 3=115000. ‐ Drive Modbus Protocol. 0‐5 = N1, N2, E1, E2, O1, O2 (Always 8 data bits, parity, stop bits).Used for Delta drive. ‐ Drive Command Update Rate. Rate at which commands are sent to the drive. 0=10 msec (HPV‐900, DSD‐412, HPV‐600 and QuattroDrives). 1=15msec. 2=20msec. ‐ EE Memory Type. Selects the type of memory chip used with the TS‐5600 CPU. 0=STK16C88 1=STK16C68. Not used with GALX‐1100AN CPU board. P a g e | 391 Section 12 – Combined Field Adjustable Variables CPUTimOutput 0 Initial Units Table 13: System Options Field Variable Min Max Encoder Baud Encoder Intrvl Encoder NodeID Encoder Sample Encoder Type Exclusion FLT 1 0 1 1 2 0 0 1 5 127 10 3 Max Faults Initial Units 0 3 63 10 0 0 Description Encoder CAN Open Baud Rate. bps 0=250K bits per second. 1=125K bits per second. ‐ Encoder Interval. Defines the intervals for sampling the encoder reads for calculating speed. Default value of 3 will work on most jobs. For cars with distance feedback from pulses on a tape selector, a value of 5 will work best. ‐ Encoder Node ID. Selects the Node ID for the CAN Open encoder. Must be set for the specific vendor’s encoder (also see encoder type): 1=Dynapar. 63=Turck 127=Wachendorff. Not used when Encoder Type = 4 (TapeSelector). ‐ Encoder Samples. Determines the number of samples used to calculate the speed from the encoder. Default values should work in all jobs. ‐ Encoder Type. Selects type of encoder feed back used. 0=CONS file setting. 1=Turck CAN Open Encoder. 2=Dynapar CAN Open Encoder. 3=Wachendorff CAN Open Encoder. Exclusion Fault 1. Set to fault code number. This prevents faults from being fault recorded in the fault log. It should only be set for nuisance and noncritical faults. Controller still goes through all the logic for each fault code except a fault is not recorded in the fault log. Table 13: System Options Field Variable Min Max Exclusion FLT 2 Exclusion FLT 4 Exclusion FLT 5 Exclusion FLT 6 KEB Dpy Type LowBat CapLev 0 0 0 0 0 0 Max Faults Max Faults Max Faults Max Faults Max Faults 1 101 Description 0 Exclusion Fault 2. Set to fault code number. This prevents faults from being fault recorded in the fault log. It should only be set for nuisance and noncritical faults. Controller still goes through all the logic for each fault code except a fault is not recorded in the fault log. 0 Exclusion Fault 3. Set to fault code number. This prevents faults from being fault recorded in the fault log. It should only be set for nuisance and noncritical faults. Controller still goes through all the logic for each fault code except a fault is not recorded in the fault log. 0 Exclusion Fault 4. Set to fault code number. This prevents faults from being fault recorded in the fault log. It should only be set for nuisance and noncritical faults. Controller still goes through all the logic for each fault code except a fault is not recorded in the fault log. 0 Exclusion Fault 5. Set to fault code number. This prevents faults from being fault recorded in the fault log. It should only be set for nuisance and noncritical faults. Controller still goes through all the logic for each fault code except a fault is not recorded in the fault log. 0 Exclusion Fault 6. Set to fault code number. This prevents faults from being fault recorded in the fault log. It should only be set for nuisance and noncritical faults. Controller still goes through all the logic for each fault code except a fault is not recorded in the fault log. 0 50 ‐ KEB Display Type. 0=Standard Red LED Display. 1=LCD Display. Power must be cycled for change in serial protocol % UPS Low Battery Capacity. For UPS Systems, this is the battery level at which the controller will decclare a fault due to Low Battery Capacity. P a g e | 393 Section 12 – Combined Field Adjustable Variables Exclusion FLT 3 0 Initial Units Table 13: System Options Field Variable Min Max Initial Units Password 0 9999 0 ‐ Pword Time‐out 0 3200 300 sec Description Password. Password code to modify and adjust field variables. Password Time‐out. The amount of inactive time for the LCD to lock out the field variables. RS485COMBaud 0 3 0 RS485 COM Baud Rate. 0=2400. bps 1=4800. 2=9600. 3=19.2K. SafeTestDay 1 31 0 day Safety Test Day. SafeTestMonth 1 12 0 month Safety Test Month. 2000 2999 0 year Safety Test Year. SafeTestYear ServiceUPS 0 1 0 ‐ Service UPS Mode. Turning on this parameter disables UPS faults. It should only be used in Construction mode or while servicing the UPS. UPS Baud Rate 0 3 2 UPS Baud Rate. 0=2400. bps 1=4800. 2=9600. 3=19200. Video Timeout 0 3200 0 sec Video Time‐out. Turn off the machine room video after this timer times out. This function is disabled when set to zero. Table 14: Safety Processor Adjustable Variables Field Variables Min Max Initial Units 2Stop CANBaud ComChk 0 0 0 1 1 1 1 0 2 Stop. Set to 1 if this car travels to only two landings. This parameter tells the Safety Processor that there are no middle door locks. 0 Buffer Type. This parameter is set to 1 when there is a reduced stroke buffer, and enables the use of the ETU and ETD verification limits. This parameter must match the job configuration setting for reduced stroke buffer in the configuration file (CONS) and the ETS board must be detected by the PAL on the 1066 (Safety Processor) board. If all three do not match, the car is not allowed to run. 0 0 CtrlTyp 0 2 0 DTCount 0 10000 12 ‐ CAN Baud Rate. Sets the baud rate for the CAN Bus. bps 0=115.2K. 1=57.6K ‐ Communications Check. This parameter disables the CAN Bus communications check. This variable allows a new Safety Processor Board to be used on older GALaxy I or II controllers that did not use CAN Bus communications. On GALaxy III controllers, the main CPU must have CanBus communications. ‐ Control Type. This parameter tells the Safety Processor what the controller cofiguration is intended to be. 0=Hydro. 1=Traction Non‐Distance Feedback. 2=Traction Distance Feedback. DT Count. count Number of pulse count after the DT limit is hit when the slowdown velocity check is made. P a g e | 395 Section 12 – Combined Field Adjustable Variables BuffTyp 0 Description Table 14: Safety Processor Adjustable Variables Field Variables Min Max Initial Units DT Vel DTSVel DTS2Vel 0 0 0 500 1600 1600 1 Description 200 Down Terminal Slowdown Velocity. Maximum velocity to hit the down terminal slowdown “software” limit. The sequence is this: the DT Switch is hit and the software counts the fpm number of pulses set in "DT Count" (See above, set to 12), it is when the "DT Count" elapses that the velocity check is performed. Hitting the limit at a higher velocity than set by this parameter will cause the safety processor board to shut the car down from a velocity error. 200 Down Emergency Terminal Slowdown Velocity. Maximum velocity allowed when activating the down terminal fpm slowdown limit. Hitting the limit at a higher velocity will cause the Safety Processor board to shut the car down from a velocity error. For cars with speeds greater than 200 fpm. 200 Down Emergency Terminal 2 Slowdown Velocity. When the car is setup with reduced stroke buffer, if the car hits the fpm DTS2 limit at a velocity greater than this value, the PAL will drop the RUN and Brake contactors to stop the car. 0 EncDir 0 EncPPR 10 18000 2048 PPR Encoder PPR. Pulses Per Revolution of the Encoder. EncRPM 2.5 1800 Encoder RPM. Revolutions Per Minute of the Encoder. 105 ‐ Encoder Direction. Determines if rotation for the up direction is clockwise or counter‐clockwise. 0 =CW. 1=CCW. RPM Table 14: Safety Processor Adjustable Variables Field Variables Min Max Initial Units Description Feedback Type. Type of feedback used by the Safety Processor to calculate the car’s velocity. 0=Tape. 1=Governor Encoder. 2=Encoded Tape. 3=Governor Pulses. 4=Incremental Encoder. 0 4 0 ‐ InsVel 0 200 140 fpm Leveling Velocity. fpm Maximum velocity the car is allowed to run while leveling with the doors open. Inspection Velocity. Maximum velocity the car is allowed to run on inspection. LevVel 0 200 140 PlsFtim 1 10 2 sec Pulse Count Fault Delay Time. Time delay to detect that the selector pulses have stopped. Pulses/Ft 1 3200 16 ppf Pulses Per Foot. Number of pulses in one foot. RearDoors 0 1 0 ‐ Rear Door. Indicates that the car has rear doors and the Safety Processor must verify the rear door gate and locks. ‐ Short Floor. This parameter informs the Safety Processor there is a short floor at the top or bottom landing. This parameter informs the safety processor that the car can be on floor next to the terminal landing and have the terminal limits still active. 