Part: 4 - AA3
FIELD COMPONENT MANUAL
OTIS No.: GAA26800KFII_FC1
Vintage: 01 / 1
Engineering Center Start up Routine Page: 1/ 12
Berlin MCB III Date: 19-Mar-
GeN2
MCB III – GeN2
Startup Routine
Authorization Date D1: 01-Mar-2002
Running on PCB: GAA 26800 KF1
Software Version: GAA 30762 BAA
Document Revision :
Date Author Page Comment
14-Sep-2001 M. Mann all adapted from FOD-FE
13-Dec-2001 P. Walden all Revision
14-Jan-2002 [Link] all Revision
Copyright 2002, OTIS GmbH & Co. OHG Berlin. No part of this document may be copied or
reproduced in any form or by any means without the prior written consent of OTIS.
Part: 4 - AA3
FIELD COMPONENT MANUAL
OTIS No.: GAA26800KFII_FC1
Vintage: 01 / 1
Engineering Center Start up Routine Page: 2/ 12
Berlin MCB III Date: 19-Mar-
GeN2
Table of Contents
1 Requirements.............................................................................................. 3
2 First Inspection run ................................................................................. 3
2.1 Checking of voltages and inputs ................................................................................. 3
2.2 Check the CAN Bus .................................................................................................... 3
2.3 Fundamental Parameter Set up .................................................................................. 3
2.3.1 Contract Parameters (M - 3 - 1) ...................................................................... 4
2.4 Encoder adjustment .................................................................................................... 5
2.5 Check of Direction....................................................................................................... 6
3 Prepare first Normal run.......................................................................... 6
3.1 Adjustment of magnets ............................................................................................... 6
3.2 PRS2........................................................................................................................... 7
3.3 Learn run..................................................................................................................... 8
3.4 Load Weighing Calibration .......................................................................................... 9
3.4.1 Adjustment and Calibration ............................................................................. 9
3.4.2 Check of Measured Load .............................................................................. 10
3.4.3 Check of Sensors .......................................................................................... 10
3.4.4 Check of Start behavior................................................................................. 10
4 Final adjustment of position reference ................................................ 10
4.1 Profile parameters (M – 3 – 2) .................................................................................. 10
4.2 Vane parameters (M – 3 – 3) .................................................................................... 11
4.2.1 LV DLY UP and LV DLY DOWN (Adjustment of floor level) ......................... 11
4.2.2 1LS, 2LS (Adjustment of deceleration limit switch) ....................................... 11
4.3 Start / Stop Parameters (M – 3 – 4) .......................................................................... 11
5 Event logging ......................................................................................... 12
6 Parameter backup storage .................................................................... 12
Part: 4 - AA3
FIELD COMPONENT MANUAL
OTIS No.: GAA26800KFII_FC1
Vintage: 01 / 1
Engineering Center Start up Routine Page: 3/ 12
Berlin MCB III Date: 19-Mar-
GeN2
1 Requirements
Starting up of the WWOVF Drive - System should be performed only by authorisizied
personal!
The mechanical works of hoistway and cabine as well as the electrical installation in the
hoistway, controller and E&I Panel have to be finished to ensure inspection run.
The encoder have to be mounted at the machine and properly connected to the MCB.
2 First Inspection run
2.1 Checking of voltages and inputs
1) Switch the unit to ERO operation.
2) Switch on the main switch.
3) Check the power supply 110VAC (P1.8) and HL1 connection (P1.7) according to the
wiring diagram.
4) Check that the following inputs/outputs of the MCB have the correct voltage of 24VDC:
P4.8 (24V - output)
P4.7 (DBD - signal) in each case against P4.9 (HL2)
2.2 Check the CAN Bus
The MCB, TCBC and SPBC boards are communicating via a serial bus, the CAN bus. The
MCB gets its commands from the TCBC via the CAN bus. Note that MCB service tool
communication is only possible via SPBC plug and CAN-bus link.
Check the CAN LED on the MCB. This LED shows the following states:
LED off: CAN bus not working
LED blinking: CAN bus working
If the CAN bus does not work, the hardware connection has to be checked:
P6 Pin1 : VRS 30Vdc
P6 Pin2 : CAN_H
P6 Pin3 : CAN_L
P6 Pin4 : HL2
2.3 Fundamental Parameter Set up
Connect a service tool to the SPBC and establish connection to the MCB3.
Normally all parameters are factory-preadjusted. To run the car in ERO- or INS-Mode only
an Encoder Adjustment (see section below) has to be performed. For operation in "normal
mode" a Learn Run has to be performed before (see section below).
