Gearless Open Loop Commissioning

The Elevator Core drive can control Gearless Permanent Magnet Motors in Open Loop (No Encoder Feedback) in specific situations.

Gearless Open Loop - Limitations

Operating Gearless Permanent Magnet Motors with no encoder feedback should only be used for the following:

Commissioning for closed loop operation:
- Reading the Real-time encoder offset
- Checking motor phase orientation
- Checking encoder channel direction
Encoder fault diagnosing:
- If an encoder wire break has happened detect which channel is broken
- Problem with the Universal Encoder Module so get passengers to the next floor

Gearless Open Loop Commissioning - Guide

The below procedure illustrates a method for commissioning the drive in a typical elevator application.

If you have already commissioned the drive for Gearless Permanent Magnet Motor operation in closed loop disregard Steps 1 - 5 and go straight to Step 6.

Step 1 - Wiring Connections

It is assumed the drive is connected as per Overall Wiring Diagram section and default terminal functions.

Step 2- Pre-Power Checks

Action/Checks		Additional Information
Do Not Apply Electrical Power Yet!	Check that all safety circuits/safety chains are in the correct state, failure to do so could result in damage to the equipment and possible injury or death. Check that the intended voltage source matches that of the drive voltage rating. Check that any unexpected movement in the motor will not result in damage to equipment / safety risk to persons. Check that the elevator controller will not give a start signal to the drive when Electrical power is applied. Ideally the Lift car should be balanced (i.e. with brakes off the lift car should not naturally move) and with enough shaft headroom to prevent reaching end stops during initial test travels.
Check all necessary electrical connections.	Check Electrical Supply cables are connected to the Input power terminals of the drive. Check Motor Cables are connected to the drive U, V, W terminals (If cables have identification markers connect correct phase sequence). Check Brake resistor is connected to the “+DC” and “BR” terminals of the drive and that the resistance is higher than the minimum allowable value and resistor is suitably protected from thermal overload. Check correct control connections are made between the Elevator Core control panel and the drive.

Step 3 - Applying Power

Apply Electrical Power to the drive

Apply rated voltage to the drive.

Check that the drive displays Stop or Inhibit

Check that the Encoder module (Optional) left hand LED light is illuminated Red

If Stop or Inhibit is not shown refer to the Troubleshooting Section.

Step 4 - Motor Nameplate Data Entry

Action		Additional Information
Select Gearless (Permanent Magnet) motor control mode. (P4-01)	Set P4-01 to 3	Both IPM and SPM type motors are supported.
Enter Motor Back EMF (P4-02)	Enter motor Back EMF into P4-02	Obtained from motor nameplate or datasheet. If not available can be calculated/measured with the following options: If the back-emf value is not available it can be approximated as per the following calculation : P4-02 = Motor Rated Power / Motor Efficiency / Motor Power factor /1.732 / Motor rated Current (Typical values are 0.95 for Motor efficiency and 0.90 for Motor power factor) Example: Motor rated Power = 7.2kW Motor Efficiency = 0.95, Motor Power factor (CosØ) = 0.9, Motor rated current = 16.9A. Therefore: P1-07 = 7200/0.9/0.9/1.732/16.9 = 304V Can be measured if encoder feedback is available run the drive in closed loop and read the value in P0-32 at a constant speed and enter this value into P4-02 (see Gearless Closed Loop Commissioning section for details on closed loop setup) .
Enter Motor Rated Current (P4-03)	Enter motor rated current into P4-03	Obtained from Motor nameplate (Amps).
Enter Motor Rated Frequency (P4-04)	Enter motor rated frequency into P4-04	Obtained from Motor nameplate (Hz).
Enter Number of Motor Poles (P4-05)	Enter value into P4-05	Enter motor pole value as shown on the motor nameplate, if unknown set P4-05 to 0 where the drive will automatically calculate the value providing P4-04 (Motor Rated Frequency) and P4-06 (Motor rated speed) have been entered correctly.
Enter Motor Rated Speed (P4-06)	Enter motor rated speed into P4-06	Obtained from Motor nameplate. If not available it can be calculated: Motor Rated Frequency*120/motor poles.
Enter the Maximum Speed (P8-01)	Enter value into P8-01	This is the maximum allowable speed.

Step 5 - Motor Auto-tune

A Motor Auto-tune must be carried out in order to measure the motor electrical characteristics, brakes will be applied by the drive (unless controlled by other means) during this test.

