25.3.2010
ABB high performance machines drives for lifts
Technical presentation (short version)
© ABB Group
April 2009 | Slide 1
ABB high performance machines drives for lifts
Technical presentation - Contents

Product offering for lifts

Hardware, types and ratings

Software

Example lift system configurations

Benefits

Lift control program


© ABB Group
April 7, 2015 | Slide 2
Basic functionality
References
Product offering for lifts
Hardware

High performance machine drive ACSM1

Full power size portfolio available


In-built braking chopper as standard

Flexibility with different external options



Mains filter (EMC)

Mains chokes – AC and DC

Braking resistor
Versatile control interface

Digital I/O: 6xDI, 3xDI/O, 1xRO

Analogue I/O: 2xAI, 2xAO

I/O extension modules
Complete range of feedback interfaces

© ABB Group
April 7, 2015 | Slide 3
0.75 to 110 kW, supply voltage 400 V
Incremental, SinCos, resolver, TTL/HTL

Assistant control panel

Memory unit for easy drive management
Product offering for lifts
Hardware


Integrated Safe Torque-Off function
(STO)

SIL3, certified by TÜV

Replacement of one motor contactor
Low voltage support for rescue
operation

1-phase 230 VAC UPS

DC battery from 48 V


© ABB Group
April 7, 2015 | Slide 4
External DC/DC power supply JPO-01 *
* not yet released
Regenerative supply unit

Full braking energy back to network

Group lifts with common-DC

Very low harmonic content
Product offering for lifts
Types and ratings
Frame size
A
B
Nominal current
Maximum current
2.5…7.0A
5.3…14.7A
9.5…16A
16.6…28A
Typical motor
power
0.75…3 kW 4…7.5 kW
D
E
24…46A
42…80A
60…90A
105…150A
110…210A
165…326A
11…22 kW*
30…45 kW*
55…110 kW
Braking chopper





Braking resistor





Mains choke





Mains filter (EMC)





•

*
© ABB Group
April 7, 2015 | Slide 5
C
Standard
Option, external
With a mains choke

Type codes and variants
ACSM1-04AL - air cooled
 ACSM1-04CL - cold plate

Lift system configuration (principled)
Example 1
PE L1 L2 L3
Rescue operation
External supply
DC
BATT.
K1
K2
Contactor sequence
K1
K2
External control
Lift
Controller
START UP
START DOWN
SPEED SEL1
SPEED SEL2
SPEED SEL3
Braking resistor
UDC +
UDC -
EVACUATION MODE
READY
RUNNING
Local control
CONTACTOR CONTROL
Control panel or PC Tool
(DriveStudio, optional)
M
3
Brake control
© ABB Group
April 7, 2015 | Slide 6
Encoder
Lift system configuration (principled)
Example 2
PE L1 L2 L3
L N
Rescue operation
External supply
UPS
230
VAC
K1
K2
Contactor sequence
K1
K2
External control
Lift
Controller
START UP
START DOWN
SPEED SEL1
SPEED SEL2
SPEED SEL3
Braking resistor
EVACUATION MODE
READY
RUNNING
Local control
CONTACTOR CONTROL
Control panel or PC Tool
(DriveStudio, optional)
One motor contactor
replaced with STO
M
3
Brake control
© ABB Group
April 7, 2015 | Slide 7
Encoder
Product offering for lifts
Software

DTC motor control


Lift control program (+N4000)


Lift technology library (+N6000)
Lift specific signals and parameters

© ABB Group
April 7, 2015 | Slide 8
Open and closed loop
Lift terminology and units

Control functionality for passanger and
goods lifts

Ready-made, fully parameterizable

Rescue operation

Advanced customization with DriveSPC

Lift control program Firmware Manual
Benefits



© ABB Group
April 7, 2015 | Slide 9
Excellent control performance with DTC

Open and close loop controls

Assures high riding comfort and leveling
accuracy in lift applications
Geared and gearless solutions

Both induction and synchronous motor
support with DTC

One drive can be used with various
motor types
Flexible and scalable control interface

High amount of I/O as standard

Wide range of feedback interfaces

Plug-in control options
Benefits

© ABB Group
April 7, 2015 | Slide 10
Dedicated lift control program

Ready made, fully parameterizable and
easy to use lift control program

Easy and fast start-up with control panel
or DriveStudio PC tool

Customization with DriveSPC function
block programming tool

Replacement of one motor contactor
with STO

Low voltage support for rescue
operation

1-phase 230 VAC UPS

DC battery from 48 V
Lift control program
Basic functionality
Friction Torque
(%)
FRICTION TRQ 3
(Y3)
(X3, Y3)
FRICTION TRQ 2
(Y2)
FRICTION TRQ 1
(Y1)
0
© ABB Group
April 7, 2015 | Slide 11
(X2, Y2)
(X1, Y1)
SPEED1
(X1)
SPEED 2
(X2)
SPEED 3
(X3)
Speed
(m/s)

