Camino La Xacona, 121. Pol.

Industrial Porceyo
33392 Gijón | Asturias | España
Tel.: +34 985 13 39 30. Fax: +34 985 13 39 27
info@ascensorestresa.com
www.ascensorestresa.com
________________________________________________________________________________

Controller TMC22

Gearless Machine TRESA-FUJI

Commissioning

Rev. 05 – November 2013

 Camino La Xacona, 121. Pol. Industrial Porceyo
33392 Gijón | Asturias | España
Tel.: +34 985 13 39 30. Fax: +34 985 13 39 27
info@ascensorestresa.com
www.ascensorestresa.com
________________________________________________________________________________

1> Connect the power wiring:

otor power supply (U2 (green)-L1’ / V2 (white)-L2’ / W2 (red)-L3’ / ground-PE). Connect
the shield of the motor cable to the ground both the machine side and on the side of the
drive
- Engine Temperature sensor (PTC) to terminals PTC1-PTC2
- Brake FR + / FR- (orange /green)
- Control Microswitches of the brake status: connect separately (contact NC) to terminals
24V-MIC1-MIC2 (brown-black-grey). In the Control board they are connected to terminals
24V-LLBC (CC1 connector)-LLBH (CH1 connector)
2> Connection of absolute encoder Heidenhain EnDat 2.1 ECN413:
On the side of the machine using the DB-type plug connector (do not remove protection
from the connectors until the connection is made). Make the connection carefully not to
bend or break any pins of the plug. Then tighten the screws
On the drive side, connect the hose to the encoder card OPC-LM1-PS:

Terminal No.
Black 2 PO
Black (internal shield-red terminal) 4 CM
Lilac 5 CM
White 6 PA+
7 PA-
Green 8 PB+
Yellow 9 PB-
Blue 10 CK+
Red 11 CK-
Gray 12 DT+
Pink 13 DT-
Black (external shield-blue Earth
terminal)
3> Connection of the incremental encoder HTL Hohner
In this case the option card OPC-LM1-PS is not necessary. The encoder is connected
directly to the integrated HTL interface in the drive, according to the following scheme.
Whenever you give power to the drive, there will be an automatic poletuning at the first
engine start.
The wires are:
PO - Red
CM - black
PA - Green
PB - Yellow
PZ - brown
The shield is connected to ground
 Camino La Xacona, 121. Pol. Industrial Porceyo
33392 Gijón | Asturias | España
Tel.: +34 985 13 39 30. Fax: +34 985 13 39 27
info@ascensorestresa.com
www.ascensorestresa.com
________________________________________________________________________________

To control this type of encoder the following parameters must be set according to the type of
machine:
MACHINE REF.
300.210i 375.210i 450.320i 675.320i 1275.320i
L01 (type of encoder) 1 1 1 1 1
L02 (no. of pulses) 4096 4096 4096 4096 4096
L07 (automatic poletuning active) 4 4 4 4 4
L97 (%) 40 40 20 20 20
P07 (stator resistance) 34.11 34.11 19.49 20.26 18.61
After setting these parameters, we will move in inspection mode until the engine turns a few laps,
and so do the automatic Poletuning.
Poletuning value of the parameter appears in M58.

4> Connect the DCR (DC reactor). If the wires marked "REACTANCIA" are not connected, the
drive does not work. If the DC reactor is not connected a bridge must be made between terminals
P1 and P+ in the inverter.
Check the rest of the wiring before powering up the controller and connect the braking resistor.
 Camino La Xacona, 121. Pol. Industrial Porceyo
33392 Gijón | Asturias | España
Tel.: +34 985 13 39 30. Fax: +34 985 13 39 27
info@ascensorestresa.com
www.ascensorestresa.com
________________________________________________________________________________

