VVVF DRIVE TRACTIONELEVATOR CONTROLLER

MANUAL

GAL Manufacturing Corp50 E 153rd StreetBronx NY 10451

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FORWARD

G.A.L. has developed this manual with usabilityand safety in mind. General and specific safetynotices and precautions are defined in the manual.However, G.A.L. cannot be responsible for anyinjury to persons or damage to property (includingthe elevator equipment) resulting from negligence,misuse of the equipment, misinterpretation ofinstructions included in this manual, or due to anyother cause beyond the control of G.A.L.

All drawings, illustrations and information hereinare the proprietary property of G.A.L. and mustnot be made public or reproduced by anyindividual or entity other than the purchaser hereofwithout the express written permission of G.A.L.

(REV. April, 2008)

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TABLE OF CONTENTS

IMPORTANT WARNINGS AND NOTES ...................................................... VII

1 GENERAL PRODUCT DESCRIPTION......................................................81.1 INTRODUCTION .................................................................................................................. 81.2 PHYSICAL LAYOUT OF THE CONTROLLER..................................................................... 9

1.2.1 TYPICAL PHYSICAL LAYOUT........................................................................................ 91.3 SELECTOR SYSTEM ........................................................................................................ 11

1.3.1 TAPE SELECTOR SYSTEM ......................................................................................... 111.3.2 TAPELESS SYSTEM .................................................................................................... 121.3.3 SECONDARY SPEED FEEDBACK............................................................................... 13

1.4 MODES OF OPERATION .................................................................................................. 141.4.1 OPERATING SEQUENCE ............................................................................................ 141.4.2 RESET MODE............................................................................................................... 141.4.3 SAFETY STRING OPEN MODE ................................................................................... 151.4.4 CONTROLLER INSPECTION MODE............................................................................ 151.4.5 CAR TOP INSPECTION MODE.................................................................................... 151.4.6 ACCESS MODE............................................................................................................ 151.4.7 INDEPENDENT SERVICE MODE................................................................................. 161.4.8 LOAD WEIGHING BYPASS MODE .............................................................................. 161.4.9 ATTENDANT SERVICE MODE..................................................................................... 161.4.10 CODE BLUE HOSPITAL SERVICE MODE ................................................................ 171.4.11 FIRE SERVICE PHASE I MODE ................................................................................ 171.4.12 FIRE SERVICE PHASE I ALTERNATE RETURN MODE........................................... 171.4.13 FIRE SERVICE PHASE II MODE ............................................................................... 181.4.14 EMERGENCY POWER .............................................................................................. 181.4.15 EARTHQUAKE MODE ............................................................................................... 181.4.16 STALLED MODE ........................................................................................................ 191.4.17 AUTOMATIC MODE................................................................................................... 19

2 INSTALLATION OF THE GALAXY CONTROLLER................................202.1 GENERAL INFORMATION ................................................................................................ 202.2 SITE SELECTION .............................................................................................................. 202.3 ENVIRONMENTAL CONSIDERATIONS............................................................................ 202.4 WIRING GUIDELINES AND INSTRUCTIONS ................................................................... 20

2.4.1 THE WIRING PRINTS .................................................................................................. 202.4.2 GROUND WIRING........................................................................................................ 202.4.3 HOISTWAY WIRING .................................................................................................... 202.4.4 ELEVATOR CAR WIRING ............................................................................................ 202.4.5 MACHINE ROOM WIRING ........................................................................................... 212.4.6 WIRING TO TOP OF CAR SELECTOR........................................................................ 21

2.5 SLOWDOWN LIMITS......................................................................................................... 212.6 NORMAL AND FINAL LIMIT SWITCHES .......................................................................... 212.7 SELECTOR INSTALLATION ............................................................................................. 23

2.7.1 TAPE SELECTOR INSTALLATION .............................................................................. 232.7.2 TAPELESS SELECTOR INSTALLATION ..................................................................... 29

3 ADJUSTMENT OF THE GALAXY CONTROLLER HPV 900/HPV 600DRIVE............................................................................................................34

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3.1 GENERAL SETUP ............................................................................................................. 343.2 INITIAL POWER-UP .......................................................................................................... 34

3.2.1 CHECK MAIN LINE VOLTAGE ..................................................................................... 343.2.2 SET TOGGLE SWITCHES ........................................................................................... 343.2.3 MAKE SURE THE CAR IS SAFE .................................................................................. 343.2.4 CHECK CONTROLLER VOLTAGE............................................................................... 343.2.5 VERIFY THE LCD GALaxy IS BLINKING...................................................................... 343.2.6 PRESET ADJUSTABLE VARIABLES ON SAFETY PROCESSOR BOARD ................. 343.2.7 PLACE STOP SWITCH IN RUN POSITION ................................................................. 353.2.8 HOIST MOTOR DATA .................................................................................................. 353.2.9 PRE-SET THE DIGITAL SPEED CLAMPS ................................................................... 35

3.3 RUN THE CAR ON INSPECTION ...................................................................................... 363.3.1 READY TO RUN ON INSPECTION .............................................................................. 363.3.2 ADJUST THE BRAKE VOLTAGE ................................................................................. 373.3.3 CHECK THE RUN DIRECTION .................................................................................... 373.3.4 CAR RUNS THE WRONG DIRECTION........................................................................ 383.3.5 DRIVE TRIPS IMMEDIATELY....................................................................................... 383.3.6 CAR RUNS EXTREMELY SLOW.................................................................................. 393.3.7 CHECK INSPECTION SPEED ...................................................................................... 393.3.8 VERIFY CONTROLLER ENCODER DIRECTION......................................................... 393.3.9 VERIFY SELECTOR AND SLOWDOWN INPUTS........................................................ 403.3.10 VERIFY CAR SPEED ON SAFETY PROCESSOR BOARD ....................................... 40

3.3.10.1 CORRECT CAR SPEED WHEN USING A TAPE............................................................................................................................403.3.10.2 CORRECT CAR SPEED WHEN USING AN ENCODER ................................................................................................................40

3.3.10.2.1 INCREMENTAL ENCODER 1028 BOARD ..............................................................................................................................413.3.10.2.2 ABSOLUTE ENCODER 1066 BOARD ......................................................................................................................................41

3.4 LEARN THE HOISTWAY ................................................................................................... 413.5 FINAL ADJUSTMENT........................................................................................................ 42

3.5.1 AUTOMATIC RUN ........................................................................................................ 423.5.2 DRIVE ADAPTIVE TUNE.............................................................................................. 423.5.3 FINE TUNE THE RIDE QUALITY.................................................................................. 423.5.4 ADJUST THE STOP ..................................................................................................... 433.5.5 ADJUST THE START ................................................................................................... 443.5.6 VERIFY TOP SPEED.................................................................................................... 443.5.7 ADJUST SAFETY PROCESSOR BOARD SPEED CLAMPS ........................................ 443.5.8 ADJUST DIGITAL SLOWDOWN SPEED CLAMPS ...................................................... 443.5.9 VERIFY INSPECTION VELOCITY CLAMP ON SAFETY PROCESSOR BOARD......... 453.5.10 ANALOG LOAD WEIGHER SETUP ........................................................................... 45

3.5.10.1 EMPTY CAR sETUP .........................................................................................................................................................................453.5.10.2 FULL CAR SETUP ............................................................................................................................................................................463.5.10.3 LOAD WEIGHING CALIBRATION SEQUENCE............................................................................................................................46

3.5.11 ADJUST THE MOTOR PRE-TORQUE....................................................................... 463.5.12 VERIFY THE DOORS ARE SAFE .............................................................................. 463.5.13 FINE TUNE THE RIDE QUALITY ............................................................................... 46

4 TROUBLESHOOTING.............................................................................474.1 GENERAL INFORMATION ................................................................................................ 474.2 MICROPROCESSOR CPU ................................................................................................ 474.3 INPUT/OUTPUT BOARDS................................................................................................. 474.4 RUN SEQUENCE............................................................................................................... 494.5 THE SAFETY PROCESSOR BOARD................................................................................ 504.6 SYSTEM FAULTS.............................................................................................................. 52

4.6.1 MAIN CPU FAULTS ...................................................................................................... 524.6.2 DETAILED FAULT DATA.............................................................................................. 974.6.3 SAFETY PROCESSOR FAULTS ................................................................................ 103

v5 LCD DISPLAY INTERFACE ..................................................................1065.1 OPERATING THE LCD INTERFACE............................................................................... 1065.2 THE LCD MENU STRUCTURE........................................................................................ 108

5.2.1 SET DATE AND TIME................................................................................................. 1095.2.3 ADJUSTABLE VARIABLES......................................................................................... 1105.2.4 JOB STATISTICS ....................................................................................................... 128

5.2.4.1 VIEW JOB STATISTICS .................................................................................................................................................................1295.2.4.2 CLEAR JOB STATISTICS...............................................................................................................................................................131

