DMG Junior User manual

Controller System
Installation
Manual
(Vers. 1.5 – English)

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SAFETY NOTES
INSTALLATION
The control panel must be installed internally with a degree of pollution of not more than
2.
The cabinet has an IP2X degree of protection.
The controller setup and maintenance has to be made by qualified technicians after
having carefully read the documentations and electrical schemes provided with the
controller.
Protection toward indirect contacts has to be realized through magnetothermic and
differential switches and a grounding system. Unless otherwise specified, the
customer is requested to provide these protections.
Please refer to the wiring diagram supplied with the control panel for the following
protection circuits:
- magnetotermic protection of the motor circuit
- magnetotermic protection of the safety circuit
- protection fuses of all other circuits
Protection measures against electric shock:
- The control panel case of the is metallic and must be grounded as indicated in
the circuit diagram supplied with the control panel.
- The command and control circuits (24V) are galvanically separated from the
main power supply as indicated in the wiring diagram supplied with the control
panel.
- The safety circuit is galvanically separated from the main power supply as
indicated in the wiring diagram supplied with the control panel.
MAINTENANCE
For control panel’s maintenance, please refer to the manual supplied with the control
panel. During periodic inspections of the system, check the alarm circuits’ battery
status of the and the floor return circuit (if present).
Refer to the packaging instructions to handle and move the control panel.

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Docuement References
Prepared by: Paolo Vagnoni; 05/12/2012
Verified by: Massimo Villamaino; Paolo Vagnoni; Emanuele Emiliani 22/02/2013
Approved by:
Document Changes
Description of Changes References
Correct procedure for temporary operations
Rev. 0.0
Various updates
Rev. 0.1
Various updates
Rev 0.2
Various updates and addition of chapters “Shaft access” and “Motor Tuning”
Rev 0.3
Appendix A – USB-based SW updating procedure
Rev 0.4
Kit QJR.KIMP
Rev 0.5
Connection of car key switch
Rev 0.6
List of parameters (§ 4.2, 4.3, 4.4)
Rev 0.7
Connection of modem and emergency telephone
Rev 0.8
RSP monitor fault (§ 3.3, § 3.4) – Appendix B
Rev 0.9
Motor Tuning (§ 2.2.2, § 4.7)
Rev 1.0
Troubleshooting table (§ 3.4)
Rev 1.1
Troubleshooting table (§ 3.4)
Rev 1.2
Junior HYDRO updates (§ 1.1, 2.1, 2.2.1, 2.3.1, 2.3.2, 2.4.1, 2.4.3)
Rev 1.3
Layout VVVF
Rev 1.4
Various updates (§ 2.3.1, 4.4, 4.6, 5.2.3)
Rev 1.5
• All the products and company names mentioned in this manual are trademarks or registered trademarks of
their respective holders.
• The information in this manual may vary without notice for any enhancements.