5> Check the following parameters in the drive with the values shown on the motor nameplate:
F04: Rated frequency
F05: Rated voltage
P02: Rated capacity
P03: Rated current
6> Perform the poletuning in the case of absolute encoder
- Set L65 = 0 to disable rollback control. Later it will be set to 1 to enable this function.
- Change mode to Local Drive (command from the console) by pressing the REM / LOC key
until the dash moves from top of REM to LOC
- Push KG1 and KG2 contactors manually and keep them tightly closed until the end
- Set the parameter L03 = 4 and press FUNC / DATA
- The drive waits for the RUN command to start the process. Press FWD or REV keys (and
keep it pressed). You will hear beeps while performing the measurement and displays the
message "running". In this case the motor does not rotate.
- After the poletuning has finished, the offset value is shown, in degrees, in the parameter
L04. Note down the result
Turn the engine a bit and repeat two more times. Check that the offset values do not differ
by more than 15% between them. If the difference is greater, change two wires of the
motor (U2 green - V2 white - W2 red), and perform the poletuning again.
- If the engine has no load (no ropes on it), the dynamic poletuning may be performed. In
this case the machine will rotate. To do this:
- Set the parameter L03 = 5 and press FUNC / DATA
- The drive waits for the RUN command to start the process. Press FWD or REV (and
keep it pressed). The motor will start running for a while, stop and start rotating in
the opposite direction. If the poletuning is successful, the offset value will be shown
in L04.
- If during the process Er7 appears, go to the menu 6 (Info-alarm) and press Er7 FUNC /
DATA and go down to the last line (sub-code).
If SUB=52, change two wires of the motor (U2 green - V2 white - W2 red)
If SUB=24 KG1 and KG2 were not well stuck during the process (inverter not
enabled).
If SUB=7, the RUN command was turned off during the process
- Change the mode back to Remote Drive (command from the control panel) by pressing
the REM / LOC until the dash moves from top of LOC to REM
7> Check the direction of motor rotation (up / down). If incorrect, exchange FWD and REV signals
to the inverter (do not swap two phases in the motor). These are the wires 1 and 2 on VVVF relays
board FUJI connector.
 Camino La Xacona, 121. Pol. Industrial Porceyo
33392 Gijón | Asturias | España
Tel.: +34 985 13 39 30. Fax: +34 985 13 39 27
info@ascensorestresa.com
www.ascensorestresa.com
________________________________________________________________________________

Drive Setup and Adjustment TRESA Gearless Machine

Basic Configuration

E46 keyboard language

L01 Encoder type 4 EnDat 2.1 (absolute)
1 Incremental encoder
L02 encoder resolution (pulses per turn) 2048 p / rev (absolute)
4096 p / rev (incremental)
F03 maximum rotation speed 120 rpm
F04 Rated speed (motor plate) 20 Hz (450/600/1000 Kg)
12 Hz (gearless rehabilitation)
F05 Rated voltage Motor plate
F11 Normally equal to P03 (rated)
F42 Type of control for synchronous motors
P01 number of motor poles 0 (450/600/1000 Kg)
16 (gearless rehabilitation)
P02 Motor plate
P03 Motor plate
P06 0 A (or 0.01 A)
P07 Stator resistance (R1) (%) 5% (absolute encoder)
P08 Stator reactance (X1) (%) 10%
L05 Proportional gain of current loop .5 (depending on the engine)
C05 Rescue speed 0.40Hz
C07 Slow speed (levelling) 0.90Hz
C08 3.50Hz
C11 20 Hz
C04 = C06 = C09 = C10 = 0 Hz
Acceleration and deceleration ramps
The related parameters are:
E12: Time of the acceleration ramp from 0 to the rated speed - 1.8 s.
E13: Ramp time to decelerate from rated speed to levelling speed C07 - 1.4 s.
The speed change distance (from the change from full speed to levelling speed) has also influence
on the deceleration ramp. The recommended distance for the speed of 1m/s. is 1350mm. If with a
fixed distance E13 is decreased, the ramp will be sharper and the time travelling at low speed will
be too long (there may also be problems of overcurrent faults OC)
Start settings
The related parameters are:
F23 = 0, starting speed
F24 = 0.6 to 0.8 s., holding time at starting speed
H64 = 0, H65 = 0, soft start ramps

For the rollback control, the related parameters are:

L65 = 1, to activate this feature
 Camino La Xacona, 121. Pol. Industrial Porceyo
33392 Gijón | Asturias | España
Tel.: +34 985 13 39 30. Fax: +34 985 13 39 27
info@ascensorestresa.com
www.ascensorestresa.com
________________________________________________________________________________

L66 = 2 s., Maximum time for this function

68 = 2, zero speed proportional gain. Increase if the car moves before starting
L69 = 0.003
L73 = 1
L74 = 0
F26 = 15KHz, if the drive whistles it must be increased to 16KHz, if the whistle continues,
decrease the speed.
Trip adjustment
To improve comfort during the movement of the car you can adjust the speed gains.
These gains are different for high or low speeds.

To determine where to apply the parameters use L40 and L41:

Low speeds, below L40 (for example, 2 Hz, somewhat bigger than the leveling)
High speeds, above L41 (for example, 4 Hz).

L37 (high speed) and L39 (low speed): Integral time for the speed correction. If it is too low, the
drive response is sharp and there may be vibrations in the car. Typical values are between 0.08
and 0.1 ms (range is between 0.05 and 0.15.)