0=No Short Floor. 1=Top Floor. 2=Bottom Floor. 3=Both. ShortFl 0 3 0 P a g e | 397 Section 12 – Combined Field Adjustable Variables FdbkType Table 14: Safety Processor Adjustable Variables Field Variables Min Max Initial Units SoftStop 1 10 1 SpdChk 0 1 0 TopSpd 25 2000 200 UnMotion 0 1 0 UTCount UT Vel 0 0 10000 500 12 200 Description Soft Stop Timer. During a soft stop, the speed command is brought to zero, then the sec brake is dropped and finally the run outputs are turned off. This timer is used to keep the run outputs from timing out during a soft stop. ‐ Speed Check. If the car speed is 150 fpm or less, the Safety Processor Speed Check can be disabled from this variable. If the speed is greater than 150 fpm, the variable can still be disabled but the speed check is made anyway. The speed check function, verifies the car speed on inspection, in leveling with the door open and when the UT, DT, UTS and DTS limits are hit. The Safety Processor will also shut the car down if it stops getting pulses while the car is running (has an up or down run signal). fpm Top Speed or Contract Speed of the car. ‐ Unintended Motion Check. 0=Enable Motion Check. 1=Disable Unintended Motion Check. UT Count. count Number of pulse count after the UT limit is hit where the slowdown velocity check is made. Up Terminal Slowdown Velocity. Maximum velocity to hit the down terminal slowdown “software” limit. The sequence is this: the UT Switch is hit and the software counts the fpm number of pulses set in "UT Count" (See above, set to 12), it is when the "UT Count" elapses that the velocity check is performed. Hitting the limit at a higher velocity than set by this parameter will cause the safety processor board to shut the car down from a velocity error. Table 14: Safety Processor Adjustable Variables Field Variables Min Max Initial Units UTSVel 0 1600 1600 200 UP Emergency Terminal Slowdown Velocity. Maximum velocity to hit the up terminal slowdown limit. Hitting the fpm limit at a higher velocity will cause the Safety Processor board to shut the car down from a velocity error. For cars with speeds greater than 200 fpm. 200 UP Emergency Terminal 2 Slowdown Velocity. When the car is setup with reduced stroke buffer, if the car hits the fpm UTS2 limit at a velocity greater than this value, the PAL will drop the RUN and Brake contactors to stop the car. P a g e | 399 Section 12 – Combined Field Adjustable Variables UTS2Vel 0 Description Table15: NTS Processor AdjustableVariables (GALX‐0320AN Board) Field Variables Min Max Initial Units CANBaud Rate 0 1 DecRate 50 700 LevVel NumLim DTVel DT1Vel 2 1 0 0 25 4 0 bps Description CAN Baud Rate. Set the baud rate for the CAN Bus. 0=115.2K. 1=57.6K Deceleration Rate. 180 fpm/sec Deceleration rate for the demand velocity when an emergency slowdown is commanded. 6 4 1000 200 1000 200 fpm Leveling Velocity. After an emergency slowdown is activated, the demand velocity is reduced at the deceleration rate until the Leveling Velocity is reached. The leveling velocity is demanded until the controller demand velocity to the drive goes below the Leveling Velocity. ‐ Number of Slowdown Limits. The number of Up and Down slowdown limit pairs monitored. UT/DT is counted as one slowdown limit. fpm Down Terminal Slowdown Velocity. Maximum velocity to hit the down terminal slowdown limit. Hitting the limit at a higher velocity will cause the NTS Processor to initiate an emergency slowdown. The NTS processor will independently decelerate the demand velocity to the drive at the Decel Rate until the Lev Vel is reached. The demand velocity to the drive will stay at the Lev Vel value until the demand velocity from the controller goes below that value. fpm Down Terminal Slowdown Velocity 1. Maximum velocity to hit the down terminal slowdown limit. Hitting the limit at a higher velocity will cause the NTS Processor to initiate an emergency slowdown. The NTS processor will independently decelerate the demand velocity to the drive at the Decel Rate until the Lev Vel is reached. The demand velocity to the drive will stay at the Lev Vel value until the demand velocity from the controller goes below that value. Table15: NTS Processor AdjustableVariables (GALX‐0320AN Board) Field Variables Min Max Initial Units DT2Vel DrvBaud MtrRPM 0 0 2000 200 2000 200 3 0 0.5 1800 1170 DrvType 0 3 0 TopSpd 25 2000 200 fpm Down Terminal Slowdown Velocity 2. Maximum velocity to hit the down terminal slowdown limit. Hitting the limit at a higher velocity will cause the NTS Processor to initiate an emergency slowdown. The NTS processor will independently decelerate the demand velocity to the drive at the Decel Rate until the Lev Vel is reached. The demand velocity to the drive will stay at the Lev Vel value until the demand velocity from the controller goes below that value. fpm Down Terminal Slowdown Velocity 3. Maximum velocity to hit the down terminal slowdown limit. Hitting the limit at a higher velocity will cause the NTS Processor to initiate an emergency slowdown. The NTS processor will independently decelerate the demand velocity to the drive at the Decel Rate until the Lev Vel is reached. The demand velocity to the drive will stay at the Lev Vel value until the demand velocity from the controller goes below that value. Drive Baud Rate. 0=19200 (HPV‐900, DSD‐412, HPV‐600 and Quattro Drives). baud 1=38400. 2=57600. 3=11500. (KEB Drives). rpm Motor RPM. Revolutions per Minute of the Motor. ‐ Drive Type. Type of drive used. 0=HPV‐ 900 (HPV or Quattro). 1=DSD‐412. 2=KEB LED Keypad. 3=KEB LCD Keypad. fpm Top Speed. Contract speed of the car. P a g e | 401 Section 12 – Combined Field Adjustable Variables DT3Vel 0 Description Table15: NTS Processor AdjustableVariables (GALX‐0320AN Board) Field Variables Min Max Initial Units UTVel UT1Vel UT2Vel UT3Vel 0 0 0 0 1000 200 1000 200 2000 200 2000 200 Description fpm Up Terminal Slowdown Velocity. Maximum velocity to hit the up terminal slowdown limit. Hitting the limit at a higher velocity will cause the NTS Processor to initiate an emergency slowdown. The NTS processor will independently decelerate the demand velocity to the drive at the Decel Rate until the Lev Vel is reached. The demand velocity to the drive will stay at the Lev Vel value until the demand velocity from the controller goes below that value. fpm Up Terminal Slowdown Velocity 1. Maximum velocity to hit the up terminal slowdown limit. Hitting the limit at a higher velocity will cause the NTS Processor to initiate an emergency slowdown. The NTS processor will independently decelerate the demand velocity to the drive at the Decel Rate until the Lev Vel is reached. The demand velocity to the drive will stay at the Lev Vel value until the demand velocity from the controller goes below that value. fpm Up Terminal Slowdown Velocity 2. Maximum velocity to hit the up terminal slowdown limit. Hitting the limit at a higher velocity will cause the NTS Processor to initiate an emergency slowdown. The NTS processor will independently decelerate the demand velocity to the drive at the Decel Rate until the Lev Vel is reached. The demand velocity to the drive will stay at the Lev Vel value until the demand velocity from the controller goes below that value. fpm Up Terminal Slowdown Velocity 3. Maximum velocity to hit the up terminal slowdown limit. Hitting the limit at a higher velocity will cause the NTS Processor to initiate an emergency slowdown. The NTS processor will independently decelerate the demand velocity to the drive at the Decel Rate until the Lev Vel is reached. The demand velocity to the drive will stay at the Lev Vel value until the demand velocity from the controller goes below that value. Section 13 – Safety Processor Section 13 ‐ Safety Processor 1066 LCD Interface Operating the 1066 LCD Interface UP button is used to scroll up to the next menu item or to increment a data value. DOWN button is used to scroll down to the next menu item or to decrement a data value. MODE button is used to go back to the previous menu or to select a digit of a data value. ENTER button is used to select the menu item or to complete the operation of changing a data value. Potentiometer is used to adjust the viewing angle. It will make the display lighter or darker. P a g e | 403 The four inputs