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Summary
1. JUNIOR Pre-wired System ........................................................................................... 6
1.1 JUNIOR System for Hydraulic homelifts (HYDRO) ..........................................................................6
1.1.1 Layout ...............................................................................................................................................6
1.1.2 Technical characteristics ..................................................................................................................6
1.1.3 Main functions...................................................................................................................................6
1.1.4 Integrated inspection box and switchboard ......................................................................................7
1.2 JUNIOR System for VVVF homelifts (VVVF) ...................................................................................8
1.2.1 Layout ...............................................................................................................................................8
1.2.2 Technical characteristics ..................................................................................................................8
1.2.3 Main functions...................................................................................................................................8
1.3 Use of MINIPAD programming module ............................................................................................9
1.4 Integrated Emergency System .........................................................................................................9
1.5 Door and Safeties ...........................................................................................................................10
2. Quick Installation Guide ............................................................................................. 11
2.1 Installation of the controller.............................................................................................................11
2.2 Main connections and Temporary Operations................................................................................12
2.2.1 Hydro JUNIOR ................................................................................................................................12
2.2.2 VVVF electric JUNIOR....................................................................................................................13
2.3 Connection of pre-wired components in the Car ............................................................................14
2.3.1 Travelling cable (Lenghts: 12, 15 or 18m) ......................................................................................14
2.3.2 Car module .....................................................................................................................................17
2.3.2.1. Connection of counting system and limit switches .........................................................................17
2.3.2.2. Connection of the car door safeties ................................................................................................19
2.3.2.3. Connection of door operators (lifts with automatic doors) ..............................................................19
2.3.2.4. Connection of car operating panel..................................................................................................21
2.3.2.5. Connection of car key switch ..........................................................................................................22
2.3.2.6. Connection of modem and emergency telephone..........................................................................25
2.4 Connection of shaft pre-wired equipment.......................................................................................26
2.4.1 Safety Chain ...................................................................................................................................26
2.4.2 Landing Operating Panels ..............................................................................................................31
2.4.3 Connection of shaft access control system ....................................................................................32
2.5 Normal Service Mode .....................................................................................................................33
2.6 Basic Configuration of Parameters.................................................................................................34
2.7 General Safety Measures ...............................................................................................................35
3. Diagnostics ................................................................................................................. 36
3.1 Showing system status ...................................................................................................................36
3.2 Active Faults visualization...............................................................................................................36
3.3 Fault Reset......................................................................................................................................38
3.4 Troubleshooting Table ....................................................................................................................39
4. Advanced Configuration ............................................................................................ 42
4.1 Menu Map .......................................................................................................................................42
4.2 Menu “I-O Status” ...........................................................................................................................43
4.3 Menu “Configuration” ......................................................................................................................45
4.4 “Door” Menu....................................................................................................................................46
4.5 “Signals” Menu................................................................................................................................48
4.6 Menu “Special Features” ................................................................................................................49
4.7 “System Positioning” Menu.............................................................................................................50
4.8 “Clock” Menu ..................................................................................................................................50
5. Adjustment of car position and stopping accuracy ................................................. 51
5.1 Definitions .......................................................................................................................................51
5.2 Principle of functioning of FAI / FAS (DOWN/UP) counting system...............................................51
5.2.1 Floor stopping accuracy adjustment...............................................................................................51
5.2.2 Passage to Low Speed (standard floor) .........................................................................................51

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5.2.3 Low speed in case of advanced opening .......................................................................................52
6. Appendix A – USB-based SW updating procedure .................................................. 54
7. Appendix B – RSP Monitor......................................................................................... 55

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1. JUNIOR Pre-wired System
The pre-wired electric system for homelift and moving platfoms JUNIOR by DMG is composed of:
•Controller unit (Hydro or VVVF electric)
•Shaft wiring Kit
•Pre-wired car and hall operating panels
1.1 JUNIOR System for Hydraulic homelifts (HYDRO)
1.1.1 Layout
cod.: QJR.BMHT
Dim.: 635x520x210mm
1.1.2 Technical characteristics
•Controller for hydraulic pumps (1 or 2 speeds, max 2,2 kW)
•Programmable electronic motherboard with 32bit micro-processor
•Type of operation: constant pressure, SAPB or mixed (SAPB at floors, constant pressure in the car)
•Up to 7 stops (6 if mixed operation), 1 or 2 access
•Manual, bus-type or 24V DC automatic regulated car doors management
•2 Batteries 12V at 7 Ah with integrated battery charger
1.1.3 Main functions
•Serial bus piloting (CAN BUS for the car, DMG 4-wires at floors)
•Car / hall programmable position indicators
•Advanced diagnostics through LCD display (last 60 errors)
•Car here / Busy / Registration indicators (fixed or flashing)
•Re-levelling at floor (with open/closed doors)
•Timed car illumination
•Short floor management
•Programmable return to designated floor
•Integrated emergency operation with automatic return to lowest floor and door opening
•Remote monitoring through PSTN line or GPRS network
INTERFACE
MINIPAD
CONTACTORS
TRANSFORMER
BATTERIES
P3 BOARD /
Power Supply unit
SAFETY BOARD

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1.1.4 Integrated inspection box and switchboard
Main power switch
Residual-Current device (lights and services)
Car illumination
Services power switch
Doors power switch
Shaft illumination
220V socket
Integrated inspection box
(France)