5.2.5 INPUTS AND OUTPUTS............................................................................................. 1325.2.5.1 CAR INPUTS AND OUTPUTS .......................................................................................................................................................1335.2.5.2 GROUP INPUTS AND OUTPUTS ..................................................................................................................................................134

5.2.6 SET CALLS AND LOCKOUTS.................................................................................... 1355.2.6.1 SETUP CAR CALLS........................................................................................................................................................................1355.2.6.2 SETUP DOWN hALL CALLS .........................................................................................................................................................1375.2.6.3 SETUP UP HALL CALLS................................................................................................................................................................1385.2.6.4 LOCKOUT FRONT CAR CALLS ...................................................................................................................................................1385.2.6.5 LOCKOUT REAR CAR CALLS......................................................................................................................................................139

5.2.7 ELEVATOR STATUS .................................................................................................. 1415.2.8 FAULT LOG ................................................................................................................ 144

5.2.8.1 VIEW FAULT LOG..........................................................................................................................................................................1455.2.8.2 CLEAR FAULT LOG.......................................................................................................................................................................146

5.2.9 ELEVATOR SETUP .................................................................................................... 1475.2.9.1 SET SPEED CLAMPS .....................................................................................................................................................................1485.2.9.2 AUTOMATIC LEARN HOISTWAY ...............................................................................................................................................1495.2.9.3 INSPECTION LEARN HOISTWAY................................................................................................................................................1505.2.9.4 OVERSPEED TEST.........................................................................................................................................................................1515.2.9.5 CAR AND COUNTERWEIGHT BUFFER TEST............................................................................................................................1525.2.9.6 INSPECTION OPEN/CLOSE DOOR ..............................................................................................................................................1535.2.9.7 LOAD WEIGHER SETUP ...............................................................................................................................................................154

5.2.9.7.1 SETUP LOAD WEIGHER ...........................................................................................................................................................1555.2.9.7.2 VIEW/MODIFY LW SETUP .......................................................................................................................................................1565.2.9.7.3 VIEW/MODIFY LOAD LIMITS..................................................................................................................................................1575.2.9.7.4 LOAD WEIGHER CALIBRATION.............................................................................................................................................158

5.2.9.8 RESET GRIPPER FAULT ...............................................................................................................................................................1595.2.9.9 LIFT BRAKE ON INSPECT ............................................................................................................................................................160

5.2.10 DISPLAY HOISTWAY TABLES................................................................................ 1615.2.11 SELECT VIDEO DISPLAY........................................................................................ 1625.2.12 SOFTWARE VERSION ............................................................................................ 1635.2.13 DIAGNOSTICS......................................................................................................... 164

5.2.13.1 VIEW SYSTEM STATUS LOG.......................................................................................................................................................1655.2.13.2 CLEAR SYSTEM STATUS LOg.....................................................................................................................................................1665.2.13.3 GROUP COMM STATUS ...............................................................................................................................................................1675.2.13.4 CLEAR GROUP COMM STATUS..................................................................................................................................................1685.2.13.5 CAR COMM STATUS.....................................................................................................................................................................1695.2.13.6 CLEAR CAR COMM STATUS.......................................................................................................................................................1705.2.13.7 DRIVE COMM STATUS.................................................................................................................................................................1715.2.13.8 CLEAR DRIVE COMM STATUS ...................................................................................................................................................172

6 SAFETY PROCESSOR LCD DISPLAY INTERFACE............................1736.1 OPERATING THE LCD INTERFACE............................................................................... 1736.2 THE SAFETY PROCESSOR BOARD LCD MENU STRUCTURE.................................... 175

6.2.1 ELEVATOR SERVICE................................................................................................. 1766.2.2 CAR SPEED................................................................................................................ 1776.2.3 CAR COM (SPB TO CPU) .......................................................................................... 1776.2.4 ENCODER COMMUNICATIONS (Tapeless Selector)................................................. 1786.2.5 ENCODER STATUS (Tapeless Selector).................................................................... 1786.2.6 SAFETY PROCESSOR PULSE COUNT .................................................................... 1796.2.7 SAFETY PROCESSOR ADJUSTABLE VARIABLES .................................................. 1806.2.8 SAFETY PROCESSOR INPUTS AND OUTPUTS ...................................................... 1846.2.9 LIMIT VELOCITY ........................................................................................................ 1876.2.10 SAFETY PROCESSOR FAULTS.............................................................................. 188

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6.2.11 CLEAR FAULTS ....................................................................................................... 1926.2.12 RESET SAFETY PROCESSOR FAULT LATCH....................................................... 1926.2.13 SAFETY PROCESSOR BOARD TEMPERATURE................................................... 1936.2.14 EXTERNAL TEMPERATURE ................................................................................... 193

APPENDIX A ...............................................................................................194Description of I/O Mnemonics ................................................................................................. 194I/O Locations............................................................................................................................. 198

APPENDIX B ...............................................................................................213Overspeed Test......................................................................................................................... 213Buffer Test................................................................................................................................. 214Normal Terminal Slowdown Test ............................................................................................ 215Emergency Terminal Limit Test............................................................................................... 216Reset Gripper Fault or Emergency Brake Fault...................................................................... 217

APPENDIX C ...............................................................................................218G.A.L. Factory Preset HPV 900 Drive Parameters .................................................................. 218

CONFIGURE C0 PARAMETERS............................................................................................. 218ADJUST A0 PARAMETERS .................................................................................................... 219UTILITY U0 PARAMETERS..................................................................................................... 224

APPENDIX D ...............................................................................................225G.A.L. Factory Preset HPV 600 Drive Parameters .................................................................. 225

CONFIGURE C0 PARAMETERS............................................................................................. 225ADJUST A0 PARAMETERS .................................................................................................... 227UTILITY U0 PARAMETERS..................................................................................................... 232

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IMPORTANT WARNINGS AND NOTES

The label WARNING denotes operatingprocedures and practices that may result inpersonal injury and/or equipment damage if notcorrectly followed.

The label Note denotes procedures, practices orinformation which is intended to be immediatelyhelpful and informative.

WARNING: Installation and wiring must be inaccordance with the national electrical code, alllocal codes, and elevator codes and regulations.The 3 phase A.C. power supply to the equipmentmust come from a properly fused disconnect orcircuit breaker (not capable of delivering more that10,000 rms symmetrical amperes). Impropermotor branch circuit protection will void warrantyand may create a hazardous condition.

WARNING: Wiring to the controller terminalsmust be done in a careful, neat manner. Strandedwire conductors must not have strands left out ofthe terminals. Leaving strands of wire out of theterminals creates potential shorts. All terminalsand cable connectors must be seated properly. Flatcable connectors pin #1 (arrow symbol onconnector) must match the red stripe on the cable.

WARNING: Elevator control products must beinstalled by experienced field personnel. Thismanual does not address code requirements. Thefield personnel must know all the rules andregulations pertaining to the safe installation andrunning of elevators, and local codes.

WARNING: This equipment is an O.E.M.product designed and built to comply with ASME

A17.5 and national electrical code and must beinstalled by a qualified contractor. It is theresponsibility of the contractor to make sure thatthe final installation complies with any local codesand is installed safely.

WARNING: Proper grounding is vitallyimportant to the safe and successful operation ofthis system. Bring a separate ground wire for eachcontroller from the building ground to the groundlug on the controller. You must choose the properconductor size and minimize the resistance toground by using shortest possible routing. SeeNational electrical code article 250-95, or therelated local applicable code.

WARNING: Use only the correct rated fusingfor controller protection. Use of over rated fusingwill void the warranty.

NOTE: Every precaution, whether specificallystated here or not, should be taken when installing,adjusting or servicing any elevator. Common sensesafety precautions should be followed to make surelife and limb of the service person and public is notendangered.

NOTE: Keep the machine room clean. Do notinstall the controller in a dusty area. Do not installthe controller in a carpeted area. Keep roomtemperature between 32 F and 110 F. Avoidcondensation on the equipment. Do not install thecontroller in a hazardous location and whereexcessive amounts of vapors or chemical fumesmay be present. Make sure power line fluctuationsare within +/- 10 percent.

8S E C T I O N - 1

1 GENERAL PRODUCTDESCRIPTION

1.1 INTRODUCTION

The GALaxy traction elevator controller is acomputer-based system that offers superiorperformance, flexibility and reliability. It has beendesigned to save time in installation andtroubleshooting, but it is still very important thatthe field personnel who work with this equipmentfamiliarize themselves with this manual beforeattempting to install the equipment.