Drive control logic

Mechanical brake control

Rescue operation

Speed reference selections

Speed profile

Smart slowdown

Supervision and protection
functions

Torque compensation
Lift control program
Drive control logic


Basic start/stop logic with two digital inputs

Typically two start commands: 1) UP and
2) DOWN

Alternatively: 1) START and 2) DIRECTION
(UP/DOWN)
Start/stop interlocking


End limit logic


© ABB Group
April 7, 2015 | Slide 12
Provides an interlocking to stop the drive or disable the
start without generating any fault or warning
Generate emergency stop (class 1 - controlled)
command when the final limit switch is activated in the
respective motor direction
Inspection mode operation

Dedicated mode used for maintenance operation

Inspection speed reference and acc/dec times
Lift control program
Mechanical brake control

Application software inside the drive
control board (JCON) is controlling the
mechanical brake via relay output

Lift control includes additional
functionality for basic brake control


© ABB Group
April 7, 2015 | Slide 13

Torque proving – electrical check

Brake slip detection - mechanical check

Fault diagnostics

“Gong sound remover” by limiting
stopping torque in PM motors due to
rapid change in di/dt
Brake open torque selection

Pre-defined value

External AI signal, e.g. weight
Can be disabled, if the lift control
system takes care of brake control
Lift control program
Rescue operation

Lift car has to run to the nearest floor in
case of power failure situation

© ABB Group
April 7, 2015 | Slide 14
Precondition: 1-phase UPS-supply or
DC-battery available

When the start command is given by
the lift controller, the drive checks the
load in the downward and upward
directions and then based on the lighter
load, automatically starts to
corresponding direction

Alternatively the lift controller decides
the starting direction

Separate speed reference and
acceleration/deceleration times

Jerk times (shape times) disabled
Lift control program
Automatic fault reset
Delay

Typically needed in applications, where
maintenance staff is not directly
available for performing fault reset

Resets automatically pre-defined drive
faults
Trial time
Time
Automatic Reset (3 trials)
Fault
© ABB Group
April 7, 2015 | Slide 15

Easy configuration by the user

Both application and firmware faults

Number of trials and trial time (period)
can be configured

Delay time for starting auto reset after
fault is adjustable
Lift control program
Speed profile

© ABB Group
April 7, 2015 | Slide 16
Main task to attain high riding comfort and leveling
accuracy

Guarantee the smooth movement of the lift car

High control performance with DTC

7 jerk settings can be selected for different lift operation
sequences

4 different acceleration/deceleration times
Lift control program
Speed reference selection

Easy configuration with three selection
signals (DIs)


© ABB Group
April 7, 2015 | Slide 17

Releveling speed

Leveling speed

Nominal speed

Inspection speed

Medium speed

Speed 1, 2 and 3
Off-delay feature for holding the speed
reference


Totally 8 different speeds
Adjustable delay time and
speed limit
Separate speed selection commands
for evacuation and inspection modes
Lift control program
Smart slowdown for optimizing the leveling

Needed, if the normal running speed is
not reached between the floors

Typical case is a short floor distance

Reduces the leveling run and thereby
optimizes the travel time of the lift

Lift shifts from the nominal speed to the
leveling speed only when the leveling
distance is reached

Two modes

Estimated


Encoder

© ABB Group
April 7, 2015 | Slide 18
Integral of the estimated speed
Actual position
Lift control program
Supervision and protection functions

Speed match supervision


Inverter overload supervision


Monitors the motor torque at lower
speeds and checks that the motor torque
is within the configurable limits
Action and diagnostics

© ABB Group
April 7, 2015 | Slide 19
Monitors the inverter current, torque and
power and checks that the drive is
operating within the inverter limits
Motor stall protection


Monitors the motor actual speed with
respect to the speed reference and
checks that the actual speed follows the
speed reference with a configurable
speed deviation limits
Drive trips and an alarm is given
Lift control program
Torque compensation

Method to calculate needed torque due to load and losses
beforehand and hereby to help speed regulator for better
control accuracy and performance

Functionality


Static friction compensation

Dynamic friction compensation

Inertia compensation, i.e. acceleration compensation
Final torque compensation
STATIC FRICTION TORQUE
DYNAMIC FRICTION TORQUE
ACC COMPENSATION TORQUE
© ABB Group
April 7, 2015 | Slide 20
∑
FINAL TORQUE COMPENSATION
References
Motala Hissar AB
© ABB Group
April 7, 2015 | Slide 21

Motala Hissar AB is a Swedish lift
manufacturer, founded in 1972

Develops and manufactures low speed
lifts especially to improve accessibility
for people with impaired mobility

More than 10,000 units have been
delivered and installed all over the world

More than 60% of the lifts are exported

Motala Hissar AB is part of KONE, one
of the worlds leading elevator and
escalator companies
References
Motala Hissar AB

Lifting application solution for
passenger lift without counterweight

Very good control performance



Starting torque accuracy
at zero speed

Weighting function without load cell
Requirement for open loop solution

To get rid of encoders

ABB was only supplier able to do it
successfully
Customer’s opinion of ABB’s
solution
“Lift control with ACSM1 in open
loop was more accurate than
competitors’ solution with closed
loop”
© ABB Group
April 7, 2015 | Slide 22