Part: 4 - AA3
FIELD COMPONENT MANUAL
OTIS No.: GAA26800KFII_FC1
Vintage: 01 / 1
Engineering Center Start up Routine Page: 4/ 12
Berlin MCB III Date: 19-Mar-
GeN2
Check the Status display on the service tool (M - 1 - 1). Only if there more events than
"M C: Encodr adj?" displayed you have to check especially the contract parameters.
2.3.1 Contract Parameters (M - 3 - 1)
SVT-Display Description
Con Spe[0.01m/s] Defined contract speed of the unit
Example: for contract speed = 1,60m/s Þ set Con Spe = 160
Con Nmot [rpm] Required motor r.p.m. to reach contract speed.
Describes a fixed relation to contract speed; considering roping, gear ratio and
sheave diameter.
Example: for Gen2 with contract speed = 1,60m/s Þ set Con Nmot = 611
Motor type Used motor type (pre-defined):
500:OPT 630x1.6 GeN2 PMSM w. embedded magnets; 630kgx1.6m/s
501:OPT 1000x1.6 GeN2 PMSM w. embedded magnets; 1000kgx1.6m/s
502:OPT 630x1.0 GeN2 PMSM w. embedded magnets; 630kgx1.0m/s
503:OPT 1000x1.0 GeN2 PMSM w. embedded magnets; 1000kgx1.0m/s
Note: for 800kg - duties the corresponding motor type for 1000kg must be used.
Sys Inert[g*m^2] total system inertia;
value should be factory-preadjusted depending on contract data.
Typical values are within the range of 0,5 - 2,5 kg⋅m (500 - 2500 g⋅m )
2 2
Encodertype Used encoder type (pre-defined):
4:Heid ERN461 Heidenhain "ERN461" encoder w. index pulse;
3600 ppr; 2 traces
For this baseline only this selection is possible.
LoadW type Using of Loadweighing device:
0:-none- no loadweighing available
3: analog LW Analog loadweighing(directly conncted to MCB; w/o. LWB)
Additional parameters for adjusting: see ‘Start/Stop' - parameters.
2LV avail One or two LV sensors used:
0: No only 1LV used
1: Yes 1LV and 2LV used (e.g. for RLEV)
DDP [s] DDP timeout value (set to default value of 20sec.)
Has to be increased according contract speed and floor distance if required.
TOP FLOOR Top position. Must match to TCBC system parameter "TOP".
Example: for a unit with 8 floors Þ set TOP FLOOR = 7
BOTTOM FLOOR Bottom position. Must match to TCBC system parameter "BOTTOM".
Should be 0 except for units within a group with different bottom floor numbers..
FLOORS IN 1LS Number of floors in 1LS (default = 1)
Exception: for 2 floors within 1LS area([Link] rise) Þ set FLOORS IN 1LS = 2
MCB operat. MCB operation mode:
0:Std. w. OCSS standard operation with OCSS (e.g. TCBC)
1:INS w/o OCSS INS / ERO without OCSS support
BrakeSWtype used Brake switch type:
3:2xNO separat two normally-open contacts wired separately (BS1 & BS2)
Note: for GeN2 this parameter is not changeable.
Motor Dir [0/1] Motor direction:
0: original
1: reversed profile direction and MCB speed direction encoding.
Must be toggled when car starts into other than expected direction.
Part: 4 - AA3
FIELD COMPONENT MANUAL
OTIS No.: GAA26800KFII_FC1
Vintage: 01 / 1
Engineering Center Start up Routine Page: 5/ 12
Berlin MCB III Date: 19-Mar-
GeN2
2.4 Encoder adjustment
The encoder adjustment has to be performed before the first (inspection) run.
The encoder has to be connected to plug P5 on MCB_III (a separate connector for this en-
coder type only). Check if the parameter Encodertype is properly set to 4.
The safety chain must normally be closed to perform the encoder adjustment. If this would
be possible only in ERO mode (e.g. open OS or UDLS contact) the encoder adjustment can
also be done in ERO mode (press UIB or DIB instead of switching to NOR; see below).
No passengers in car are allowed during encoder adjustment.
The adjustment is started in SVT menu ”EncAdj” (M – 4 – 2):
wait NOR/UIB/DIB switch to ”NORMAL” on ERO-Box
If this is not possible: press UIB or DIB
Switch to ERO switch on ”ERO” on ERO-Box
Release UIB/DIB
To start encoder press <ENTER> on Service Tool
adj. press ENTER
Switch NOR or switch back to ”NORMAL” on ERO-Box
press UIB/DIB If this is not possible: press UIB or DIB
Adjusting... The car starts with the adjusting procedure.