L36 (high speed) and L38 (low speed): Speed gains, values between 1 and 3. If the value is too
high, is jerky and if too low produces the yo-yo effect (slow response to the speed error). If
vibration occurs at full speed, decrease the L36 (is normally 2.5). If the vibrations are at the
starting, decrease the L38 which is normally 2.5.
During the installation with no load in the motor, it may be necessary to decrease the speed gains
if the motor makes noise. For the final adjustments, increase them again

If the jumps are at the speed changes (at the end of the acceleration or deceleration ramps) it can
be solved by increasing the gain of "feed forward" parameter L42. The normal value is 0.2, can be
increased to 0.5

If the machine is noisy (snoring) it can be solved by increasing the value of the parameter L05
(current loop gain). The L05 value can be calculated if the motor inductance (L) is known, with the
formula L05 = 4.33 * P03 * L/F05.
The default value is 1.5. It can be increased to 10
In small engines (gearless for rehabilitation) L is greater. L05 should be increased, even at 10
which is the maximum value.

You can also fix the noise with the speed gains
Brake Control.
L80 = 1 (time control)
L81 = 100%
L82 = 0.2s. is the brake release delay after the starting command
L83 = 0.1s. is the delay to de-activate the brake after stopping.
L84 = 0.

DRIVE FAULTS
When a fault in the drive happens, RFALLO is activated and the control board will display error E03
(all the LED of the safety and doors chain are off
 Camino La Xacona, 121. Pol. Industrial Porceyo
33392 Gijón | Asturias | España
Tel.: +34 985 13 39 30. Fax: +34 985 13 39 27
info@ascensorestresa.com
www.ascensorestresa.com
________________________________________________________________________________

OC - Overcurrent
It is a hardware failure, detects high output current (peak current or short circuit)
OC1 during acceleration
OC2 during deceleration (wrong L05 value)
OC3 at rated speed.
Possible causes:
Mechanical overload
Excessive ramp (Ramp time too short)
The brake was not released
Output short circuit (if disconnecting the motor continues the OC, change the drive)
Failed earth
Safety and doors chain failure

OU - Overvoltage
When the motor works as generator the voltage goes to the DC BUS. This fault a protection
against overvoltage at that BUS
Possible causes:
The braking resistor is broken, faulty, incorrectly connected or has not the appropriate
value and cannot dissipate the energy
The deceleration is very sharp
The balance is not correct

LU - Low voltage in the DC BUS

ormal voltage is 570 VDC between P (+) and N (-)
Possible causes:
A drop in the input voltage
Acceleration too sharp
Phase voltage fault.
Resistance and reactance swapped
LIN – Input phase open
OS - Overspeed
Check the gains. With the poletuning correctly performed, it is unlikely to happen.
It may be a fault in the encoder (electrical noise)
OH1 - Overtemperature
A fault in the cooling fan or the ambient temperature is too high
OL1 - Motor overload
Engine protection, detects an excessive current to the motor according to the data of P03 (rated
current)
Check the settings:
F10: Engine Type (2)
F11: overload protection level, normally equal to P03 (rated)
F12: protection time (1 minute)
OLU - Inverter Overload
The temperature in the inverter’s IGBT is very high, due to:
Not properly cooled
Very high consumption (overload in the cabin)
The switching frequency (F26) is very high
 Camino La Xacona, 121. Pol. Industrial Porceyo
33392 Gijón | Asturias | España
Tel.: +34 985 13 39 30. Fax: +34 985 13 39 27
info@ascensorestresa.com
www.ascensorestresa.com
________________________________________________________________________________

Swap U and V
Er1 - Memory failure or data loss.
Er2 - The keyboard is disconnected or is in local mode.
Er3 - CPU error
Er4, Er5 - Option Card
Communications error between the encoder card and the drive or between the encoder and the
encoder card. Check the connecting cable and the shields. When changing the encoder card
always do without voltage (the DC BUS LED off)
Er6 – Operation error

Er7 - Error during poletuning

The connection between the drive and motor was lost (KG1 and KG2 were not well stuck) or the
sequence of the motor phases is not correct.
Check that the EN input is on
ErE - Speed error
Inconsistency in speed between the theoretical and that received from the encoder
Check that the brake open properly, look at the brake microswitches.
Check that there is no mechanical lock
Check that the current limit is not enabled (F44 = 999).
If the error occurs while performing the poletuning, swap two of the motor wires
Pg - Encoder fault
Motor blocked
Brake not released
Unstable speed
Bad connection of encoder
Encoder or defective card, go to the menu 4 P2 to see if there are pulses.
ECF - Failure of EN input.