SPECIFICATIONS:Environment:

35 F to 110 F ambient12,000 ft altitude95% humidity

Standard Features:CSA B44.1-96 ASME A17.1-1996,

ASME 17.1-2000 CertifiedInspection Operation (car top andcontroller)Access OperationIndependent ServiceFire Service Phase IFire Service Phase I Alternate ReturnFire Service Phase IIEmergency PowerEarthquake ServiceOn Board Diagnostic LEDsOn Board LCD Display InterfaceTwo Motor Protection TimersDoor Motor Protection TimerSeveral Field Adjustable Parameters(Door Times, Lobby, etc.)Elevator Duty Rated Nema MotorStarters

Optional Features:Selective Rear DoorsAttendant ServiceCode Blue Hospital Service

SecurityRemote DiagnosticsEmergency Power

91.2 PHYSICAL LAYOUT OF THECONTROLLER

1.2.1 TYPICAL PHYSICAL LAYOUT

Figure 1.1 shows a typical layout of the GALaxycontroller in a standard G.A.L. cabinet. Below, is abrief description of each block:

1. 1038 Main Control Board: The maincontrol board contains input and outputdevices, controller switches, fuses andfield wiring terminal connections.

2. Safety Processor Board: The SafetyProcessor board uses a microprocessorand a PAL device to implement theindependent speed and redundancychecks required for A17.1-2000compliance. This board has its ownLCD display and parameters.

3. Main CPU: The computer board is asingle board IBM compatible computer.It executes the program and turns onand off the Inputs and Outputs.

4. LCD Display: The LCD display boardprovides a user interface to all controlleradjustment and setup parameters. It alsoshows diagnostic information.

5. Power Supply: The power supplyprovides power to the computer and itsperipheral boards. It is a 5 volt DC

regulated power supply rated at 3 ampswith over voltage, and short circuitprotection.

6. Dynamic Braking Resistors: Additionalspace for dynamic braking resistors andbrake resistors. Resistors may also bemounted in a separate enclosure on thetop, back, or side of the controller.

7. Options: This section of the controlleris provided to mount options such as theHall Call I/O board, job specific I/Oexpansion and a digital PI display driver.

8. Transformer: The system transformer islocated in the lower part of the cabinet.It is usually a 500VA building power to120 VAC transfer. It is used to convertthe building power to a lower voltage forthe signals and valve power.

9. Contactors: These are various contactorsused for the brake, brake cooling, andrun control.

10. Drive: Magnetek HPV 900, HPV 600 orGPD-515 VVVF Drive.

11. Motor Contactors: AC rated contactorsized for each specific job.

12. Ground Terminal: The ground terminalblock is where the earth ground isattached.

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Figure 1.1 Typical Physical Layout

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1.3 SELECTOR SYSTEM

The selector system for the GALaxy controllercan be either a tape system or tapeless one.

1.3.1 TAPE SELECTOR SYSTEM

The tape system uses a perforated steel tape thatis hung the length of the hoistway. A set ofmagnets are placed on the tape at each floorhaving one 8 magnet as the door zone magnet

and one to five smaller 2 magnets as binaryposition preset magnets. The selector ismounted on the car and is guided along the tapeby nylon guides to keep the tape and magnetsthe proper distance from the selector sensors.The controller uses the door zone magnet todetermine the elevators level position to thefloor. At the dead level position, the binarypreset inputs are read in to verify that the car isat the correct floor. A block diagram of the tapesystem is shown in figure 1.0.

Figure 1.0: Tape Selector

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1.3.2 TAPELESS SYSTEM

The tapeless system uses an absolute encodermounted on the governor and a four sensorselector on the car top to read the door zonemagnet for each floor. The door zone magnetsare placed in the corner of the rail.

The encoder is used for secondary speedfeedback and the absolute position of the car.The car position is read on power-up or anytime

the car would need to recover to a floor, such asbeing moved on inspection. The encoder iscoupled to a rotating shaft on the governor. Ifthe governor on the job does not have a rotatingshaft, it must be replaced with one that does.

The door zone sensors are used for exact floorposition on stop and re-leveling the car. Ablock diagram of the tapeless selector system isshown in figure 1.1.

Figure 1.1: Tapeless Selector

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1.3.3 SECONDARY SPEED FEEDBACK

With a tape system, the tape is perforated with 3/8inch holes every 3/8 of an inch. A sensor ismounted on the selector to provide a secondaryspeed feedback to the Safety Processor Board. Onthe tapeless system, the Safety Processor receivesposition information every 50 milliseconds fromthe absolute encoder and uses the change inposition to calculate velocity. In either case, theSafety Processor uses this velocity to verity that thecar is traveling at a safe speed when slowdownlimits are hit, when the car doors are open andwhen running on inspection.

There are two type of inputs used to verify the carspeed at the terminal landing. The UT & DTslowdown limits are always used to verify thevelocity of the car at the terminal landings. Theemergency slowdown limits UTS & DTS areused on traction cars greater than 200 fpm, tractioncars 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 cardown from the velocity check. For all controlsystems, the UT & DT limits are used to verifythe operation of UTS & DTS and vice versa.

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1.4 MODES OF OPERATION

1.4.1 OPERATING SEQUENCE

Normal elevator operation, Automatic Mode, isselective-collective. When the elevator is travelingupwards to answer calls, all up hall calls at floorsabove the car are answered in the order reached bythe car, regardless of the order in which the callswere registered. Upon reaching each landing witha car call or hall call registered, the car and halldoors at that floor are automatically opened.

The doors stay opened for a dwell time that is fieldadjustable. There are three different dwell timesdepending on whether it is a lobby call, car call, orhall call. The door will close before the set dwelltime has elapsed if a passenger presses the doorclose button. The door will reopen before it is fullyclosed if the door open button is pressed, if apassenger pushes on the safety edge, if the photo-eye light beam is interrupted, or if a call for thatfloor in the direction of travel is pushed. The doorwill close when the door opening condition iseliminated. When the door has fully closed, thecalls are answered.

When all up hall calls and car calls above the carhave been answered, the elevator reverses directionand travels downward to answer car calls anddown hall calls placed below the car. The calls areanswered as previously described for up calls.When all calls below a down car are answered, thecar 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 hallcalls.

In buildings with more than one elevator groupedtogether, the actual time of arrival, real time, isused to estimate how long each elevator will taketo answer a hall call. The elevator that can respondthe fastest takes the call. Real time baseddispatching permits the controllers to quicklyrespond to actual demand for elevator service.Some of the criteria used to estimate the time ofarrival are listed below.

Actual elevator floor to floor runtimes.

Actual run time to the floor whether itis a multi-floor run or a one floor run.

Whether the elevator is in or out ofservice.

Whether the elevator is in load weighbypass mode.

The direction and position of eachelevator in the group.

The average door cycle time at eachstop.

Status of each elevator, accelerating,full speed, decelerating, actual time inmotion.

Number of stops required due to carcalls.

Number of stops required due topreviously assigned hall calls.

System demand.

The above performance criteria is continuouslymeasured and stored for improved accuracy in thedispatching algorithm. All of the above data iscontinuously scanned and the hall calls arereassigned if the conditions change and another carcan respond faster. The ability to measure actualhall waiting time virtually eliminates long waitingand improves the average hall call waiting intervalsthroughout the building.

1.4.2 RESET MODE

Reset mode is initiated when the elevator power isfirst turned on, or when the system is reset. Whenthe reset mode is initiated, the controller programis automatically loaded, and internal tests are run toensure that both the car and controller are

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electrically operational before putting the car intoservice. The car will not move until reset mode iscompleted. Some of the tests are: is the safetystring made, is the elevator on inspectionoperation, is the door close limit open, are theinterlocks made up, and whether the controllerknows where the elevator car is within thehoistway. If all the safeties are made up, and theelevator is on automatic operation, and it is floorlevel, the elevator will go into automatic mode. Ifthe elevator is not at floor level, it will run slowspeed down to the nearest floor, level into thefloor, and reset the floor position count.

1.4.3 SAFETY STRING OPEN MODE

Safety string open mode is initiated when a safety isopen. Some of the safeties are listed below.

The reverse phase relay.

The top final

The bottom final

The pit switch

The car top stop switch

The governor overspeed switch

The safety operated switch

The Drive Ready relay

When the safety string is made back up, theelevator will go back to reset mode.

1.4.4 CONTROLLER INSPECTION MODE

The controller inspection mode is initiated byplacing the INS switch on the 1038 board in theinspection position (down). Controller inspectionmode permits operation of the car from themachine room. This mode performs the followingoperations:

Enables the controller inspectionUP and DOWN pushbuttons.

Door locks are active and must beclosed to move the car.

Pressing the controller UPpushbutton causes elevator to move atinspection speed in the up direction.

Pressing the controller DOWNpushbutton causes the elevator tomove at inspection speed in the downdirection.

1.4.5 CAR TOP INSPECTION MODE

This inspection mode is initiated by placing theinspection switch on top of the car in theinspection position. Inspection mode permitsoperation of the car from the car top inspectionstation. This mode performs the followingoperations:

Disables access top and access bottomhall switches. Disables the controllerinspection up and down pushbuttons.Enables the car top inspection stationup and down pushbuttons.

Door locks are active and must beclosed to move the car.

Pressing the inspection station up andsafe pushbuttons causes the elevator tomove at inspection speed in the updirection.

Pressing the inspection station downand safe pushbuttons causes theelevator to move at inspection speed inthe down direction.