buttons used with the 1066 LCD interface are, UP, DOWN, MODE and ENTER. The UP and DOWN buttons are used to scroll up and down to each menu item. When an appropriate menu item is reached, the ENTER button is used to select the item. Some menu items, once selected, show a second menu. Again, use the UP and DOWN buttons to scroll through the menu items and the ENTER button to select a particular item. The MODE button is used to go back to the previous menu. When a menu item is an adjustable variable, select the item with the ENTER button and change the variable with the UP or DOWN button. The MODE button is used to move the cursor to the next digit. When the appropriate value is reached, used the ENTER button to complete the variable change operation and return to the current menu. The diagram in the next page illustrates the Safety Processor Functions. All these functions are monitored and any one function can cause the Safety Processor to deny or stop a run. Safety Processor Board CPU Outputs UP DNR UF DF RUNA BRK Run Control Safety Processor Board Outputs Elevator Inputs DLT DLM DLB RLM GBP LBP Door Status UT DT UTS DTS Terminal Limit Status AUTO ICI ACC TAU TAD BAU BAD INS IU ID MRI MRIU MRID Inspection Status And Control UL DZ DL Door Zone Status PAL Logic PIC Software PAL Inhibit UP UF DNR DF BRK RUNA PIC Inhibit SFC Calculate Leveling Velocity LSC Leveling Speed Control Distance Vel Upd Absolute Encoder - Tape Serial Comm - PP/PPs P a g e | 405 Section 13 – Safety Processor Safety Processor Functions 1066 LCD Interface Main Menu Power up Status GALaxy Elev Serv GALaxy Car Spd GALaxy PAL I/O GALaxy Enc Com GALaxy PAL Vrsn GALaxy Enc Stat GALaxy Version GALaxy Pls Cnt GALaxy Ext Temp GALaxy Adj Var GALaxy Brd Temp GALaxy Inp/Out GALaxy Reset GALaxy Lim Vel GALaxy Clr Flts GALaxy Faults This diagram below shows the current operation type based on the state of the inspection inputs and the gate and lock bypass switch inputs. It also displays the door status based on the condition of the gate and lock inputs. If any inputs are in error, the error status is displayed. The list below describes the different types of satus and errors displayed GALaxy Elev Serv Enter Car Status Mode MR INS Open Up Door Status Car Dir P a g e | 407 Section 13 – Safety Processor 1066 LCD Interface Elevator Service Table 1: Safety Processor Elevator Service Table 1: Safety Processor Elevator Service Elevator Service Condition for Service AUTO Auto input is on and all inspection inputs are off. CT INS Car is on car top inspection GATE BYP Car is on car top inspection and the gate bypass switch is on. LOCK BYP Car is on car top inspection and the lock bypass switch is on. ACCESS Car is on access operation. MR INS Car is on motor room inspection. IC INS Car is on in car inspection INS ERR An inspection error has occurred. There must be one and only one inspection or auto input on. All inputs are off or more than one input is on. BYP ERR A gate or lock bypass switch is on but the car is not on car top inspection. VEL ERR The car has a velocity error from inspection speed, leveling speed or a terminal slowdown speed. UP ERR The up output is on during power up. DNR ERR The down output is on during power up. DNR/UP Both up and down outputs are on during power up. EEP ERR Safety Processor board has an EEPROM error. NO UTS UTS input not detected at top terminal landing. NO DTS DTS input not detected at bottom terminal landing. Section 13 – Safety Processor 1066 LCD Interface Car Speed GALaxy Car Spd Enter Car Direction Mode Car Spd U 350 fpm Actual car speed from feedback device 1066 LCD Interface Encoder Comm The diagram above shows the communications status between the Safety Processor Board and the Turck Absolute Encoder. P a g e | 409 1066 LCD Interface Encoder Status Enter GALaxy Enc Stat Car Status Mode Bat: Ok Norm CW Operating Status Mode Encoder Com Flt Rotation direction If Com is faulty Section 13 – Safety Processor 1066 LCD Interface Pulse Count GALaxy Pls Cnt Mode Enter Pls Cnt 15000 Car pulse count from secondary speed feedback P a g e | 411 1066 LCD Interface Adjustable Variables GALaxy Adj Var Enter Mode Adj Var Top Spd Enter Top Spd 0350 fpm Up Down Adj Var CAN Baud Adj Var UnMotion Mode Adj Var Enc RPM MODE - Selects Digit UP – Increments Value DOWN – Decrements Value ENTER – Stores Value MODE – Returns To Menu Section 13 – Safety Processor 1066 LCD Interface Inputs & Outputs GALaxy Inp/Out Enter Mode Inp/Out DLT-1 = 1 Down Up Inp/Out DLM-1 = 1 Inp/Out DLB-1 = 1 Inp/Out PALIH = 1 This display shows all of the inputs and outputs for the Safety Processor. The following table lists these I/Os and their associated descriptions. P a g e | 413 Table 3: Safety Processor Inputs & Outputs Table 3: Safety Processor Inputs & Outputs Name Description DLT‐1 Door Lock Top Secondary Input. Input equals 1 when the top door lock is made. DLM‐1 Door Lock Middle Secondary Input. Input equals 1 when the middle door locks are made. DLB‐1 Door Lock Bottom Secondary Input. Input equals 1 when the bottom door lock is made. GS‐1 Gate Switch Secondary Input. Input equals 1 when the front door gate switch is made. RLM‐1 Rear Lock Middle Input. Input equals 1 when the rear middle locks are made. RGS Rear Gate Switch. Input equals 1 when the rear door gate switch is made. GBP Gate Bypass. This is the input from the gate bypass switch. 1=bypass switch is on. LBP Lock Bypass. This is the input from the lock bypass switch. 1=bypass switch is on. MRI Motor Room Inspection. Input equals 1 when the car is on motor room inspection. CTI Car Top Inspection. Input equals 1 when the car is on car top inspection. ACC Access. Input equals 1 when the car is on access operation. ICI In Car Inspection. Input equals 1 when the car is on in‐car inspection operation. AUTO Auto Input. Input equals 1 when the car is on automatic operation. UL‐1 Up Level Secondary Input. Input from the selector that the car is on the up level sensor in the door zone. DL‐1 Down Level Secondary Input. Input from the selector that the car is on the down level sensor in the door zone. UP Up Run Output. Output from the main CPU when the car is running up. DNR Down Run Output. Output from the main CPU when the car is running down. UTS Up Emergency Terminal Slowdown. Input goes low when the car is on the up emergency terminal slowdown limit. Section 13 – Safety Processor Table 3: Safety Processor Inputs & Outputs Name Description DTS Down Emergency Terminal Slowdown. Input goes low when the car is on the down emergency terminal slowdown limit. UT Up Terminal Slowdown. Input goes low when the car is on the up terminal slowdown limit. DT Down Terminal Slowdown. Input goes low when the car is on the down terminal slowdown limit. LSCS Leveling Speed Control. Output comes on when the car is traveling less than 150 fpm. SFCO PICEN Safety Fault Control Output. Output must be on to energize the SFC relay. When this relay is dropped out, the safety string will be opened. PIC Enable. The Safety Processor uses a PIC CPU. This is the enable line to the PAL device that allows the run outputs from main CPU. 1=OK to run. P a g e | 415 1066 LCD Interface Limit Velocity GALaxy Lim Vel Enter Mode UTS Vel 180 fpm Down Up DTS Vel 0 fpm UT Vel 100 fpm DT Vel 0 fpm When the car runs to the terminal landings and activates the terminal limit switches, the velocity of the car is recorded at each limit switch. This velocity value is cleared when the car runs in the opposite direction. This display is used to setup the Safety Processor Board speed clamps in the 1066 LCD interface, "Adj Var" menu. Once the car is running on automatic, send the car to the terminal landing and record the velocity values after the car stops. Begin with a one‐floor run and increase the distance of the run by one floor until the car reaches top speed. When the highest value is determined for each limit switch, add 20 fpm and enter those values in the 1066 LCD interface "Adj Var" menu, "UTS Vel", "UT Vel", "DTS Vel", and "DT Vel" respectively. Section 13 – Safety Processor 1066 LCD Interface Faults GALaxy Faults Enter Mode Faults 0 UTS Spd Down Up Faults 1 INS Sp Faults 2 EEprom Faults 9 No Flt Index Number Fault Message Faults are4 displayed in the order that they occur with index “0” being the most recent. In the figure above, an EEprom fault occurred followed by an Inspection Speed fault followed by a UTS Speed fault. Any index location that