The adjusting is finished after approx. 20 sec.
When the adjustment has finished successfully,
Adjusting... Switch back to ERO or release UIB / DIB
Switch to ERO to prevent the car from running immediately
after adjusting.
Adjust finished Adjustment has finished w/o any error.
successfully The drive is now ready for any run.
Adjustment was aborted by an error condition
Adjust aborted! (see error message xxxxxxx).
xxxxxxx After solving the possible problem the
adjustment has to be started over again.
After success the operation in INS/ERO mode should be possible now.
Part: 4 - AA3
FIELD COMPONENT MANUAL
OTIS No.: GAA26800KFII_FC1
Vintage: 01 / 1
Engineering Center Start up Routine Page: 6/ 12
Berlin MCB III Date: 19-Mar-
GeN2
2.5 Check of Direction
After setting the contract parameters and encoder adjustment you should check the run
direction with the ERO-Buttons.
For INS- or ERO- operation the MCB needs the input signals UIB or DIB (M – 1 – 2 –
GOON).
By pushing of UIB- or DIB-buttons the motor should start.
The main contactors SW and BR will be activated. The activation is done by the MCB in
conjunction with UP- or DOWN- signals if the safety chain is closed. At the same time the
DBD-input will be inactive.
The status of the drive can be controlled via Service Tool (M – 1 – 1).
If the run direction is not the same as the wanted direction do the following:
• check if the displayed SVT status direction (e.g. INS_UP) matches to the pressed button
(e.g. UIB). For mismatch: check the wiring from ERO-box to UIB / DIB-inputs for
possible swapping.
• if direction on SVT is OK but the car moves into the opposite direction: change the
Contract parameter Motor Dir [0/1] from 0 to 1 or vice versa (Default = 0).
Note: do not swap any motor phase wires to change direction. Otherwise the car would
perform an uncontrolled movement during run. A new encoder calibration would be
necessary.
If the car does not move at all the possible error is displayed in the status display.
If Shut Down (SHT DWN) is displayed please check the Error logging (ErrLog)
(M – 2 – 2 – 1 – GOON).
By switching OFF / ON of the main switch in several shutdown cases a possible drive
blocking can be cancelled.
3 Prepare first Normal run
3.1 Adjustment of magnets
Magnets with a length of 250 mm can be used. At shorter landings you have to consider
that the distance between door zones must be at least 180 mm. Otherwise the door zones
can not be separareted with normal speed.
Part: 4 - AA3
FIELD COMPONENT MANUAL
OTIS No.: GAA26800KFII_FC1
Vintage: 01 / 1
Engineering Center Start up Routine Page: 7/ 12
Berlin MCB III Date: 19-Mar-
GeN2
3.2 PRS2
Requirements: Floating tape and sensor head have to mounted according instructions and
the magnets are to be located at the same level in each landing (to related
to the hoistway door sill)
Length of magnet: - 250 mm (1LV, 2LV)
- as stop distance (1LS, 2LS)
2LS magnet
Floor level
Top Floor
DZ magnet
Tape
Sensor Unit
12mm 2LS
UIS
SAC1
DZI
1LV
250mm 30mm
2LV
Floor level
DIS SAC2
DZ magnet
1LS
DZ magnet
Floor level
Bottom Floor
1LS magnet
Part: 4 - AA3
FIELD COMPONENT MANUAL
OTIS No.: GAA26800KFII_FC1
Vintage: 01 / 1
Engineering Center Start up Routine Page: 8/ 12
Berlin MCB III Date: 19-Mar-
GeN2
3.3 Learn run
The learn run has to be performed before the first normal run.
The parameters ''TOP FLOOR' and 'FLOORS IN 1LS' have to be set correctly.
The learn run can be started inside the lowest LV zone or at any other position
outside the 1LS switch.
The car runs with fast speed down to the lowest LV zone and then it runs with 15 cm/s
up to the highest LV zone.
The drive stores the distances between the LV zones and the length of all LV zones.
In case of two LV switches the inner door zone is stored.
To avoid trouble with passengers switch off the door operator (e.g. by DDO) and disable
hall calls (e.g. by CHCS).
The learn run is started in SVT menu ”Learn” (M – 4 – 1):
wait for NORMAL switch to ”NORMAL” on ERO-Box
Switch to ERO switch on ”ERO” on ERO-Box
To start learn- press <ENTER> on Service Tool
run press ENTER
Switch back to switch back to ”NORMAL” on ERO-Box.
NORMAL
Learn active nn The car starts with the learn run procedure.
xxxxxxxx If necessary, a correction run is made before.
nn: floor counter
xxxxxxx: information about possible events
Learn finished Learn run has finished w/o any error.
successfully The drive is now ready for normal run.