1.4.6 ACCESS MODE

The access mode is initiated by placing the keyoperated access switch located in the car operating

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panel to the on position. Access mode allowsentrance into the hoistway by qualified andauthorized elevator maintenance personnel forequipment inspection and service. Access to thetop of the car is possible from the top landing, orto the pit from the bottom landing. Enabling thismode permits the following operation.

Enables the access key switches at thetop and bottom landing in theentrance door jambs.

Bypasses the gate switch to allow carmovement with the car door open.

Bypasses the top or bottom landinghall door lock, depending on whichterminal access switch is being keyed.

Turning the access key switch to theup position causes the elevator tomove at inspection speed in the updirection.

Turning the access key switch to thedown position causes the elevator tomove at inspection speed in the downdirection.

1.4.7 INDEPENDENT SERVICE MODE

The independent service mode is initiated byplacing the key operated independent switchlocated in the car operating panel to the onposition, or by placing the controller toggle switchIND to the down position. Independent modepermits operation of the car with an operator. Thismode performs the following operations:

Hall initiated calls are ignored.

Hall lanterns and gongs are disabled.

The doors open automatically and stayopen until closed by the operator.

Closing the doors requires constantpressure on the door close button.

When the car door is closed, the caranswers the nearest car initiated call inthe direction of travel.

1.4.8 LOAD WEIGHING BYPASS MODE

The load weighing bypass mode is initiated whenthe car is loaded to a predetermined percentage offull capacity, by closing a connection betweenterminals LC and LW. Load weigh bypassmode allows the car to answer car calls and lightenthe load before answering any more hall calls. Thismode performs the following operations:

Hall initiated calls are ignored.

All other elevator functions as if on fullautomatic service.

1.4.9 ATTENDANT SERVICE MODE

The attendant service mode is initiated by placingthe key operated attendant switch located in the caroperating panel to the on position. Attendantmode permits operation of the car with anattendant. This mode performs the followingoperations.

The doors open automatically and stayopen until closed by the attendant.

Closing the doors requires amomentary pressure on the door closebutton, or the up or down buttonslocated in the car operating panel.

Hall initiated calls are answered unlessthere is constant pressure on thebypass button.

Hall lanterns and gongs are enabled.

The direction of preference can bespecified by momentary pressure onthe up or down buttons located in thecar operating panel.

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1.4.10 CODE BLUE HOSPITAL SERVICEMODE

Code blue hospital service mode is initiated byturning one of the code blue switches, located ateach floor where medical emergency service isrequired, to the on position. A car is selected torespond to the code blue call. That car will performthe following:

Cancel all car calls

Any hall calls previously assigned willbe transferred to another car.

If traveling toward the code blue call, itwill proceed nonstop to the code bluecall floor.

If traveling away from the code bluecall, it will slow down and stop at thenearest floor, maintain doors closed,reverse direction and proceed nonstopto the code blue call floor.

If at a floor other than the code bluecall floor, the elevator will close thedoors and proceed nonstop to thecode blue call floor.

Once at the code blue call floor, thedoors will open and remain open.

The code blue in car switch located inthe car operating panel must then beturned to the on position. If the codeblue in car switch is not turned to theon position within 60 seconds fromthe time the doors reach full open onthe code blue call floor, the car willrevert back to normal operation.

Upon activation of the key switch, itwill allow the car to accept a car callfor any floor, close the doors, andproceed nonstop to the floor desired.

The return of the code blue in car keyswitch to the normal position willrestore the car to normal service.

1.4.11 FIRE SERVICE PHASE I MODE

Fire service phase I is initiated when the primarysmoke sensor is activated or the fire key switchlocated in the hall station on the primary returnfloor is turned to the on position. The primaryreturn floor is usually the lobby floor, but could beanother landing if it better serves the needs ofemergency personnel when fighting a fire orperforming rescues. When fire service phase I isenabled:

The fire emergency return lightilluminates and the fire buzzer sounds.

The emergency stop switch is disabledwhen the door closes.

The car travels to the primary returnfloor without answering any calls, thenparks with the door open. The firebuzzer turns off, but the fireemergency return light staysilluminated.

If the car is at a landing with the doorsopen, the doors will close, and the carwill return non-stop to the primaryreturn floor. If the car is travelingaway from the primary return floor,the car will stop at the next landing,then go immediately to the primaryreturn floor.

Turning the fire service key switch tothe bypass position will restore theelevator to normal service.

The elevator will perform per ASMEA17.1 section 211.3 unless otherwisespecified.

1.4.12 FIRE SERVICE PHASE I ALTERNATERETURN MODE

Fire service phase I alternate return is initiatedwhen the smoke sensor in front of the elevator atthe primary return floor is activated. When fireservice phase I alternate return is enabled:

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The fire emergency return lightilluminates and the fire buzzer sounds.

The emergency stop switch is disabledwhen the door closes.

The car travels to the alternate returnfloor without answering any calls, thenparks with the door open. The firebuzzer turns off, but the fireemergency return light staysilluminated.

If the car is at a landing with the doorsopen, the doors will close, and the carwill return non stop to the alternatereturn floor. If the car is travelingaway from the alternate return floor,the car will stop at the next landing,then go immediately to the alternatereturn floor.

Turning the fire service key switch thebypass position will restore theelevator to normal service.

The elevator will perform per ASMEA17.1 section 211.3 unless otherwisespecified.

1.4.13 FIRE SERVICE PHASE II MODE

To initiate fire service phase II, the car must firsthave been placed in fire service phase I, and, as aresult, be parked at the designated level with thedoor fully open. Following that, the key operatedfire service phase II switch, located in the caroperating panel must be placed in the on position.Fire service phase II permits operation of the carby a fire fighter. This mode performs operations inaccordance with ASME A17.1 as follows:

The doors close only with constantpressure on the door close button,after they have been fully opened.

The doors open only with constantpressure on the door open button,after they have been fully closed.

Hall lanterns and gongs are disabled.

Safety edge and electric eye aredisabled

All registered car calls can be canceledwith momentary pressure on the callcancel button located in the caroperating panel.

All hall calls are disabled.

To remove the car from fire servicephase II the car must be at the firereturn landing with the doors in thefull open position and the phase IIswitch turned to the off position.

See ASME A17.1 for specificoperation of fire service phase II.

1.4.14 EMERGENCY POWER

Emergency power is initiated when a connection ismade between terminals HC and EMP. Thismode performs the following operations:

All cars are returned to the bottomfloor one at a time, and remain therewith their doors open.

If a car is selected to run it will go backinto normal operation.

Removing the connection betweenterminals HC and EMP willremove the cars from emergencypower operation.

1.4.15 EARTHQUAKE MODE

Earthquake mode is initiated upon activation of aseismic switch or counterweight derailment switch.This mode performs the following operations:

If in motion, and the seismic switch isactivated, the car will decelerate intoslow speed, proceed to the nearest

19

available floor, open the doors andshut down.

If in motion, and the counterweightderailment switch is activated, and thecar is moving away from thecounterweight, then the car willdecelerate into slow speed, andproceed to the nearest available floor,open the doors and shut down.

If in motion, and the counterweightderailment switch is activated, and thecar is moving toward thecounterweight, then the car willperform an emergency stop, thenmove at slow speed away from thecounterweight to the nearest availablefloor. After stopping at the nearestfloor, the doors will open and the carwill shut down.

1.4.16 STALLED MODE

Stalled mode is initiated when the elevator hasbeen in run mode longer than the field adjustableanti-stall timer. This mode performs the followingoperations:

Shuts down the elevator.

Does not allow the elevator to restartuntil elevator is put on inspection ormain line switch is cycled.

The door open button remains active.

1.4.17 AUTOMATIC MODE

Since this is the normal operating mode, thecontroller automatically enters this mode if none ofthe previously described modes are activated, and ifno fault is detected. The following operations areperformed in automatic mode:

The car operates in selective-collectivecontrol sequence when answering calls.

Hall calls and car calls are functional.

Hall lanterns and gongs areoperational.

Simplex cars park at the last callanswered unless simplex lobby parkinghas been enabled in the program. In amulti-car group, a car is always parkedat the lobby if no other demand exists.

The doors remain closed when the caris parked.

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S E C T I O N 2

2 INSTALLATION OF THEGALaxy CONTROLLER

2.1 GENERAL INFORMATION

This section provides basic guidelines andrecommendations for the proper installation of thecontroller equipment. These guidelines should beused as general instructions. They are not intendedto usurp local codes and regulations.

2.2 SITE SELECTION

When choosing the installation site of thecontroller, several factors should be considered. Ifat all possible, the controller should be installed in alocation where the mechanic has a good view ofthe machine when he is standing in front of thecontroller. There should be no obstructionsaround the controller that would prevent properrouting of necessary conduits entering thecontroller. The controller doors should haveenough room to fully open and close. Allclearances, working space, lighting, and guardingshould comply with governing codes.