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1.2 JUNIOR System for VVVF homelifts (VVVF)
1.2.1 Layout
cod.: QJR.BMVF18 (1.8kW)
cod.: QJR.BMVF22 (2.2kW)
cod.: QJR.BMVFML (2.2kW Gearless)
Dim.: 423x900x210mm
1.2.2 Technical characteristics
Same features and functions as the HYDRO Junior, except:
•Quadro elettrico compatibile con motori geared e gearless fino a 2,2 kW
•Integrated Emergency System (optional) with automatic return to floor and door opening
1.2.3 Main functions
Same features and functions as the HYDRO Junior.
CONTACTORS
SAFETY BOARD
MINIPAD
VVVF
P3 BOARD
BATTERIES
TRANSFORMER
EMERGENCY BOARD INTERFACE BOARD

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1.3 Use of MINIPAD programming module
With its function keys and LCD screen, the MINIPAD module allows to see the status of the lift, access the
diagnostics, view and modify all controller parameters.
1.4 Integrated Emergency System
The JUNIOR controller is equipped with an integrated emergency system which moves
automatically the car to floor and opens doors (if automatic) in case of power failure.
This device is always present in Hydro Junior systems and is considered as (strongly
recommended) optional in VVVF Junior (Part number: QJR.EMVF).
Emergency Procedure for Hydro Junior:
•The controller is re-powered with the emergency batteries;
•If the car is not at floor, it is moved to lowest floor at reduced speed;
•Once lowest floor is reached, doors are opened (if automatic) and the system remains
active for 30 seconds;
•After 30 seconds, the system is shut down.
•During the emergency procedure, all displays show the symbol “E-”.
Emergency Procedure for VVVF electric Junior:
•The controller is re-powered with the emergency batteries;
•If the car is not at floor, it is moved to nearest floor at reduced speed;
•Once lowest floor is reached, doors are opened (if automatic) and the system remains
active for 30 seconds;
•After 30 seconds, the system is shut down.
•During the emergency procedure, all displays show the symbol “E-”.
Status LEDs:
1: Point 1 safeties (car stop, pit stop, rope slack)
2: Point 2 safeties (extra run, shaft access control)
3: Point 3 safeties (landing door preliminary contacts)
4: Point 4 safeties (landing door locks)
5: Point 5 safeties e (car door contact)
6: Status OK if permanently lit, active error when flashing,

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1.5 Door and Safeties
The JUNIOR controller can manage the following combinations of car and landing doors (see
also the Door Menu (§ 4.4), parameters “Door A Type” and “Door B Type”):
MANUAL car & landing doors:
In such configuration, the landing door can be unlocked:
•By a mechanical device (cam)
•By an electro-mechanical device (electromechanical lock).
In the second case, the controller must be equipped with a dedicated device to control the
landing electromechanical locks (Part number: QJR.BSES).
In case of no car door, the (mandatory) light cell must be connected to the safety chain (NC
contact).
SEMI-AUTOMATIC doors (automatic car doors and manual landing doors):
In such configuration, the landing door can be unlocked as in the previous case.
The optional light door in the car must be connected to the door operator (NO contact).
AUTOMATIC car and landing doors:
This configuration implies the presence of one or more 24V DC door operators. Optional light
cells must be connected to door operators (NO contacts).
MOTORIZED landing doors with electric lock:
This configuration includes the use of swing doors automatically opened by a motorized drive
and locked by an electric lock.

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2. Quick Installation Guide
For the first installation of the Junior controller follow these instructions:
2.1 Installation of the controller
•HYDRO JUNIOR
•VVVF ELECTRIC JUNIOR
•The JUNIOR controller is equipped with a key (optional) to lock the external cover lid.
1
2
4
3
1
4X
2
3
6
4
5
Control unit models:
-
Moris HL300/AR, HL420/AR
- Start Elevator SL-02