does not yet contain a fault will show “No Flt”. There are 10 fault locations all of which are cleared on power up or from the Clear Fault menu. Below is a list of faults and their possible causes. P a g e | 417 Table 2: Safety Processor Faults Table 4: Safety Processor Faults Fault Description and Cause DL/GS Door Lock/Gate Switch Fault. Car is moving outside the door zone with the door open. The car will immediately shut down. Address for Safety Processor Board should not be set internally to a value different than Add Er 5. Replace PIC micro controller unit Com Er CAN communication with CPU timed out. Safety Processor Board stopped receiving packages from the CPU. This fault always occurs once when the controller powers up. DT Spd DT Speed Fault. The car hit the DT limit at a higher velocity than the value set for the DT Velocity adjustable variable. The car will immediately shut down. DTS Sp DTS Speed Fault. The car hit the DTS limit at a higher velocity than the value set for the DTS Velocity adjustable variable. The car will immediately shut down. EEprom fault. Defective EEprom device or EEprom device is not installed. The car will EEprom not be able to run until the EEprom is installed or replaced. EncBat Encoder Battery Error. The encoder uses an internal battery to maintain position of the car when power is off. While the system is powered up and communicating, the Safety Processor Board monitors the status of the encoder battery. If the battery level is too low to maintain the position count, a battery error is declared. Replace the encoder. Encoder Communication Error. Encoder and Safety Processor Board stopped communicating. Possible causes: • Improper connection on SPB for R./T+ or R/T‐ EncCom • Faulty driver chip on Safety Processor Board • Improper connection on Encoder EncFlt EncIni •Encoder Fault Fault. Encoder The encoder has detected an internal fault. Replace the encoder. Encoder Initialization Error. On power up of the controller the Safety Processor Board will request the position count from the encoder. If the SPB is unable to receive the position count and the encoder is still communicating, an initialization error will be declared. See possible causes under EncCom error. Fault Description and Cause Encoder Position Error. Once the encoder position count has been initialized during the learn hoistway procedure, the Safety Processor Board will monitor that the count does not go above 30,000,000. If it does, then a position error is declared. Possible causes: EncPos • Faulty encoder coupling to governor • Car was lost from fault UT or DT limit switch and ran down. If the count decrements past zero it will roll over to 35,000,000. EncVel Encoder Velocity Error. To calculate velocity from the encoder a position update must be received every 50 milliseconds. If the SBP fails to receive 5 consecutive data packets from the encoder, then the velocity cannot be calculated properly and you will get this error. See EncCom error for possible causes. INS DO Inspection Door Open Fault. A door is open while running on inspection and the gate and locks are not being bypassed. The car will immediately shut down. INS Sp Inspection Speed Fault. The car exceeded the INS Velocity adjustable variable while running on inspection. The car will immediately shut down. Invalid Invalid fault number. (This can only be caused by a programming error in the chip). I/O Fault. An input is on in error. The Elev Serv display will show the I/O error. Possible causes are as follows: • All inspection inputs and the auto input are off. • More than one inspection or auto input is on at the same time. IO Flt • A bypass input is on while the car is not on Car top inspection. LEV Sp • Both up and down run output from the main CPU are on at the same time. The car will not be able to run until the error is cleared. Leveling Speed Fault. The car exceeded the LEV Velocity adjustable variable while leveling with a door open. The car will immediately shut down. No Flt No fault is recorded in this index location. • PAL chip not responding • Reset Safety Processor Board PAL Er • Replace PAL chip • Replace Safety Processor P a g e | 419 Section 13 – Safety Processor Table 4: Safety Processor Faults Table 4: Safety Processor Faults Fault Description and Cause Pulse Error. Not enough pulses have occurred during the Pulse Fault Time period. This error is detected only on automatic operation. Verify that the pulse LED on the Safety Processor board blinks while the car is running on inspection. Possible causes are as follows: • Improper connection for PP and PPS. Refer to the job specific prints. Pls Er • PP and PPS field wires need to be swapped. • Photocoupler in selector is faulty. Call the Factory. • Voltage from PP to PPS on the Safety Processor Board is less than 15 VDC with the PP and PPS wires disconnected. Call the Factory. Unintended motion detected. No up or down run signal and velocity greater than UmotEr 75 fpm. UT Speed Fault. The car hit the UT limit at a higher velocity than the value set for UT Spd the UT Velocity adjustable variable. The car will immediately shut down. UTS Speed Fault. The car hit the UTS limit at a higher velocity than the value set for UTS Sp the UTS Velocity adjustable variable. The car will immediately shut down. Section 13 – Safety Processor 1066 LCD Interface Clear Faults GALaxy Clr Flts Enter Clr Flts Hit Entr Mode Enter clears faults 1066 LCD Interface Reset Fault Latch GALaxy Reset Mode Enter Reset Hit Entr Enter resets fault latch P a g e | 421 1066 LCD Interface Board Temperature GALaxy Brd Temp Mode Enter Brd Temp 36 C Enter Brd Temp 97 F 1066 LCD Interface External Temperature NOTE: Only valid if external Temperature sensor is provided GALaxy Ext Temp Mode Ext Temp 36 C Enter Ext Temp 97 F Enter Section 14 - GALX‐0320AN NTSD Board This board is a retrofit for the GALaxy III Controller. The board’s function is to detect if the set limit velocities are exceeded, if so then the board commands the drive to slow down through the drive communications. The image below shows the connections and LEDs for the board. Section 14 – GALX-0320AN NTSD Board P a g e | 423 In the schematic example below we only monitor DT/UT. Next the adjustable variables must be set in the GALX‐0320AN. Top Speed – Number of Pairs of Limits – Drive Type – Drive Baud Rate, must all be set. The limit velocities in the adjustable variables must be determined using the “Lim Vel” menu. If running on construction mode set the limit velocities to car speed. Make long runs to the top and bottom floors and write down the values in “Lim Vel” for each of your limits. This menu will display values for the UT limits when you reach the top landing and the DT limits when you reach the bottom landing. Add 20 to the numbers obtained from the “Lim Vel” menu and enter these numbers in Adj Var‐>UT Vel, UT1 Vel, etc. P a g e | 425 Section 14 – GALX-0320AN NTSD Board When the board is first installed the GALX‐0320AN board has to be inserted into the controller/drive communications. The communications wiring is as follows: Controller ‐> GALX‐0320AN ‐> Drive. The table below can be used to determine how many limits you should have. FPM UT/ DT UT1/ DT1 UT2/ DT2 UT3/ DT3 50 100 10” 21” 150 31” 200 41” 250 52” 300 350 31” 40” 62” 80” 400 50” 99” 450 60” 120” 500 71” 143” 600 700 65” 85” 130” 170” 195” 255” 800 80” 160” 240” 320” UT4/ DT4 UT5/ DT5 UT6/ DT6 900 98” 196” 293” 391” 1000 93” 187” 280” 374” 467” 1100 1200 110” 106” 219” 211” 329” 317” 439” 422” 548” 528” 633” 1300 103” 206” 310” 413” 516” 619” 723” 1400 102” 204” 306” 408” 510” 612” 714” UT7/ DT7 816” Run / Com status Car Dmd FPM Current demand speed from controller Drv Dmd FPM Current demand speed from drive Car Com Drv Com Can Com Adj Var Top Spd Dec Rate Lev Vel CTX / CRX DTX / DRX NTX / NRX Car Com status Drive Com status Can Bus Comm status FPM FPM FPM Top Speed of Car Decel Rate Leveling Velocity FPM FPM FPM FPM FPM FPM FPM FPM RPM Total number of limit pairs (UT/DT= 1 pair) Velocity limit for UT Velocity limit for UT1 Velocity limit for UT2 Velocity limit for UT3 Velocity limit for DT Velocity limit for DT1 Velocity limit for DT2 Velocity limit for DT3 Nameplate RPM Num Limit UT Vel UT1 Vel UT2 Vel UT3 Vel DT Vel DT1 Vel DT2 Vel DT3 Vel Mtr RPM Drv Typ 0‐3 Drv Baud 0‐3 Can Baud Inp/Out UT UT1 UT2 UT3 DT DT1 DT2 DT3 0‐1 Section 14 – GALX-0320AN NTSD Board GALX‐0320AN Menu Structure Run