2.3 ENVIRONMENTALCONSIDERATIONS

The standard controller package is provided with aNEMA 1 enclosure. This type of controllershould be installed in a clean and dry environment.Ideally, the equipment room should betemperature controlled between 70 and 90 degreesF. However, control equipment will functionproperly within an ambient temperature range of35 to 110 degrees F. If temperatures remain at theupper and lower extremes of this range for anextended period of time, the life expectancy of thecontrol equipment may be shortened. If wet,dusty, or corrosive environments are expected,

then optional non-standard enclosures can beprovided. For example NEMA 4, NEMA 12, orNEMA 4X.

The control system is designed to have a highimmunity to electrical noise, radio frequencyradiation, and magnetic interference. However,high levels of these items could cause interferencewith certain parts of the control system.

The power supply feeding the controller shouldhave a fluctuation of no greater than + or - 10%.

2.4 WIRING GUIDELINES ANDINSTRUCTIONS

2.4.1 THE WIRING PRINTS

Each set of wiring schematics is job specific. Thejob name and number will be listed in the bottomright corner of each page of the print. A separatebinder will be provided for each job containing acomplete set of wiring schematics.

2.4.2 GROUND WIRING

Proper grounding of the power supply, controller,elevator car, and hoistway is required. Separateconductors should be run for EG (earth ground)and GND terminals. These terminals andconductors are detailed on the wiring schematics.

2.4.3 HOISTWAY WIRING

All hoistway wiring is detailed on the wiringschematics. The number of hoistway conductors iscalculated and listed per job on the wiringschematics. A job specific pull sheet is alsoprovided with the wiring schematics.

2.4.4 ELEVATOR CAR WIRING

All elevator car wiring is detailed on the wiringschematics. The number of traveling cableconductors is calculated and listed per job onthe wiring schematics. A job specific pullsheet is also provided with the wiringschematics.

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2.4.5 MACHINE ROOM WIRING

All machine room wiring is detailed on thewiring schematics. All wire sizes are listed formain power supply, motor wiring, brake wiring(traction only), and field wiring.

2.4.6 WIRING TO TOP OF CAR SELECTOR

The car top selector is wired according to theschematics for the job. However, specialattention should be given to wiring the pulsesensor on the selector since the output on thisdevice uses +15VDC. Terminal PPS on theselector is wired to PPS on the controller andselector terminal PP/US is wired to PP on thecontroller.

2.5 SLOWDOWN LIMITS

There are two sets of slowdown switches used, theUT/DT switches (including UT1, UT2, UT3,DT1, DT2, DT3) and the UTS/DTS switches.UT, UT1, UT2, UT3 & DT, DT1, DT2, DT3are used to clamp the speed command to the driveat the terminal landings independent of the controlof the CPU.

UTS & DTS are emergency slowdown limitswitches used on cars with a top speed greater than200 fpm or having reduced stroke buffers. Theseswitches are used as the slowdown speedverification points by the Safety Processor board. Ifthe car hits the limit at a speed greater than thepreset speed parameter, power is immediatelyremoved from the motor and brake for anemergency stop independent of the main CPU.

The UT & DT limit switches are also used asspeed verification points by the Safety Processorboard. When the limit is first hit, the SafetyProcessor counts an adjustable number of pulsecounts from that point to determine the velocitytrip point. Since cars with only one slowdown limitwould hit the limit at high speed when recoveringfrom being lost, the extra pulse counts from thelimit allows the car to slowdown before the trippoint is reached.

The Safety Processor board uses the UT & DTlimits to verify the operation of the UTS & DTSlimits. The pulse input is also verified while runningon automatic.

The distance that the limits are placed from theterminal landing depends on the speed of the car.Below, Table 2.0 shows the slowdown limitlocations with respect to contract speed. Alldistances are show in inches.

2.6 NORMAL AND FINAL LIMITSWITCHES

The up and down directional limit switches UN &DN should be set to open one inch past theterminal floor levels. The top and bottom finallimit switches should be set to open four inchespast the terminal floor levels.

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Fpm UT/DT UT1/DT1 UT2/DT2 UT3/DT3 UT4/DT4 UT5/DT5 UT6/DT6 UT7/DT7 UTS/DTS

UTS/DTS(with

ReducedStrokeBuffer)

50 10 Not Used 8"100 21 Not Used 17150 31 Not Used 28200 41 Not Used 39250 52 36 36300 31 62 40 40350 40 80 52 52400 50 99 66 66450 60 120 81 81500 71 143 98 98600 65 130 195 137 137700 85 170 255 181 181800 80 160 240 320 232 232900 98 196 293 391 289 2891000 93 187 280 374 467 353 3531100 110 219 329 439 548 380 3801200 106 211 317 422 528 633 448 4481300 103 206 310 413 516 619 723 521 5211400 102 204 306 408 510 612 714 816 600 600

Table 2.0: Slowdown Distances from terminal landing.

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2.7 SELECTOR INSTALLATION

2.7.1 TAPE SELECTOR INSTALLATION

The tape is installed by first attaching it at thetop of the hoistway approximately 12 inchesfrom the rail, see Figure 2.0. The tape is thenunreeled from the top of the car while runningdown on inspection. At the bottom of thehoistway it is attached with a spring to keep ittaut. The selector is then mounted on the top ofthe car and is connected to the tape by the nylonguides. Figure 2.1 shows a typical mounting ofthe selector to the crosshead. . Figure 2.2ashows the original selector board (A1011) and2.2b shows the new selector board (PCB-1011BN).

To install the floor magnets, the car is placeddead level to the desired floor. The tape is thenmarked at the top left of the selector through afactory cut guide hole. The car is moved belowthe floor so the tape can be accessed where theselector was sitting at floor level. A door zonetemplate, provided by G.A.L., is placed at themark and the door zone and binary presetmagnets are placed in the appropriate locationsin the template. The template is then removedfrom the tape. The location of each magnet isshown in Figure 2.3.

Table 2.0, listed below, shows which binarypreset magnets are used for each floor. A 1 inthe table indicates that a magnet is used and a0 indicates no magnet.

BINARY FLOOR MAGNETS

FLOOR BP32 BP16 BP8 BP4 BP2 BP11 0 0 0 0 0 12 0 0 0 0 1 03 0 0 0 0 1 14 0 0 0 1 0 05 0 0 0 1 0 16 0 0 0 1 1 07 0 0 0 1 1 18 0 0 1 0 0 09 0 0 1 0 0 110 0 0 1 0 1 011 0 0 1 0 1 112 0 0 1 1 0 013 0 0 1 1 0 114 0 0 1 1 1 015 0 0 1 1 1 116 0 1 0 0 0 017 0 1 0 0 0 118 0 1 0 0 1 019 0 1 0 0 1 120 0 1 0 1 0 021 0 1 0 1 0 122 0 1 0 1 1 023 0 1 0 1 1 124 0 1 1 0 0 025 0 1 1 0 0 126 0 1 1 0 1 0

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FLOOR BP32 BP16 BP8 BP4 BP2 BP127 0 1 1 0 1 128 0 1 1 1 0 029 0 1 1 1 0 130 0 1 1 1 1 031 0 1 1 1 1 132 1 0 0 0 0 033 1 0 0 0 0 134 1 0 0 0 1 035 1 0 0 0 1 136 1 0 0 1 0 037 1 0 0 1 0 138 1 0 0 1 1 039 1 0 0 1 1 140 1 0 1 0 0 041 1 0 1 0 0 142 1 0 1 0 1 043 1 0 1 0 1 144 1 0 1 1 0 045 1 0 1 1 0 146 1 0 1 1 1 047 1 0 1 1 1 148 1 1 0 0 0 049 1 1 0 0 0 150 1 1 0 0 1 051 1 1 0 0 1 152 1 1 0 1 0 053 1 1 0 1 0 154 1 1 0 1 1 055 1 1 0 1 1 156 1 1 1 0 0 057 1 1 1 0 0 158 1 1 1 0 1 059 1 1 1 0 1 160 1 1 1 1 0 061 1 1 1 1 0 162 1 1 1 1 1 063 1 1 1 1 1 1

Table 2.0: Binary Position Presets

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Figure 2.0: Typical Tape Mounting

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Figure 2.1: Typical Mounting of Selector

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Figure 2.2a Selector Board A1011 Figure 2.2b Selector Board PCB-1011BN

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Figure 2.3: Selector Tape Layout Figure 1.5: Magnets Each Floor

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2.7.2 TAPELESS SELECTORINSTALLATION

Installation of the tapeless selector begins withreplacing the existing governor if it does nothave a rotating shaft to one that does. Mountthe encoder on the governor and connect theencoder cable to the Safety Processor Board asper the job prints.

Mount the selector box on top the car with theprovided brackets, see figures 2.4. The magnetswill be placed in the corner of the rail. The doorzone sensors will face the magnet and make a 45degree angle with the face of the rail.Use the template to position the selector headthe correct distance from the rail, see figure 2.5.The mounting screws on the selector box andon the brackets are slotted to make thenecessary alignments.