Learn run has been aborted by an error condition
Learn aborted! (see error message xxxxxxx).
xxxxxxx After solving the possible problem the
learn run has to be started over again.
Part: 4 - AA3
FIELD COMPONENT MANUAL
OTIS No.: GAA26800KFII_FC1
Vintage: 01 / 1
Engineering Center Start up Routine Page: 9/ 12
Berlin MCB III Date: 19-Mar-
GeN2
3.4 Load Weighing Calibration
Check the discrete wiring from the load weighing system to the MCB_III (Plug 3).
P6 Pin1 : VRS 30Vdc
P3 Pin1 : 24V_LW (derived from VRS, load sensors may use another 24V supply)
P3 Pin2 : analog sensor value
P3 Pin3 : analog sensor value
P3 Pin4 : HL2
Inspect all equipment for signs of damage, loose connections or other defects.
3.4.1 Adjustment and Calibration
Adjustment and calibration of the load weighing system is done by Parameter Setup (MCB)
via SVT and has to be performed in the following sequence:
I. Setup the parameters
II. Perform offset calibration
III. Perform gain calibration
I. Parameter Adjustment (MCB)
Before setting the loadweighing parameters the contract parameter
"LoadW type" (M-3-1-GOON) has to be set to "3: analog LW".
Loadweighing parameters (located under Start / Stop parameter menu; M-3-4-GOON):
SVT-Display Description
FULL LOAD [kg] Nominal full load of car in [kg] (e.g. 630 or 1000)
BALANCE [%] Nominal counterweight balance setting in [%] (e.g. 47)
LNS threshold[%] Above this load the load status "LNS" is sent to the TCBC.
ALWcomp Corr [%] Correction factor for internally calculated loadweighing compensation torque.
Can be modified when there are still slightly start rollbacks after calibration.
II. Offset Calibration
The offset calibration can be done in every floor. Preference is given to the ground floor. It
has to be performed with empty car.
SVT Sequence: M - 4 - 3 - 1 - ENTER
If the calibration is finished correctly, "done" is displayed. In case of "failed" the failure rea-
son is displayed.
III. Gain Calibration
The gain calibration has to be done in the same floor as the offset calibration but with the
car full loaded.
The value of the gain calibration load in kg is asked by the Service Tool menu.
Enter (<M> <4> <3> <2> <Load [kg]> ENTER) the actual load value according to the load
placed in the car.
If the calibration is finished correctly, "done" is displayed. In case of "failed" the fail-
ure reason is displayed.
Part: 4 - AA3
FIELD COMPONENT MANUAL
OTIS No.: GAA26800KFII_FC1
Vintage: 01 / 1
Engineering Center Start up Routine Page: 10/ 12
Berlin MCB III Date: 19-Mar-
GeN2
3.4.2 Check of Measured Load
The load measurement result can be checked by the MCB Service Tool menu:
M - 2 - A (shift 4).
3.4.3 Check of Sensors
The second row shows the two analog to digital converted values of the load sensors.
For empty car they have to be inside the range 5<value<150.
3.4.4 Check of Start behavior
If the load weighing works correctly the check can be done as well in normal as in inspec-
tion mode:
• Increase the parameter "PROF DLY [10ms]" (M-3-4) to 200.
• Select the parameter "ALWcomp Corr [%]" (M-3-4-goon..).
• The rollback or roll forward is faded into the display in [mm]. If no rollback or roll forward
occurs, the display remains unchanged.
• The parameter "ALWcomp Corr [%]" can be modified to remove the rollback and roll
forward.
• Decrease the parameter "PROF DLY [10ms]" to its original value.
4 Final adjustment of position reference
Hint: before normal runs can be done the DCS Run ( TCB-Menu DCS-Run, (M – 1 – 3 – 5)
has to be performed.
4.1 Profile parameters (M – 3 – 2)
Adjust all parameters as decribed below if necessary.
SVT-Display Description
INS SPE[0.01m/s] Speed at inspection run (max. 0,63m/s).
Example: for inspection run with 0,5m/s Þ set INS SPE = 50
NOM SPE[0.01m/s] Nominal speed at constant run (normally set to "Con Spe").
Can be used to reduce nominal speed for test purposes.
Example: to run a 1,6m/s -unit at half speed Þ set NOM SPE = 80
REL SPE[0.01m/s] Relevelling speed.
The releveling speed should be 2...3 [0.01m/s].
CRE SPE[0.01m/s] Creep speed.