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2.2 Main connections and Temporary Operations
1. Connect:
•Main Power Supply (“ALI” connector – Junior VVVF)
(screw terminal PE/N/L – Junior HYDRO)
•Traction motor / Hydro pump (“MOTOR” connector – Junior VVVF)
(screw terminal U/V – Junior HYDRO)
•Brake / Valves (“VALV” connector – Junior VVVF)
(screw terminal V-DW / V-HS / V-COM – Junior HYDRO)
•Temperature sensor (connectors TH2/TH1 on INT J board – Junior VVVF)
(screw terminal THM2 / THM1 / GND – Junior HYDRO)
•The inspection box for temporary operations:
- Use the one provided in the package or, alternatively, a third party
one, to be connected to boards SEC J and INT J (Junior VVVF)
- Connector REV (Junior HYDRO)
2. Switch on main power
3. Set the “Temporary Operation” mode from the MINIPAD: enter the “Installation” menu
with ▼ key and press OK twice to access and modify the parameter “Temporary
Operation”:
4. Press ►and then OK to select “Yes”
2.2.1 Hydro JUNIOR
JUNIOR HYDRO controller is pre set for the following control unit models:
1) Moris HL300/AR, HL420/AR -2) Start Elevator SL-02
Wiring schematics
(ALI) (MOTOR) (VALVE)
PE L N U V (+) (+) (-)
Pump
Motor
1
M
N
L
PE
Down Valve
High Speed
Valve
Common Valve (-)
4 7 11
3812
12 3 4
4
3
3
4
4
3
3
4
MOR_REV.COM
MOR_REV.UP
MOR_REV.DWN
MOR_REV.REV
Up
button
Down
button
Normal/Inspection
Selector
Overload Contact
Motor Thermic Sensor
Oil Thermic Sensor THM1
THM2 GND GND OVL
PBJ
(THM)
PBJ
(OVL)
MOR_REV.BYPASS_SV1
MOR_REV.BYPASS_SC1
56
Temporary operation box
(REV)
Temporary Operation
No

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2.2.2 VVVF electric JUNIOR
Wiring schematics
J27
(MAIN) (MOTOR) (BRAKE) (EME)
J5 J6 J25PE N L U V
ATT1 ATT2
general
switch T hird pole
Motor
3M
L
N
PE
Motor Brake
2N 08
1N 05
B- B+W
Overloa d Conta ct
Motor Thermic Senso r
THM1 THM2 GND GND OVL
I NT J
(THM)
I NT J
(OVL)
4-GND
I NT J
(REV)
3-RED 2-REM 1-REV
4 7 11
3 8 12
1 2 3 4
43
34
43
34
MOR_ REV.C OM MOR_ REV.U P MOR_ REV.D WN MOR_ REV.R EV
MOR_REV.BYPASS_ SV1 15
14 13 12 1
1
10 9 8 7 6 5 4 3 2 1 8 7 6 4 3 2
1
SEC J
(SV1 - SHAFT)
16 - SHAFT STOP
MOR_REV.BYPASS_ SC1
5 6
Temporary operation box
5 - CAR DOOR
SEC J
(SC1 - CAR)
Up
button
Down
button
Normal/Inspection
Selector
TUNING PROCEDURE
• Enter the following motor parameters in the VVVF unit:
-F03 (Max motor Frequency)
-F04 (Rated Frequency)
-F05 (Rated voltage)
-P02 (Rated Power)
-P03 (Rated Current)
• Access the <Installation> menu from the MINIPAD and press Enter.
• Access the “Temporray Operation” parameter and press Enter (flashing value)
• Press ►twice to modify the value to “Tuning”; Press Enter;
• In the VVVf unit, set Parametro P04 to 1 (start tuning) and press Func/data: The '1' value on
the display of the VVVF starts blinking;
• Press and hold ►on the MINIPAD to enable the contactors; the '1' value on the display of
the VVVF turns fixed
• Wait for the end of the tuning procedure: "End" is showed on the VVVF display;
• Release the ►key on the MINIPAD: the value on screen is now “Yes” (Temporary
Opeation).
The end of the safety chain must be closed.
Note: when in Tuning mode for more than 1 minute, the system automatically returns to
Temporary Operation mode.