Figure 2.4: Tapeless Selector Mounted on Crosshead.

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Figure 2.5: Door zone Template Used to Set Selector Distance.

The selector head can be mounted with a left orright vertical orientation. Each of the sensorwires are individually plugged into the selectorboard according to the orientation of how thebox is mounted. The sensors are wired with ULat the top then DZU, DZD and finally DL atthe bottom, see figure 2.6. If the box has to bemounted upside down (having the PC board

upside down) simply re-wire the sensors in theorder listed above always starting with the topsensor as UL, see figure 2.7. Since the PC boardmounting holes are symmetrical, the board canbe rotated to the right side up position. Withthe selector and car top box mounted on the cartop, wire the selector board to the car top board.

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Figure 2.6: Sensor Orientation and Wiring

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Figure 2.7: Sensor Orientation Upside Down

After the selector installation is complete and thecar is running on inspection, door zone magnetscan be placed at each floor. With the car dead levelat the floor, place the template in the corner of therail with the tab lined up with top of the selectordoor zone sensor bracket see figure 2.8 Make a

mark across the flat edge of the template. Movethe car down then place the template on the railand align the position mark. Place the magnet inthe slot and remove the template.

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Figure 2.8: Door zone Template

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S E C T I O N - 3

3 ADJUSTMENT OF THEGALaxy CONTROLLER HPV 900/HPV 600 DRIVE

3.1 GENERAL SETUP

Before adjustment begins the following items mustbe completed.

1. All field wiring and safety circuitsinstalled

2. Temporary jumpers from terminalHC to terminals MES & ALT

3. All hoistway limit switches installed

4. All car and hoistway doors andinterlocks installed and pre-adjusted

5. Selector installed and magnets pre-adjusted

6. Familiarize yourself with all wiringschematics

7. Familiarize yourself with the MagnetekHPV 900/600 AC Vector ElevatorDrive Technical Manual.

8. Verify that the AC motor is properlywired.

9. Verify that the tachometer isconnected properly.

3.2 INITIAL POWER-UP

3.2.1 CHECK MAIN LINE VOLTAGE

With main-line disconnect in the off position,check the line-side voltage with a volt meter toinsure the voltage matches the controller nametag Input Power voltage. Check to insure allthree phases are present. If voltage is not

correct or all three phases are not present, donot proceed until corrected.

3.2.2 SET TOGGLE SWITCHES

Flip all toggle switches on the 1038 board downexcept for the gate and lock bypass switches.The gate and lock bypass switches should beplace in the up position.

3.2.3 MAKE SURE THE CAR IS SAFE

Verify that all elevator doors are closed and thatall safety circuits are functional.

3.2.4 CHECK CONTROLLER VOLTAGE

Turn the main-line disconnect to the onposition. Check the voltage at R, S, and T on theAC drive. Verify that all three phases arepresent. Check the voltage at fuses L1 and L2on controller. If correct, check the voltage atterminal LIN with respect to GND. Thevoltage should read 120VAC. If correct, checkthe voltage at terminals S10, LC, & HC withrespect to GND. All should read 120VAC. Ifnot, check wiring diagram to determine problembefore continuing.

3.2.5 VERIFY THE LCD GALaxy ISBLINKING

Check to make sure that the axy of GALaxyon the LCD display is blinking. If the axy isblinking, continue to the next step. If not,check voltage at terminals 5V to 0V on the 1038board to insure 5VDC. If 5VDC is present andthe axy on the LCD display is not blinking,then contact factory.

3.2.6 PRESET ADJUSTABLE VARIABLESON SAFETY PROCESSOR BOARD

The safety processor (1028N) board is normallypreset prior to leaving the factory, however, it isprudent to check the setup values for the proper

35

settings. Refer to section 6 of this manual for theoperation of the safety processor board LCDdisplay interface. The following adjustmentvariables must be set properly:

Top Spd (contract speed)Enc RPM (if Fdbk Typ=1)Enc PPR (if Fdbk Typ=1)Fdbk Typ (0=tape, 1=enc)Ctrl Typ (1=Tr NDF, 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 500)DT Vel (Set to 500)UL Vel (Set to 160 if Non-DF)DL Vel (Set to 160 if Non-DF)Dmd Mult (Set to 1.000)SoftStop (Set to 1)

Note that the velocity variables will be setuponce the car is running on automatic.

3.2.7 PLACE STOP SWITCH IN RUNPOSITION

Flip the STOP toggle switch on the 1038board to the up position. Verify that inputLEDs for LC, HC, DN, UN, SS, GTS, RDYand CS are all on. If not, then correct fieldwiring.

3.2.8 HOIST MOTOR DATA

At this time the hoist motor data must beentered into the AC drive. The followingfunctions must be entered or verified using thedrive display unit. Follow the instructions in theHPV 900 or HPV 600 drive manual to enter thefollowing data:

DRIVE A1 Sub MenuCONTRACT CAR SPDCONTRACT MTR SPD(motor nameplate RPM)ENCODER PULSERS(PPR from encoder on motor)

MOTOR A5 Sub MenuRATED MTR PWR(motor nameplate)RATED MTR VOLTS(motor nameplate)RATED MOTOR CURR(motor nameplate)MOTOR POLES

for 1800rpm motor enter MOTORPOLES to 4.

for 1200rpm motor enter MOTORPOLES to 6.

for 900rpm motor enter MOTORPOLES to 8.RATED MTR SPEED(motor RPM on nameplate)

Most of the drive parameters have been presetto values required for your specific job. Otherparameters not listed here may need to beadjusted in the field. Please refer to theMagnetek HPV Technical manual for moreparameter information and trouble shootingguidelines.

From the digital operator for the drive, reset anyactive faults and clear the fault history log.

3.2.9 PRE-SET THE DIGITAL SPEEDCLAMPS

Pre-set the software digital speed clamps fromthe LCD interface under the Elevator SetupMenu. The submenus for the clamp speeds areas follows:

Set Ins/Leveling ClampSet DT/UT Slowdown ClampSet DT1/UT1 Slowdown ClampSet DT2/UT2 Slowdown ClampSet DT3/UT3 Slowdown ClampSet DTS/UTS Slowdown Clamp

36

Set the speed for Ins/Leveling for 140 fpm andall the remaining slowdown limit speeds to thecontract speed of the car. Please note that thedisplayed value of Clamp Speed is the valuethe clamp should be set to. The slowdown limitClamp Speed: will show 0000 until the car isrun into the limits and the speed is recorded.Please refer to the LCD Display Interfacesection for the Elevator Setup Menu.

1.

3.3 RUN THE CAR ON INSPECTION

3.3.1 READY TO RUN ON INSPECTION

From the LCD interface, select the AdjustableVariables menu, and set the inspection speed to10% of contract speed. Before moving the caron inspection, verify again that all door locks,gate switches, safety circuits, and limit switchesare functioning properly.

The car should be ready to run on inspection ifall is wired correctly. Select the ElevatorStatus on the main CPU board LCD display.The display should show Out of Service on

the first line and Inspection Mode on thesecond. The LCD display on the SafetyProcessor Board will display one of thefollowing 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 INSshould be displayed.

The inspection string consists of contactsfrom the inspection switches and the gate andlock bypass switches in series. One and only oneof the five inspection inputs should be on forthe car to run. Starting from the car topinspection input, the five inspection inputs are,INS for car top, ACC for access, ICI forin-car, MRI for motor room, and AUTOfor automatic (no inspection). The inspectionstring circuit is shown in figure 3.1.

37

Figure 3.1.

Note that any one of the following conditionswill 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 roominspection at this point, then verify all switchpositions and wiring before proceeding.

3.3.2 ADJUST THE BRAKE VOLTAGE

Momentarily push the inspection UP orDOWN pushbutton on the 1038 board while

checking the DC brake voltage with a meter. Ifthe voltage is not correct, adjust the voltage byturning power off from the main-line disconnectand then moving the resistor tap on the brakeresistor. Re-apply power and then test the brakevoltage again. Make sure that the brake is liftingand setting properly before proceeding.

3.3.3 CHECK THE RUN DIRECTION

Again momentarily push the inspection UP orDOWN pushbutton on the 1038 board. Oneof the following should take place:

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The elevator will run controlled, in thecorrect direction (up for UP button,down for DOWN button) with nodrive faults. If so, proceed to CheckInspection Speed.

The elevator will run controlled, but inthe wrong direction with no drive faults.If so, proceed to the next step.

The elevator will try to run, butimmediately trips on a driveENCODER FLT. If so proceed toDrive Trips Immediately.

The elevator runs much slower than theinspection speed demand. If so, followthe steps in the Car Runs ExtremelySlow section.

3.3.4 CAR RUNS THE WRONG DIRECTION

If the elevator runs controlled but in the wrongdirection with no drive faults, then change therun direction of the motor by one of thefollowing two ways.