The creep speed should be 6...8 [0.01m/s]
2
ACC [0.01m/s^2] Acceleration rate (max. 1,2m/s ).
Can be decreased indepently from nominal speed or deceleration.
2
Example: for an acceleration rate of 0,5m/s Þ set ACC = 50 [0.01m/s²]
2
DEC [0.01m/s^2] Deceleration rate (max. 1,2m/s ).
Can be decreased indepently from nominal speed or acceleration.
2
Example: for a deceleration rate of 0,5m/s Þ set DEC = 50 [0.01m/s²]
Part: 4 - AA3
FIELD COMPONENT MANUAL
OTIS No.: GAA26800KFII_FC1
Vintage: 01 / 1
Engineering Center Start up Routine Page: 11/ 12
Berlin MCB III Date: 19-Mar-
GeN2
4.2 Vane parameters (M – 3 – 3)
Before adjusting the vane parameters (hoistway signals), an (inspection-) run through all
hoistway signals should be done.
The switching of 1LV, 2LV 1LS and 2LS switches should be watched with the Service Tool
(M – 1 – 2 – GOON).
After this test the vane-parameters should be adjusted (hoistway variable).
The next step is to search a “reference floor” in the middle of the hoistway.
4.2.1 LV DLY UP and LV DLY DOWN (Adjustment of floor level)
Check the floor level in down- and up-direction in the ”reference floor”.
Leveling inaccuracy can be cancelled by adjusting the parameters LV DLY UP [mm] (Stop
after previous run in up-direction) and LV DLY DOWN [mm] (Stop after previous run in
down-direction).
If the car stops too early (before level), this value has to be higher
(+ leveling inaccuracy in [mm]).
If the car stops too late (after level), this value has to be lower
(- leveling inaccuracy in [mm]).
Note: these parameters affect the level accuracy for every landing. If the magnets are
placed correctly at each floor, the car should stop now correctly at each landing, otherwise
the magnets should be replaced accordingly.
4.2.2 1LS, 2LS (Adjustment of deceleration limit switch)
The deceleration rate at a correction run initiated by 1LS or 2LS is constant (1.2 m/s) and
independent from the parameter DEC. If a normal run is decelerated by 1LS or 2LS the
parameter 1LS DLY or 2LS DLY has to be increased. After increasing 1LS DLY or 2LS DLY
a correction run has to be performed (move the car in ERO-mode outside the doorzone and
switch back to NORMAL). The creep time at a correction run has to be more than 500 ms.
4.3 Start / Stop Parameters (M – 3 – 4)
Adjust all parameters as decribed below if necessary.
SVT-Display Description
PROF DLY [10ms] delay from BS1/BS2 feedback (brake lifted) to start of speed profile.
Adjust so that the speed profile starts after the brake has completely lifted.
For testing of start jerk behaviour this parameter can be set temporarly to a high
value.
RMP DWN T2[10ms] Ramp down period.
During this time the speed profile is reduced from creep speed to zero.
DRP BK DLY[10ms] Drop brake delay. Starts at the same time when the ramp down time starts.
Adjust so that the brake becomes effective after the drive has stopped electrically.
EL HLT PER[10ms] Electrical halt period.
After the ramp down period the drive is still powered by the inverter.
Adjust so that the brake becomes mechanical effective within this period.
DEMAG PER [10ms] Demag period (torque current rampdown) after brake has dropped (for noise re-
duction).
A value of 0 will switch off motor current immediately (fast but noisy).
Part: 4 - AA3
FIELD COMPONENT MANUAL
OTIS No.: GAA26800KFII_FC1
Vintage: 01 / 1
Engineering Center Start up Routine Page: 12/ 12
Berlin MCB III Date: 19-Mar-
GeN2
5 Event logging
Possible events stored in the event logging are not necessarily reasons for shutdown
and / or callbacks.
These events are described in detail in chapter ”Service Tool User Guide”.
All logged events can be cleared by SVT: M - 2 - 2 - 2 - <SHIFT-5>.
If the drive is blocked by an occurrence of too many fatal events this will be displayed on
SVT after pressing the M key.
By pressing <SHIFT-5> the drive blockage can be cleared.
Saved events (logged before the last power-down) can be found in the menu ”Saved” (M –
2 – 2 – 2).
Normally no failures should be registered in the event logging.
6 Parameter backup storage
The actual parameter setting can be stored into an EEPROM backup area by pressing
M – 3 – 7 on the SVT.
The previously (in the backup area) stored parameter settings can be reloaded by pressing
M – 3 – 8 on the SVT.
In addition it is helpful to have a hardcopy backup of the actual parameter settings stored in
the E&I-panel.