Stat Normal / Com 0=HPV 1=DSD412 2=KEB 3=KEBlc (LCD Keypad) 0=19.2 (HPV, DSD412) 1=38.4 (KEB) 2=57.6 3=115.2 0=115.2, 1=57.6 1=made, 0=open 1=made, 0=open 1=made, 0=open 1=made, 0=open 1=made, 0=open 1=made, 0=open 1=made, 0=open 1=made, 0=open P a g e | 427 Lim Vel UT UT1 UT2 UT3 DT DT1 DT2 DT3 Speed when limit is opened Speed when limit is opened Speed when limit is opened Speed when limit is opened Speed when limit is opened Speed when limit is opened Speed when limit is opened Speed when limit is opened Faults UT Spd UT1 SPD UT2 Spd UT3 Spd DT Spd DT1 Spd DT2 Spd DT3 Spd Clr Faults Reset GALaxy Version UT speed clamp fault. Elevator speed exceeded limit when UT switch opened. Check UT speed clamp parameter. UT1 speed clamp fault. Elevator speed exceeded limit when UT1 switch opened. Check UT1 speed clamp parameter. UT2 speed clamp fault. Elevator speed exceeded limit when UT2 switch opened. Check UT2 speed clamp parameter. UT3 speed clamp fault. Elevator speed exceeded limit when UT3 switch opened. Check UT3 speed clamp parameter. DT speed clamp fault. Elevator speed exceeded limit when DT switch opened. Check DT speed clamp parameter. DT1 speed clamp fault. Elevator speed exceeded limit when DT1 switch opened. Check DT1 speed clamp parameter. DT2 speed clamp fault. Elevator speed exceeded limit when DT2 switch opened. Check DT2 speed clamp parameter. DT3 speed clamp fault. Elevator speed exceeded limit when DT3 switch opened. Check DT3 speed clamp parameter. Clears all current faults Resets board Firmware version Appendix A - Mnemonics Appendix A - Mnemonics Appendix A will help with the identification of common mnemonics. Mnemonic I/O Name 1C‐29C 1st – 29th Floor Car Call Inputs 1CA‐29CA 1st – 29th Floor Car Call Acknowledge Outputs 1CAR‐29CAR 1st – 29th Floor Rear Car Call Acknowledge Outputs 1CR‐29CR 1st – 29th Floor Rear Car Call Inputs 1U‐28U 1st – 28th Floor Up Hall Call Inputs 1UA‐28UA 1st – 28th Floor Up Hall Call Acknowledge Outputs 1UAR-28UAR 1st – 28th Floor Rear Up Hall Call Acknowledge Outputs 1UR‐28UR 1st – 28th Floor Rear Up Hall Call Inputs 2D‐29D 2nd – 29TH Floor Down Hall Call Inputs 2DA‐29DA 2nd – 29th Floor Down Hall Call Acknowledge Outputs 2DAR‐29DAR 2nd – 29th Floor Rear Down Hall Call Acknowledge Outputs 2DR‐29DR 2nd – 29TH Floor Rear Down Hall Call Inputs ACC Access Operation Input. AD Automatic Door Switch Input AD0‐AD11 Analog to Digital Input Data ALT Alternate Fire Smoke Detector Sensor Input ATT Attendant Operation Input. ATTDN Attendant Down Input. ATTUP Attendant Up Input. AUTO Automatic Operation Input. B16 Binary Position Sensor 16 Input BAD Bottom Access Down Input. BAU Bottom Access Up Input. BKC Brake Cool Pilot Output P a g e | 429 Mnemonic I/O Name BKS Brake Switch Input BP Fire Phase I Smoke Detector Bypass Input BP1 Binary Position Sensor 1 Input BP2 Binary Position Sensor 2 Input BP4 Binary Position Sensor 4 Input BP8 Binary Position Sensor 8 Input BRK Brake Pilot Output BRKI Brake Control Input. CAR Car number CDL Cab Down Lantern Output CNV DAC Convert Output COL Counter Weight Collision Switch Input (Traction Elevators) CUL Cab Up Lantern Output DA0‐DA7 Digital to Analog Output Data DC Door Close Output DCB Door Close Button Input DCBR Door Close Button Rear Input DCC DAC Clear Output DCL Door Close Limit Input DCLR Door Close Limit Rear Input DCR Door Close Rear Output DCS DAC Chip Select Output DDA Down Direction Arrow Output DEL Delta Relay Input DF Down Fast Pilot Output DFI Down Fast Input DL Down Level Sensor Input DL‐1 Down Level Sensor Secondary Input. DLB Door Lock Bottom Input. I/O Name DLB‐1 Door Lock Bottom Secondary Input DLM Door Lock Middle Input DLM‐1 Door Lock Middle Secondary Input DLT Door Lock Top Input. DLT‐1 Door Lock Top Secondary Input. DN Down Normal Limit Input Dni Down Run Input. DNR Down Pilot Output DO Door Open Output DOB Door Open Button Input DOBR Door Open Button Rear Input DOL Door Open Limit Input DOLR Door Open Limit Rear Input DON Drive On. DOR Door Open Rear Output DPR Door Protect Relay Input DS Down Slowdown Sensor Input DT Down Terminal Limit Input DT1 Down Terminal Input 1 DT2 Down Terminal Input 2 DT3 Down Terminal Input 3 DZ Door Zone Relay Input EE Electric Eye Input EER Electric Eye Rear Input EMP Emergency Power Input EPS Emergency Power Select Input EQ Earthquake Sensor Input FB Fire Buzzer Output FF Full Field Pilot Output Appendix A - Mnemonics Mnemonic P a g e | 431 Mnemonic I/O Name FL Fire Phase I Light Output FS Fire Phase I On Hall Switch Input FS2 Fire Switch Phase II On Input FS2C Fire Switch Phase II Call Cancel Input FS2H Fire Switch Phase II Hold Input FST Fire Stop Switch Override Output FSTi Fire Stop Switch Override Input GBP Gate Switch Bypass Input. GR1R Rope Gripper 1 Relay Output. GR2R Rope Gripper 2 Relay Output. GRT1 Rope Gripper Test Switch Input 1. GRT2 Rope Gripper Test Switch Input 2. GS Car Gate Switch Input GS‐1 Gate Switch Secondary Input. GTS Rope Gripper Trip Switch Input. HB Handicap Buzzer Output HBE Handicap Buzzer Enable Input HC Hall Call Common Input HWS Hoistway Smoke Sensor Input ICI In‐Car Inspection Input. ICR Inconspicuous Riser Input ICS In Car Stop Switch Input ID Car Top Inspection Down Input IND Independent Input INS Car Top Inspection Input ISER In Service Output IU Car Top Inspection Up Input LBE DAC Low Byte Enable Output LBP Lock Bypass Input I/O Name LC Logic Common Input LD Down Hall Lantern Output LDR Rear Down Hall Lantern Output LE Level Enable Output LE1 Level Enable 1 Output. LE2 Level Enable 2 Output. LOA DAC Load Output LU Up Hall Lantern Output LUR Rear Up Hall Lantern Output LW Load Weighing Bypass Input MCA Motor Contactor Output MCAI Motor Contactor Input. MCC Motor Contactor Output MCCI Motor Contactor Input. MES Main Egress Smoke Detector Sensor Input MRI Motor Room Inspection Input. MRID Motor Room Inspection Down Input. MRIU Motor Room Inspection Up Input. MRS Motor Room Smoke Sensor Input NB Nudging Buzzer Output NUD Door Nudging Output NUDR Door Nudging Rear Output OT1 OT1 Job Specific Output 1/Fire Service On Output OT2 OT2 Job Specific Output 2/Motor Starter Timer Relay Output OT3 OT3 Job Specific Output 3/Generator Pilot Output OT4 OT4 Job Specific Output 4/Field Weakening Pilot Output OVL Overload Input P Potential (Run Contactor) Input P1‐P29 1ST – 29th Discrete Floor Position Indicator Outputs Appendix A - Mnemonics Mnemonic P a g e | 433 Mnemonic I/O Name PFC Primary Fault Control Output. RDY Drive Ready Input RGS Rear Car Gate Switch Input. RGS‐1 Rear Car Gate Switch Secondary Input. RLM Rear Lock Middle Input. RLM‐1 Rear Lock Middle Secondary Input. RST Reset Drive Output RTL Return to Lobby Input RUN Run Pilot Output RUNAi Run Auxiliary Input. RUNi Run Input. SC1 Speed Clamp 1 Output (Used by CPU for setup) SC2 Speed Clamp 2 Output (Used by CPU for setup) SC3 Speed Clamp 3 Output (Used by CPU for setup) SC4 Speed Clamp 4 Output (Used by CPU for setup) SC5 Speed Clamp 5 Output (Used by CPU for setup) SE Safety Edge Input SER Safety Edge Rear Input SPI# Spare Input, # references input number SPO# Spare Output, # references output number SS Safety String Input TAD Top Access Down Input. TAU Top Access Up Input. TPL Temp Low Input (Hydraulic Elevators) UDA Up Direction Arrow Output UFi Up Fast Input UL Up Level Sensor Input UL‐1 Up Level Sensor Secondary Input UN Up Normal Limit Input I/O Name UP Up Pilot Output UPF Up Fast Pilot Output UPi Up Run Input. US Up Slowdown Sensor Input UT Up Terminal Limit Input UT1 Up Terminal Input 1 UT2 Up Terminal Input 2 UT3 Up Terminal Input 3 Appendix A - Mnemonics Mnemonic P a g e | 435 Appendix B - Compliance Testing Appendix B is a useful guide to performing common compliance tests. 1.0 Overspeed Test on a DSD-412 To perform an overspeed test, the mechanic should follow the required precautions and procedures set forth in the local and national elevator codes. 1. With the car on automatic, run the car to the top or bottom (away from the desired test run direction). 3. Set the Overspeed % (Function #12) fault trip value to a number greater than the desired over speed. 4. Set the Overspeed Test flag (Function 5. #80) in the drive. This will cause the drive to run over speed for one run. 6. Please note that the “Weak Field Current” parameter (Function #49) may need to be adjusted to allow the car to reach the desired overspeed velocity. 