Change the motor rotation on the drivefrom forward to reverse.

USER SWITCHES C1MOTOR ROTATION

Run the elevator on inspection again.

Swap the motor leads. Turn off the maindisconnect. If an encoder isolation boardis not used then swap the encoderdirection by swapping the wires at thedrive as shown below:

HPV 900A+ (TB1-21) with A-

(TB1-20)HPV 600

A+ (63) with A- (62)

If an encoder isolation board (1022N)is used, move J5 and J6 on the

encoder board instead of moving theencoder wires at the drive. Refer tothe jumper diagram on the board.

Turn the main disconnect on and run theelevator on inspection again.

The car should run controlled and in correctdirection. If so proceed to Check InspectionSpeed. If not contact the factory.

3.3.5 DRIVE TRIPS IMMEDIATELY

If the elevator tries to run, but immediately tripson a drive ENCODER FLT, recheck the drivemotor parameters. This fault is most likelycaused by improper parameter settings.Carefully review the drive MOTOR A5parameters to match the motor data. Correctany invalid parameters and re-test the car.

If the parameters are correct, then measure thevoltage of the encoder at the drive terminals asshown below:

Voltage between A+ and A- should readgreater than1.5 VDC. For the HPV 900drive, check terminals A (TB1-21) andA- (TB1-20). For the HPV 600 drive,check terminals A+ (63) and A- (62).

Voltage between B+ and B- should readgreater than1.5 VDC. For the HPV 900drive check terminals B+ (TB1-23) andB- (TB1-22). For the HPV 600 drive,check terminals B+ (65) and B- (64).

Voltage between +5 and 0V should readroughly 5 VDC. For the HPV 900 drivecheck terminals +5 (TB1-25) and 0V(TB1-19). For the HPV 600 drive, checkterminals +5 (67) and 0V (61).

If the voltage is incorrect then verify theencoder cable connections. Refer to the jobschematics to correct any wiring error. If noerror is found then contact the factory.

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If the voltage is correct then change the encoderdirection.

Turn off the main disconnect. If an encoderisolation board is not used then swap theencoder direction by swapping the wires at thedrive as shown below:

HPV 900A+ (TB1-21) with A- (TB1-20)

HPV 600A+ (63) with A- (62)

If an encoder isolation board (1022N) isused, move J5 and J6 on the encoder boardinstead of moving the encoder wires at thedrive. Refer to the jumper diagram on theboard.

Turn on the main disconnect and run theelevator on inspection again. If the elevatorruns controlled and in the correct direction,proceed to the next step. If the elevator runscontrolled but in the wrong direction, the goback and follow the directions in the Car RunsThe Wrong Direction section.

If the car still trips immediately on anENCODER FLT, then contact the factory.

3.3.6 CAR RUNS EXTREMELY SLOW

If the car runs much slower than the inspectionspeed demand, then change the encoderdirection.

Turn off the main disconnect. If an encoderisolation board is not used then swap theencoder direction by swapping the wires at thedrive as shown below:

HPV 900A+ (TB1-21) with A- (TB1-20)

HPV 600A+ (63) with A- (62)

If an encoder isolation board (1022N) isused, move J5 and J6 on the encoder boardinstead of moving the encoder wires at the

drive. Refer to the jumper diagram on theboard.

Turn on the main disconnect and run theelevator on inspection again. If the elevatorruns controlled and in the correct direction,proceed to the next step. Otherwise contact thefactory.

3.3.7 CHECK INSPECTION SPEED

With a hand held tachometer, check the speedof the elevator while running on inspection.The elevator should be running at 10% contractspeed or 25 fpm for a 250 fpm car. Also runthe elevator while monitoring SPEEDFEEDBACK on the HPV 900 drive display.The display should show 10% of contract speed.

From the LCD interface, select the DisplayHoistway Tables menu. While running oninspection, monitor the controller velocity. Ifthe velocity on the LCD display is incorrect,check the Encoder RPM and PPRparameters from the Adjustable Variablesmenu. These variables should be set thesame as the Contract Mtr Speed andEncoder Pulses parameters on the drive,respectively.

With the speed on all three of these devicesreading approximately 10% of contract speed(within +/-2 fpm) continue to the next step. Ifnot, contact the factory.

3.3.8 VERIFY CONTROLLER ENCODERDIRECTION

With the LCD interface displaying ElevatorStatus, hit the Up or Down menu buttonto change the screen to a motion screen.Monitor the direction of the car from DIR onthe display or from the direction the pulsecounts are counting. DIR will show Up forup and Dn for down. The pulse countsshould increment going up and decrement goingdown.

40

If the direction is wrong or the pulse countschange in the wrong direction, then the encoderdirection to the controller must be changed.If an encoder isolation board (1022N) isused, move J1 and J2 on the encoder board.Refer to the jumper diagram on the board.

If no encoder isolation board is used, the A+and A- encoder wires from the drive must beswapped. Note that the motor encoder wires aredaisy chained from the encoder to the drive andthen from the drive to the controller encoderboard. Only the A+ and A- wires from thedrive to the controller board must be swapped.The wires from the encoder to the drive mustremain on the same terminal locations on thedrive.

If the encoder is counting properly continue tothe next step. If not, contact the factory.

3.3.9 VERIFY SELECTOR ANDSLOWDOWN INPUTS

Run the elevator up on inspection until it stopson the up normal limit. The up and downnormal limits should be set one inch above andbelow the terminal floors respectively. Verifythe selector inputs are being set properly on thecontroller by running the elevator down until itstops on the down normal limit.

As the car approaches dead level to the floorgoing down, DL turns on first, then DZand then finally UL At floor level, UL, DL,and DZ inputs should all be on at the sametime. Leaving the floor going down DL willturn off first, then DZ and last UL.

Also verify that the up and down terminalslowdown limits inputs UT, UTS, DT & DTSare breaking at the proper distances as shown inthe slowdown table 2.0. UT, UTS, DT &DTS turn off when active.

3.3.10 VERIFY CAR SPEED ON SAFETYPROCESSOR BOARD

Run the car in either direction and check the carspeed on the safety processor LCD display. Thespeed shown should match the cars actualspeed. If the speed does not match and thesecondary feedback comes from pulses from thetape go to Correct Car Speed When Using ATape. If the secondary feedback comes froman encoder go to Correct Car Speed WhenUsing An Encoder. If the correct speed isshown proceed to the Learn the Hoistwaysection.

3.3.10.1 CORRECT CAR SPEED WHENUSING A TAPE

The tape has holes every 3/8 that are 3/8 indiameter. On the selector unit adjust the PPsensor closer to the tape until the orange LEDat the end of the sensor turns on. Then turn thesensor inwards another 1/8 and lock in thesensor. While running on top of car inspectionverify that the orange LED at the end of the PPsensor turns on and off as it passes by the holeson the tape. The safety processor board on thecontroller measures the time between each pulseto calculate the velocity. If the velocity is notdisplayed correctly first make sure that thefeedback type in the safety processor boardadjustable variable is set to 0 for a tapeapplication. Next, while the car is running,make sure that the XP LED on this board ispulsing. As the car increases in speed the LEDwill glow solid on. If the LED does not pulse,try swapping the wires at the PPS and PPterminals. If the LED still does not work,contact the factory. If the correct speed isshown proceed to Learn the Hoistway.

3.3.10.2 CORRECT CAR SPEED WHENUSING AN ENCODER

When using an encoder for the secondary speedfeedback, make sure that the adjustable variableson the safety processor board are set properly. Setthe feedback type to 1 for encoder and set theencoder RPM and PPR appropriately for how theencoder is driven. To calculate the RPM, dividethe contract speed of the car by the distance travelin one revolution with the governor as shownbelow:

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RPM = Speed fpm/(diameter GOV * pi ft/rev)

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

3.3.10.2.1 INCREMENTAL ENCODER 1028BOARD

On a standard incremental encoder, the pulsesper revolution are usually part of the partnumber such as 1024 or 2048. Check theencoder part number and enter the encoderPPR. Run the car on inspection and verify thevelocity on the CAR SPD display. Comparethe velocity with a hand held tachometer on thevertical part of the governor cable. If thecorrect velocity is not obtained, contact thefactory. If the correct speed is shown proceedto the Learn Hoistway step.

3.3.10.2.2 ABSOLUTE ENCODER 1066 BOARD

The Safety Processor 1066 Board uses a serialinterface to a Turck absolute encoder, part #T8.5882.3FB8.3001. With this system, theencoder PPR is 8192 and this value should set inthe SPB. The RPM is calculated as above.

Verify communications between the encoderand the Safety Processor Board on the LCDInterface Display ENC COM. Run the carand verify that the PLS CNT on the SPB isincrementing when running up or decrementingwhen running down. The PLS CNT valuecan be considerably out of range but willautomatically correct during the Learn Hoistwayprocedure. To reverse the direction of counting,change the adjustable variable ENC DIR onthe SPB LCD Display Interface from CW toCCW or vise versa. Run the car at a knowinspection speed and verify the velocity on theCAR SPD display. If the correct velocity isnot obtained, contact the factory. If the correctspeed is shown proceed to the LearnHoistway step.