Action	Additional Information
If the motor contactor(s) are controlled by the elevator controller then they should be activated to close so that the motor is electrically connected to the drive, otherwise the “Auto-tune” cannot be carried out. If the motor contactor(s) are controlled by the drive (connected to relay 1) the motor contactor will automatically be energised when the “Auto-tune” is enabled. NOTE: For the motor contactor to close the safety chain will need to be closed.
Check Safe Torque off input connections have been made.		Drive should now show Stop if not see Troubleshooting.Troubleshooting The STO input status can be viewed in parameter P0-03 (0 = Open 1 = Closed)
Enable Stationary Motor Auto-tune	Set P4-08 to a 1 and press . on the drive keypad.	The motor contactors will close (if controlled by the drive “Relay 1”). The motor brakes will remain applied. (Relay 2 as default) The display will show Auto-t. (Test procedure may take several seconds to complete). The motor contactors will open once the test has completed. (Relay 1 controlled by default) Once the Auto-tune has been completed P4-08 will return to 0 and the display will show Stop (parameters P4-24, P4-26, P4-27 and P4-30 should change values from their defaults). NOTE: Motor Auto-tune will need to be repeated if the motor, motor cables, motor parameters or drive control mode is changed in P4-01.

Action

Additional Information

If the motor contactor(s) are controlled by the elevator controller then they should be activated to close so that the motor is electrically connected to the drive, otherwise the “Auto-tune” cannot be carried out.
If the motor contactor(s) are controlled by the drive (connected to relay 1) the motor contactor will automatically be energised when the “Auto-tune” is enabled.

NOTE: For the motor contactor to close the safety chain will need to be closed.

Check Safe Torque off input connections have been made.

Drive should now show Stop if not see Troubleshooting.Troubleshooting

The STO input status can be viewed in parameter P0-03 (0 = Open 1 = Closed)

Enable Stationary Motor Auto-tune

Set P4-08 to a 1 and press Elevator_Core_Size_2_navigate_button.eps . on the drive keypad.

The motor contactors will close (if controlled by the drive “Relay 1”).
The motor brakes will remain applied. (Relay 2 as default)
The display will show Auto-t. (Test procedure may take several seconds to complete).
The motor contactors will open once the test has completed. (Relay 1 controlled by default)

Once the Auto-tune has been completed P4-08 will return to 0 and the display will show Stop (parameters P4-24, P4-26, P4-27 and P4-30 should change values from their defaults).

NOTE: Motor Auto-tune will need to be repeated if the motor, motor cables, motor parameters or drive control mode is changed in P4-01.

Step 6 - Open Loop Drive Setup

When running a Gearless Permanent Magnet Motor in open loop there is no feedback to align the poles at start. So boost must be provided to run the drive.

Action	Additional Information
Set low frequency boost	Set P4-12 to 10% Set P4-13 to 10% Set P4-14 to 10% Set P4-15 to 10%	These parameters provided extra boost to help with motor control. A general run on setting is start at 10% and if that is not enough increase in increments of 10%.
Disabling the Encoder	Set P6-05 to 0	You only need to do this action if you had commissioned the drive for Gearless Closed Loop Operation and want to switch to open loop operation.

Action

Additional Information

Set low frequency boost

Set P4-12 to 10%
Set P4-13 to 10%
Set P4-14 to 10%
Set P4-15 to 10%

These parameters provided extra boost to help with motor control.

A general run on setting is start at 10% and if that is not enough increase in increments of 10%.

Disabling the Encoder

Set P6-05 to 0

You only need to do this action if you had commissioned the drive for Gearless Closed Loop Operation and want to switch to open loop operation.

Step 7 - First run of the elevator

Action	Guidance
Check for Suitable travel headroom	Ideally the Lift car should be balanced (i.e. with brakes off, the lift car should not naturally move) and with enough shaft headroom to prevent reaching end stops during initial test travels.
Run the elevator at reduced speed	Close STO1 & STO2 inputs and the drive should show Stop on the display.
	Provide a speed reference to the drive Normally inspection speed is used. If P1-02 is at default value (P1-02=1) then inspection speed is defined in parameter P8-08, in this case inspection speed is selected when DI6 is high. . Alternatively use the maximum speed parameter P8-01 to clamp the speed to a lower value.
	Provide a run-direction command to the drive.
	If the drive trips refer to Troubleshooting.Troubleshooting
If no problems are encountered then the lift can now be run normally.

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