7. On the controller main LCD interface select “Run Overspeed Test” under the Elevator Setup menu. Follow the directions on the LCD display to make sure the automatic door switch is off and the car is level at the floor on automatic operation. Enabling the overspeed test will prevent the CPU from detecting an overspeed condition for one run. 8. Place a car call to run the car in the desired direction to perform the overspeed test. 9. Place the car on inspection and inspect the car. 10. Reset the Overspeed % (Function #12) back to the original setting. 11. When the test is complete, return the car to automatic operation. If there is any uncertainty about performing this tests with a GALaxy controller, please call toll free at 1 (877) 425‐7763 for free technical assistance. P a g e | 437 Appendix B – Compliance Testing 2. Access the Overspeed Reference Multiplier parameter (Function #81) in the drive and set to the desired multiplier value (1.25 for 125%). 2.0 Overspeed Test on a KEB Drive (For AC Geared & PM Gearless) To perform an overspeed test, the mechanic should follow the required precautions and procedures set forth in the local and national elevator codes. 1. With the car on automatic, run the car to the top or bottom (away from the desired test run direction). 2. Set LF.20 (car speed) to 135% of the value already there. 3. Set LF.42 (high speed) to 135% of the value already there. 4. In the controller change the following: Adj Var -> Car Motion -> MTR RPM to 125% (or more if necessary) of the value already there. 5. In the controller, go to: Elevator Setup -> Overspeed Test and press “Enter”. You can now place a car call in the direction you need to test. The car will overspeed in the desired direction. 6. Return all parameters to the original values. If there is any uncertainty about performing this tests with a GALaxy controller, please call toll free at 1 (877) 425‐7763 for free technical assistance. 3.0 Overspeed Test on a HPV-600/900 W Distance Feedback (Also For Quattro Cube) To perform an overspeed test, the mechanic should follow the required precautions and procedures set forth in the local and national elevator codes. 7. With the car on automatic, run the car to the top or bottom (away from the desired test run direction). 8. Access the Overspeed Mult parameter (sub menu A1) in the drive and set the % overspeed. 9. Set the Overspeed Test Flag (sub menu U4) in the drive. This will cause the drive to over speed for one run. 10. On the controller main LCD interface, select “Run Overspeed Test” under the Elevator Setup menu. Follow the directions on the LCD display to make sure the automatic door switch is off and the car is level at the floor on automatic operation. Enabling the overspeed test will prevent the CPU from detecting an overspeed condition for one run. 11. Place a car call to run the car in the desired direction to perform the overspeed test. 12. Place the car on inspection and inspect the car. 13. Return the car to automatic operation. If there is any uncertainty about performing this tests with a GALaxy controller, please call toll free at 1 (877) 425‐7763 for free technical assistance. 4.0 Buffer Test To perform a buffer test, the mechanic should follow the required precautions and procedures set forth in the local and national elevator codes. The following test procedure is written to show how to override the car’s position system so that it will run into the terminal landing at contract speed but is not intended to circumvent any procedure mandated by the elevator code. Inspect and prepare the car according to the “Elevator Industry Inspection Handbook”. Make sure that the car is loaded properly for the test and that the appropriate car or counterweight safety is tied. 15. From the Controller’s LCD display, select the “Elevator Setup” menu and then select “Car Buffer Test” or Counterweight Buffer Test”. 16. Turn off the automatic door switch. To execute the test, the car must be level at the floor and on automatic operation. 17. The test also cannot be started from a terminal landing. If the car is at a terminal landing, the LCD display will show “To position the car press Enter”. Pressing “Enter” will place a car call in the middle of the hoistway. If the car is already positioned properly for the run, the display will give the option to position the car or the skip to the next step. 18. Once the car is located in the correct starting position, select “Run Buffer Test”. When the “Enter” button is pressed, the car’s position will be modified internally to the top of the hoistway for a car buffer test or to the bottom of the hoistway for a counterweight buffer test. The car will then run high speed to the appropriate buffer. 19. While the car is in motion, the LCD display will change to “Press Enter Button to Cancel Buffer Test”. Pressing the “Enter” button will cause the car to execute an emergency slowdown. 20. After the test is complete, place the car on inspection and inspect the car and buffer. 21. Remove all jumpers, remove load weights and untie the car or counterweight safeties if previously tied. 22. Return the car to automatic operation. If there is any uncertainty about performing this tests with a GALaxy controller, please call G.A.L. toll free at 1 (877) 425‐7778 for free technical assistance. P a g e | 439 Appendix B – Compliance Testing 14. For the car buffer test, jump DT, DT1, DT2, DT3 and DTS terminal limits to SFC (110VAC). For the counterweight buffer test, jump UT, UT1, UT2, UT3 and UTS terminal limits also to SFC. Refer to the job schematics specific terminal wiring locations. 5.0 Normal Terminal Slowdown Test To perform a normal terminal slowdown test, the mechanic should follow the required precautions and procedures set forth in the local and national elevator codes. The following test procedure is written to show how to override the car’s position system so that it will run into the terminal landing at contract speed but is not intended to circumvent any procedure mandated by the elevator code. Inspect and prepare the car according to the “Elevator Industry Inspection Handbook”. Make sure that the car is loaded properly for the test. 1. For the bottom normal terminal slowdown test, jump DTS terminal limit to SFC (110VAC). For the top normal terminal slowdown limit test jump UTS terminal limit also to SFC. Refer to the job schematics for specific terminal wiring locations. 2. From the Controller’s LCD display, select the “Elevator Setup” menu and then select “Car Buffer Test” to perform a bottom normal terminal slowdown test or “Counterweight Buffer Test” to perform a top terminal slowdown limit test. 3. Turn off the automatic door switch. To execute the test, the car must be level at the floor and on automatic operation. 4. For this test only adjust parameters UT Vel and DT Vel on the Safety Processor Board to contract speed. 5. The test also cannot be started from a terminal landing. If the car is at a terminal landing, the LCD display will show “To position the car press Enter”. Pressing “Enter” will place a car call in the middle of the hoistway. If the car is already positioned properly for the run, the display will give the option to position the car or the skip to the next step. 6. Once the car is located in the correct starting position, select “Run Buffer Test”. When the “Enter” button is pressed, the car’s position will be modified internally to the top of the hoistway for a car buffer test or to the bottom of the hoistway for a counterweight buffer test. The car will then run once high speed to the appropriate limit. 7. While the car is in motion, the LCD display will change to “Press Enter Button to Cancel Buffer Test”. Pressing the “Enter” button will cause the car to execute an emergency slowdown. 8. After the test is complete remove all jumpers and adjust the UT Vel and DT Vel parameters on the Safety Processor Board back to their original values. If there is any uncertainty about performing this tests with a GALaxy controller, please call G.A.L. toll free at 1 (877) 425‐7778 for free technical assistance. 