3.4 LEARN THE HOISTWAY

The elevator should now be stopped on thedown normal limit with the inspection speed setto 10% of contract speed. Verify that the DNand DL input LEDs are both off. From theLCD interface choose to Learn Hoistway.Follow the instructions on the screen.

In general, the car is run from the bottom of thehoistway, the down normal limit, to the top ofthe hoistway, the top normal limit.

NOTE!!! The car must run the entirehoistway without stopping.

As the elevator moves up the hoistway, go to theDisplay Hoistway Tables menu on the LCDdisplay and verify again that the DPP pulsecount on the screen are incrementing. Also asthe elevator passes each floor, the pulse countand distance for that floor should change and bestored. Verify that the floor distances are valid.The pulse count for the terminal slowdowns willalso be stored. The elevator will stop when itreaches the up normal limit.

If this car uses a tapeless selector with anabsolute encoder, verify that the PLS CNT onthe Safety Processor Board was reset close to acount of 5000 when the car first starts movingto learn the hoistway. If the number isextremely large or is decrementing, stop thelearn hoistway procedure, correct the directionon the SPB and then restart the learn process.

After the elevator stops, move the elevator oninspection until the DZ and DL LEDs areon. Flip the INS toggle switch on the 1038board to the up position, and the elevatorshould level down to floor level at the top floor.If so, proceed to final adjustment.

If the car levels down but does not run, thencheck Elevator Status and View Fault Logon the LCD interface for a binary preset error.

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If the car oscillates at the floor, then check thedistance of the UL and DL sensors. If hesensors are too close together, spread bothsensors apart slightly. After problem iscorrected, proceed to final adjustment.

3.5 FINAL ADJUSTMENT

3.5.1 AUTOMATIC RUN

The elevator should now be sitting idle at thetop floor. The AD and IND toggleswitches on the 1038 board should still be in thedown position. If the learn procedure wassuccessful the elevator should be ready to makean automatic run.

The default parameter settings for the ridequality should be adequate for an initial run.From the LCD interface select the Set CarCall menu and using the up and down arrowkeys, setup a call. The elevator should run toanswer the call. When the elevator levels in andstops at the floor, the doors will remain closed.

The acceleration and deceleration of the carshould be smooth and stepless regardless of thedistance of the run. If the elevator does notfunction as described above, then problemshould be analyzed before proceeding.

3.5.2 DRIVE ADAPTIVE TUNE

To finish the setup of the drive, an adaptive tuneis required. It is necessary that the car run 70%of contract speed when running this test so thatthe drive does not go into flux weakening. Inthe DRIVE A1 Sub Menu, set the CONTRACTMTR SPD parameter to 70% of the rated motorRPM. If this value was adjusted to correct thetop speed of the car, use 70% of the adjustedvalue. To calculate 70%, multiply the value by0.7. For example, if the motor RPM is 1050then 70% of the motor RPM is (1050 x 0.7 =735).

This procedure will also require balanced load inthe car. Follow the adaptive tune procedure setin the Magnetek HPV 900 or HPV 600Technical Manual. After completing theadaptive tune, reset the CONTRACT MTRSPD parameter and then proceed to the nextstep.

3.5.3 FINE TUNE THE RIDE QUALITY

In order to fine tune the ride quality, refer tofigure 3.2 which describes what part of the S-curve that the different parameters effect. Ingeneral, higher numbers in the given parameters,cause quicker and more abrupt changes fromone mode to the next during a run. All of the S-curve parameters have a minimum andmaximum value. The control will not allow youto enter values that are not valid. After adjustingthe S-curve parameters for the desired ride,proceed to the next step.

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Figure 3.2: Speed Profile

3.5.4 ADJUST THE STOP

When at floor level the UL, DL, & DZ inputLEDs should be on. If the elevator continuallytries to seek floor level by leveling up and down,try the following steps to correct the problem:

1. Increase the response of the drive andretest the car.

2. Reduce the leveling and re-levelingvelocity parameters in the car andretest.

3. If the car still oscillates, adjust thedead zone on the selector. Thedead zone is increased by movingthe selector sensor boards closertogether.

If the car stops hard on the brake, then increasethe brake drop delay until the motor stopsturning completely before the brake sets. Thesoft stop time MUST be set to at least 0.5seconds LONGER than the brake drop delay.

Important: If you increase the soft stop timeon the controller you need to also increase thesoft stop parameter on the safety processorboard. Make sure that the soft stop parameteron the safety processor board is larger than thesoft stop parameter on the controller.

If the car spots when approaching the floor, thecause is usually from the car not tracking (thedrive response is set too low) or the speedprofile into the floor is too sharp. First try toincrease the response of the drive.

If the car still spots increase the floor targetingdistance and retest the ride. The default valuefor the floor targeting distance is 12 inches.Increase it by steps of 2 or 3 and continueretesting until the parameter is adjusted to 18. Ifno change is notices, start again from 12 anddecrease the value.

The deceleration rate can also be reduced a littleto help remove the spotting. Proceed with

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adjusting the start once the proper stop isachieved.

3.5.5 ADJUST THE START

To provide a proper start, adjust the brake pickdelay, pattern delay, and soft start jerk rate.Initially, set the brake pick delay to 0 andincrease the pattern delay by 0.1 seconds untilthe controller picks the brake completely beforethe motor starts to move. If roll back occurs,then reduce the pattern delay until the roll backis gone. Sometimes, the timing works out betterif the brake pick delay is set to 0.1 second.

Adjust the soft start to for the quickness inreaching constant acceleration. Keep in mindthat the larger the soft start number, the quickerthe start. The ride should now be acceptable.

3.5.6 VERIFY TOP SPEED

To fine tune high speed, make high speed runswhile monitoring the SPEED FEEDBACK onthe HPV drive display. The speed should beslightly under contract speed. If the speed is notcorrect increase or decrease drive parameter A1CONTARCT MTR SPD until the AC drivedisplay reads contract speed, proceed to the nextstep

3.5.7 ADJUST SAFETY PROCESSORBOARD SPEED CLAMPS

Make a one floor run to the top floor.After the car stops, record the velocity the carhit the UT, DT, UTS & DTS slowdownlimits. UTS & DTS are used on car withreduced stroke buffers or with a top speedgreater than 200 fpm. The velocity value isshown from the LIM VEL menu on the safetyprocessor board LCD display.

The velocity value shown on the display for theUT or DT limit is the value after the car hitsthe limit then counts the adjustable number ofcounts set from UT Count or DT Count.

When using a tape feedback, there are 16 pulsecounts per foot or 1.333 pulses per inch. If thelimit is set to 40 from the terminal, to set thecheckpoint at 20 use a count value of (20 *1.333) = 26.6. Round up and set the UT andDT count to 27. If the UT or DT Counts aremodified, the limit velocity has to be rechecked.

Run the car again to the top repeatedly from 2floors, then 3 floors, etc, until top speed isreached. Record the limit velocities each timethe car stops at the top floor.

Make the same runs to the bottom floor startingfrom 1 floor, then 2 floors, then 3 floors, etc,until top speed is reached. Record the limitvelocities each time the car stops at the bottomfloor.

Take the highest speed value for the up or downterminal slowdown limit, add 20 fpm and thenset the new value in the corresponding variablefrom the ADJ VAR menu.

3.5.8 ADJUST DIGITAL SLOWDOWNSPEED CLAMPS

Having just made several runs into the top andbottom landings, the main CPU has alsorecorded the cars velocity when the slowdownlimits were hit. If the car has been powereddown prior to this step, several runs have to bemade to the limits to allow the main CPU torecord the limit velocity values.

From the main CPU LCD interface, chooseElevator Setup and hit enter. Next chooseDT/UT Slowdown Clamp and again hit enter.The display will show the Speed the car hit theclamp on the previous run as Clamp Speedand UT/DT Limit with a value to bemodified. Set the UT/DT Limit with the valueshown as Clamp Speed. If the Clamp Speedshows 0000 either the limit is not being used orthe limit was not hit.

The number of slowdown limits depends on thespeed of the car as show in the table below:

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CARSPEED

NUMBER OFSLOWDOWNLIMITS

CLAMPNUMBER

LIMITUSED

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3.5.10.2 FULL CAR SETUP

The empty car setup must be successfullycompleted to run the full load setup.

Once the empty setup is complete, run to theloading floor and turn the auto-door switch onto allow weights to be loaded on the car. Withthe car fully loaded, turn off the auto-doorswitch and run the car to the bottom floor.Again if the doors are not closed, make a onefloor run to force the doors to close.

With the car at the bottom floor, follow theLCD interface instructions to press enter to startthe full load setup sequence. The car willautomatically run to each floor and measure thefull load value. When the full load measurementis complete, the car can be run to the loadingfloo