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2.3 Connection of pre-wired components in the Car
2.3.1 Travelling cable (Lenghts: 12, 15 or 18m)
Installation
½ RUN
Clamp fixed
to the car
Clamp fixed
in the shaft
JUNIOR
controller
Quadro
J U NI O R

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HYDRO JUNIOR Connections
CONTROLLERTOP OF CAR BOX
TRAVELLING CABLE
cod.: QVA.C24P__
TOC
TENSIONER 1 (TFUNE)
TENSIONER 2 (TFUNE)
STOP
TRAP DOOR (SIC TET)
DOOR-A
DOOR-B
CAR safety device
SC CAR.1
SC CAR.2
SC CAR.3
SC CAR.4
SC CAR.5
SC CAR.6
SC CAR.7
SC CAR.8
SC DOOR.1
SC DOOR.2
SC DOOR.3
SC DOOR.4

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VVVF ELECTRIC JUNIOR Connections
SEC J
board
ISO
ISO 1
ISO 2
SV1
(SHAFT)
BDU B
(FLOOR)
BDU A
(FLOOR)
SZP
REV
MR
TH1
TH2
JTOC
FREE
TENSIONER 1 (TFUNE)
TENSIONER 2 (TFUNE)
STOP
PANEL (SIC PAN)
TRAP DOOR (SIC TET)
DOOR-A
DOOR-B
JUNIOR controller boards
INT J
board
Quadro
J U NI O R
CONTROLLERCAR MODULE
TRAVELLING CABLE
CAR safety device
CAR MODULE
cod.: QVA.C24P__
cod.: QJR.MCAB
SEC CABSEC
PORTE

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2.3.2 Car module
The Junior Car Module (QJR.MCAB) is connected to the controller through the travelling cable
QVAC24Pxx. The following devices must be connected to this module:
•JUNIOR Sensor Kit (QJR.KIMP), composed of:
oMagnetic Counting system (“FAI/FAS”): 2 x NO magnetic sensors
oHigh speed and reset limit switches (“AGB/AGH”): 2 x NO magnetic sensors
•Wiring Kit for pre-wired car panel:
-QJR.KIMP
-QJR.CC1F (1,5mt) / QVA.C04P4BDX (4mt.)
2.3.2.1. Connection of counting system and limit switches
Connect the QJR.KIMP kit as indicated in the picture and position the magnetic strips
(QTC.CAL) on the guiderails as illustrated in Fig. 1; in the case of pre-opening doors, refer to the
indications given in section 5.2.3

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AGB/AGH
FA I FA S
AGH
AGBD = 15 cm(slowdown distance)
D
D
CAR MODULE
FAI FASAGH AGB
floor 0
upper floor
floor 1
D
D
cod.: QJR.MCAB
cod.:
QJR.KIMP
cod.:
QJR.KIMP
(Fig. 1)

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2.3.2.2. Connection of the car door safeties
Connect the car door safety contat (included in the car panel Kit QJR.KIMP) as indicated in
Picture 2.
2.3.2.3. Connection of door operators (lifts with automatic doors)
JUNIOR controller manages 24VDC automatic door operators (mod. Fermator 40/10)
-Fermator 40/10
-ECC (folding door)
Fig. 2a (with TOC box)
LIGHT CURTAINS DOOR CONTACT
DOOR DETECTORS
DOOR OPERATOR + BRAKE
OR DOOR INJECTION
MODULO CABINA
CLOSE-A
COM-A OPEN-A
BRA GND
+24
JUNIOR
controller
2nd ACCESS
2nd
ACCESS
Alimentazione porte
(solo con porte automatiche)
JTOC cod.: QJR.MCAB
For connections
see the controller wiring diagram
TRAVELLING CABLE
cod.: QVA.C24P__
SEC
PORTE
Car door safeties
contact
cod.kit: QJR.KIMP
FREE
SEC CAB
TOC DOOR-A
DOOR-B
SC DOOR.1
SC DOOR.2
SC DOOR.3
SC DOOR.4
PHEC-A

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Fig. 2b (without TOC box)
LIGHT CURTAINS DOOR CONTACT
DOOR DETECTORS
DOOR OPERATOR + BRAKE
OR DOOR INJECTION
CAR MODULE
CLOSE-A
COM-A
OPEN-A BRA GND +24
JUNIOR
controller
2nd ACCESS
2nd
ACCESS
Power doors
(automatic doors only)
JTOC cod.: QJR.MCAB
For connections
see the controller wiring diagram
TRAVELLING CABLE
cod.: QVA.C24P__
SEC
PORTE
Car door safeties
contact
cod.kit: QJR.KIMP
FREE
SEC CAB