6.0 Emergency Terminal Limit Test To perform an emergency terminal limit test, the mechanic should follow the required precautions and procedures set forth in the local and national elevator codes. The following test procedure is written to show how to override the car’s position system so that it will run into the terminal landing at contract speed but is not intended to circumvent any procedure mandated by the elevator code. Make sure that the car is loaded properly for the test. 1. For the bottom emergency terminal limit test, jump the bottom normal terminal slowdown limit switches DT, DT1, DT2, DT3 depending on how many normal slowdown switches the job has to SFC (110VAC). For the top emergency terminal limit test jump the top normal terminal slowdown limit switches UT, UT1, UT2,UT3 also to SFC. Refer to the job schematics specific terminal wiring locations. 2. From the Controller’s LCD display, select the “Elevator Setup” menu and then select “Car Buffer Test” to perform a bottom emergency terminal limit test or “Counterweight Buffer Test” to perform a top emergency terminal limit test. 3. Turn off the automatic door switch. To execute the test, the car must be level at the floor and on automatic operation. 4. The test also cannot be started from a terminal landing. If the car is at a terminal landing, the LCD display will show “To position the car press Enter”. Pressing “Enter” will place a car call in the middle of the hoistway. If the car is already positioned properly for the run, the display will give the option to position the car or the skip to the next step. 5. Once the car is located in the correct starting position, select “Run Buffer Test”. When the “Enter” button is pressed, the car’s position will be modified internally to the top of the hoistway for a car buffer test or to the bottom of the hoistway for a counterweight buffer test. The car will then run once high speed to the appropriate limit. 6. While the car is in motion, the LCD display will change to “Press Enter Button to Cancel Buffer Test”. Pressing the “Enter” button will cause the car to execute an emergency slowdown. 7. After the test is complete remove all jumpers. If there is any uncertainty about performing this tests with a GALaxy controller, please call G.A.L. toll free at 1 (877) 425‐7763 for free technical assistance. P a g e | 441 Appendix B – Compliance Testing Inspect and prepare the car according to the “Elevator Industry Inspection Handbook”. 7.0 Reset Gripper Fault or Emergency Brake Fault To reset a rope gripper fault, first verify that the cause of the rope gripper fault has been corrected and then follow the directions below: 1. Place the car on machine room inspection. 2. From the LCD Interface, select the Elevator Setup menu and press the enter button. 3. Use the up or down button to select the “Reset Rope Gripper” menu and press enter. 4. Follow the directions on the screen to press and hold the enter button to reset the gripper. The enter button must be held for approximately 10 seconds. If the car moves unexpectedly within the 10 second delay time, releasing the enter button will cause the gripper to re‐ engage. When the gripper is full reset the screen will display “Gripper is Reset”. Appendix C is a guide for the latest GAL CPU, the GALX‐1100. Please note that this CPU is backwards compatible with previous versions. P a g e | 443 Appendix C – GALX-1100 CPU Appendix C – GALX-1100 CPU GALX‐1100 CPU (Replacement CPU for TS‐5300 board) GALX‐1100 CPU The GALaxy GALX‐1100 CPU has beenimplemented as the replacementboard for the previously used TS‐5300 CPU (now obsolete). The new CPUuses a dual‐core 32‐bit Freescale CPU that include all the components and features used on the GALX‐1036COMM Memory Board, the GALX‐1092 Encoder Board, the TS‐SER2 serial expansion board and theexisting TS‐5300 CPU. It uses Secured Digital Card storage instead ofCompact Flash so that programupgrades and data/parameter storage can be easily transferred to any device that can copy text files from an SDCard file. The TS‐9500 VGA board and GALX‐ 1021 board combination is replaced with a single GALX‐1101 LCD/VGA board. The single GALX‐1021/1101/1005 LCDboard is replaced with a GALX‐1005LCD board. GALX‐1100 CPU Board Replacement‐ Installation Items required for installations: Laptop (to copy configuration file from CF card to SD card), small common screwdriver, USB Card Reader to read and write CF card and SD card, GALX‐1100 CPU board, 10‐pin encoder cable (supplied with CPU), GALX‐1101 LCD/VGA board or GALX‐ 1005 LCD board, SD card with one of the following controller files: tract.mot, tracthr.mot or hydro.mot files. The procedure to replace an existing CPU, COMM Memory board andEncoder board is as follows: Place the car on inspection. Power the controller off. Remove the CF card from the existing CPU and copy the cons.dat or conshr.dat file to the SD card for the GALX‐1100 CPU. Disconnect the encoder connector from the encoder board on the stack and then remove all boards off the stack except the 1036 comm memory board. Disconnect the comm connectors from 1036 board. Plug in the new CPU on to PC‐104 connector on top of the 1036 board. Install spacers onto new CPU board to support the LCD or LCD/VGA display board and plug in the display board. Wire the power connector to the new CPU board and then power up the controller. From the LCD screen, select the Software Utilities menu and then select to “Load 1036 Field Variables”. If data is read successful, the field variables are now stored in the new CPU. If not, the parameters must be added manually and the car must be re‐ adjusted. From the LCD screen select the menu “Load 1036 Hoistway Setup”. If data is read successful, the hoistway setup data and the load weigher data is now stored in the new CPU. If not, the load weigher Once both the parameter and hoistway data tables are read from the 1036 board, power down the controller, remove the LCD or LCD/VGA board, remove the new CPU and then remove the 1036 board. Re‐install the new CPU adding the required screws and then re‐ install the LCD or LCD/VGA board also adding the required screws. Connect the communications connectors that were previously on the 1036 board to the new CPU board. The new CPU board is supplied with an encoder cable. If the existing system had used a 1092 board, plug in the encoder cable from the 1092 board to the CPU board encoder connector (left most 10‐pin connector on the board). If the existing system used a 4I30 encoder, replace the encoder cable with the supplied cable from the encoder isolation board to the CPU board. Power up the controller. Run the car on inspection making sure the CPU pulse count is incrementing or decrementing in the correct direction. If the direction needs to be reversed, then change the “Encoder Dir” parameter to the opposite value under the “Car Motion” menu listed under the “Adjustable Variables” menu. Run the hoistway learn setup procedure. (Recommended) Place the car on automatic with the door service turned off and run the car to verify all is good. Once the car operation is verified, place the car on inspection and from the “Software Utilities” menu; select the “SD Card Read/Write Data” menu. Select the following menus to save the field variables, job setup, hoistway table, and security and timer information to the SD card: “Write Field Variables”, “Write Job Setup Data”, “Write Hoistway Data”, “Write Service Timers”, and “Write Security Data”. Remove the SD Card and copy the data to a laptop using and SD card reader. Replace the SD Card back into the controller CPU. The SD card must be installed in the CPU SD card slot in order for the car to power up properly. The car will not run after power up if the SD card is not installed. Place the car on automatic service and enable door operation. Load job software to CPU The following procedure is used to load the job software to the new CPU: When the CPU is powered up, the program must be operating in the Power‐ Up Mode and have an SD Card with the appropriate “.dat” and “.mot” files installed. If controller software is already copied into Flash, either place the car on inspection and from the Software Utilities menu, select to run Power‐Up Mode or cycle power on the CPU board while pressing the Mode and Enter button on the LCD Display. P a g e | 445 Appendix C – GALX-1100 CPU must be setup and a hoistway learn must be done once the 1036 board is removed. It is recommended to do a hoistway learn regardless of the outcome of the hoistway read. Disconnect the Car to Car communications cable. While the CPU flash is being programmed, the output pins for the Car to Car communications port may be left in an unfavorable state that can prevent it from working properly. It is best to disconnect the cable to avoid loss of communications between the remaining cars. Once in Power‐Up Mode, select the “Update/Verify Program” menu and then select the “Load Program from SDCard” menu. Press the Enter button to begin the file transfer when prompted to do so. The flash memory will be erased and then the new program will be copied to the onboard flash. Power must be kept on the CPU throughout the entire process. The display will show “Operation Complete” once the load is finished. Cycle power on the CPU or hit the Mode button and then select the “Run Controller Program” menu, to run the controller software. LCD Display The main menu on the LCD display now shows Software Utilities instead of Software Version to allow for additional features implemented with the new GALX‐1100 CPU board. The diagram below shows the new menu items, in yellow, and also includes the latest menu changes. Appendix C – GALX-1100 CPU P a g e | 447 Software Utilities Menu The Software Utilities menu provides access to special functions that do not directly affect the adjustment and setup of the controller. Most functions in this menu require that the car be on inspection to execute the operation. The diagram of this menu is shown below: View Software Version – Display the software version, revision and interim revision in the form 6.00.18. Run Power‐Up Mode – The Power‐Up Mode is a program that executes first upon power up of the controller. It checks that there is a valid controller program in memory and that a valid cons.dat file is on the SD Card. Once this is validated, the power up program runs the controller program. If the power up program is executed from the controller program or if during power up, the user presses and holds the enter and mode buttons, this routine does not run the controller program but stays in the power up routine to allow for updates of the controller program. Test Watchdog Reset – The watchdog is a CPU timer that must be updated periodically in software to confirm that the program is still running correctly. If the watchdog is not updated, the timer will expire and cause the CPU to do a hard reset to allow the program to restart. To test the watchdog timer, when the command is given, the controller program sits in an infinite software loop without updating the watchdog time to test that the reset function works. Reset Debug Variables – The debug variables are set by a software engineer to aid in debugging a software problem. Some problems are especially difficult to catch because they occur infrequently or at seemingly random times. The debug variables are displayed in the detailed Elevator Status Menu so that a mechanic view the variable and report back to the software engineer. The reset debug variables menu allows the mechanic to reset the variables to zero to aid in debugging. SD Card Read/Write Data – This menu item allows the user to read and write controller data to and from the SD Card. This menu is explained in detail in the next section. SD Card Status – This is the Secured Digital Card Status showing if the card has been initialized (Init=1), if it is standard or High Capacity (HC=1), and if it can operate at an acceptable voltage level (VStat=1). Load 1036 Field Variables – If replacing a TS‐5300 CPU board with a GALX‐1100 CPU board, the user can have the GALX‐1100 CPU read the Adjustable Field Variables from the 1036 board memory before removing the 1036 board. Load 1036 Hoistway Setup – If replacing a TS‐5300 CPU board with a GALX‐1100 CPU board, the user can have the GALX‐1100 CPU read the Hoistway Setup Data from the 1036 board memory before removing the 1036 board. The Hoistway Data includes the floor position counts, the normal slowdown limit counts, the selector top and bottom counts, the DZU and DZD distances, the up and down floor level distances, the floor offset values, the speed clamp data, the car call security mask, the load weigher setup data and the service timers. P a g e | 449 Appendix C – GALX-1100 CPU Below is a list of the Software Utilities menu items and the function of each menu: SD Card Read/Write Data The SD Card Read/Write Data Menu give the user the ability to store, retrieve and transfer controller data, to and from the controller, the SD Card and to a PC or Laptop. The SD Card Read/Write Data menu is shown below: Write Field Variables – Write Adjustable Field Variables to a text file, fvars.txt, on the SD Card. Read Field Variables – Read Adjustable Field Variables from the text file, fvars.txt, on the SD Card. Write Job Setup Data – Write the job setup data to the setup.txt file on the SD Card. The job setup data includes the speed clamp data, car call security mask and load weigher setup data. Read Job Setup Data – Read the job setup data from the setup.txt file on the SD Card. Write Hoistway Data – Write the learned hoistway data to the hoistway.txt file on the SD Card. The hoistway data includes the floor position counts, the normal slowdown limit counts, the selector top and bottom counts, the DZU and DZD distances, the up and down floor level distances, and the floor offset values. Read Hoistway Data – Read the hoistway data from the hoistway.txt file on the SD Card. Write Service Timers – Write the service timer tables to the SD Card file, svctmr.txt. Read Service Timers – Read the service timer tables from the SD Card file svctmr.txt. Write Security Data – Write the security data to the security.txt file on the SD Card. This data is the codes tables for each floor for the Push Button Car Call Security option. There are 200 codes per floor. Read Security Data – Read the security data from the security.txt file on the SD Card. Write Fault Log – Write the detailed fault data from the standard 50 fault buffer to the SD Card file fault.txt. Write Long Term Fault Log – Write the long term detailed data to the SD Card file ltfault.txt. Each time a fault occurs, the fault data is stored in the 50 fault buffer and in the long term fault buffer. The long term fault buffer stores the data for 600 faults in a circular buffer that cannot be erased. Since there is so much data, the only way to view the data is by writing the fault data to the SD Card, copying the data to a PC or Laptop and then viewing the data with Note Pad or Word Pad. P a g e | 451 Appendix C – GALX-1100 CPU Below is a list of the “SD Card Read/Write Data” menu items and the purpose of each menu. The files written to the SD Card are text files that can be viewed from a Windows text editor such as Note Pad or Word Pad. Below is an example of the “Write Field Variables” Menu. All other SD Card Read/Write Data menus function in a similar manner. The Detailed Fault Data includes additional information from the Safety Processor Board. The typical Detailed Fault would be written to the SD Card as follows: 3 Position Fault 11:18:06 6/05/2007 Position = 1 Occurrences = 1 srv=001, prc=015, drf=000, rdf=000, dpr=000, dir=000, emp=000, med=000 cbl=000, equ=000, fir=000, rfi=000, hsf=000, stf=000,cal=000, esp=000 nst=000, rlv=000, ste=001, pdo=000, st0=000,ins=00h, nds=000, dev=00h pf1=00h, pf2=00h, dv2=00h, io0=02h, io1=f0h, io2=0fh, io3=dch, io4=00h io5=e8h, io6=7fh, io7=84h,io8=3dh, io9=30h, ioA=d0h, ioB=21h, ioC=01h ioD=ffh, statusf=00000100h DPP Count = 4831446, Target = 815660, Dmd Vel = 0, Enc Vel =0 SPB Poscnt = 504433, SPB Serv = 0h, SPB Vel = 0, SPB Stat = 0h The additional Safety Processor data included in the fault log is described in the table below: P a g e | 453 Appendix C – GALX-1100 CPU Detailed Fault Data Detailed Fault Data Description SPB Poscnt Safety Processor Board Position Count Safety Processor Board Service: 0: Automatic SPB Serv SPB Vel 1: Car Top Inspection 2: Gate Bypass Operation 3: Lock Bypass Operation 4: Access 5: Motor Room Inspection 6: In Car Inspection 7: Inspection Error 8: Gate or Lock Bypass Err 9: Velocity Error 10: UP Error on pwrup 11: DNR Error on pwrup 12: Both UNI and DNI inputs 13: EEprom Error 14: No UTS error 15: No DTS error 16: Pulse Error 17: Unintended Motion Error Safety Processor Board Velocity in fpm Safety Processor Board Status: SPB Stat Bit 0: Secondary Fault Control (SFC Relay 0 = On) Bit 1: Pic Enable (SPB CPU 1=Okay) Bit 2: Leveling Speed Control (1=Speed < 150 fpm) Bit 3: Comm Fault (1=fault) Bit 4: Velocity Fault (1=fault) B it 5: Position Count Initialized (1=initialized) Bit 6: Active Fault (1=fault) Bit 7: Position Count updated (1=count updated)
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