Lester Controls ALMEGA2 User manual

CD 617 ISSUE 1 : 27/07/2020
1
ALMEGA2 POSITIONING SYSTEM: QUICK SETUP GUIDE
“HYDRAULIC, KP” ISSUE: 3 Date: 05/04/2019
1. PRE-CHECKS (see page 5).
2. SETTING THE OVERRUN DISTANCE
In general the default value of 500mm should suffice to cover the max distance the lift could ever overrun.
However check this distance to ensure the max shaft position values are set correct, before using in normal
operation. They can also be adjusted after the learning run.
a. Set parameters MENU->POSITIONING SYSTEM PARAMETERS->OVERRUN TOP/BOT,
typically-500mm.
3. CLEARING OUT THE FLOOR LEVELS / PREVIOUSLY LEARNED VALUES
This is recommended for each new installation to clear (at the start of installation) any previously learned
floor position values. If this is not carried out the lift may have limited travel because of incorrect
information such as the terminal limits. A common occurrence is the Lift does not go UP on inspection.
This feature can only be selected when on inspection. Once the lift has been commissioned DO NOT USE
THIS FEATURE, IT WILL WIPE ALL FLOOR LEVELS!
a. Select option MENU->POSITIONING SYSTEM INFO->CLR ALL FLOOR LEVELS->YES to
clear floor levels, terminal limit positions, and correction information. *Note only when on
Inspection*
4. SETTING THE TERMINAL LIMITS
a. If parameter “SOFTWARE TERM LIMITS” = NO, Mechanical Terminal Limit Switches
are fitted.
i. Set Terminal Stopping limit switches above/below, top/bot floor level as required.
b. Else if Parameter “SOFTWARE TERM LIMITS” = YES.
Note: Software terminal limits are NOT recommended when using an Over-speed Governor
Encoder because excessive rope slip could cause the terminal limits to move position and
hence the lift could either under-travel, or over-travel onto the Over-travel limits.
i. Set parameter MENU->POSITIONING SYSTEM PARAMETERS->UP TERM LIMIT
DIST as desired (distance above top floor level). Typically set at 25mm.
ii. Set parameter MENU->POSITIONING SYSTEM PARAMETERS->DN TERM LIMIT
DIST as desired (distance below bot floor level). Typically set at 25mm.
iii. If Terminal Limits are required before the LEARN RUN (i.e. manual setting)
1. Take the lift to the terminal floors and record the Absolute Top / Bottom Position
Values, Position Value found by pressing MAIN MENU then LIFT / GROUP
VIEWER and reading P=????
2. Enter the values into system as ENTER FLOOR LEVELS (6). (POSITIONING
SYSTEM PARAMETERS->FLOOR LEVELS).
3. The terminal limits will now be set e.g. 25mm above and below top/bot floor
levels. The lift will stop on these on Inspection Control.
5. LEARNING THE FLOOR LEVELS BY TAKING THE LIFT TO EACH FLOOR ON INSPECTION.
a. If PANEL TEST CONTROL is fitted
i. Switch to Inspection.
ii. Take the lift to the bottom, and ensure not on the mechanical stopping limit (so the bottom
floor level is not below the limit!)
iii. Record the bottom floor level. Position Value is found by pressing MAIN MENU then
LIFT/GROUP VEIWER and reading P=????
iv. Take the lift UP to the next floor level, and Record the floor level.
v. Continue until all floor levels have been recorded.
b. Else if PANEL TEST CONTROL is NOT fitted
i. On the main terminal rail (lift shaft/car side) remove the wire in terminal TS and mark it,
then wire in the same terminal as TS1. This will switch to Inspection.
Lester Control Systems Ltd
Unit D, 18 Imperial Way, Croydon, Surrey, CR0 4RR.
Tel: [phone]
Fax: [phone]
Email: [e-mail]
www.lestercontrols.co.uk

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ii. Take the lift to the bottom (by bridging the Test Down connections TF and TD). Ensure
not on the mechanical stopping limit (so the bottom floor level is not below the limit!)
iii. Record the bottom floor level. Position Value is found by pressing MAIN MENU then
LIFT/GROUP VEIWER and reading P=????
iv. Take the lift UP to the next floor level, and Record the floor level.
v. Continue until all floor levels have been recorded.
6. ENTER FLOOR LEVELS
Once the levels have been learned / recorded a table will be produced (as Fig1). These need to be entered
into the position system as Fig 3 below. Absolute mode is selected via the option box (GREEN when
selected), otherwise UP / DN adjust is selected.
a. From the menu POSITIONING SYSTEM PARAMETERS->FLOOR LEVELS, select each floor
in turn and use the selection wheels to adjust the absolute position in millimetres.
7. PUT THE LIFT ON PREPARE TO TEST CONTROL (DOORS OFF)
a. Press MAIN MENU then ENGINEERS SELCTION, or
i. press MAIN MENU then PARAMETERS then SPECIAL SERVICE2 on the screen.
b. Move the cursor DOWN to highlight “PREPARE TO TEST CTRL”; Press SELECT
c. Select the Option DOOR OFF.
d. Press OK.
8. ADJUSTING THE LEVELLING TIME (FROM THE CONTROL PANEL) (see Fig 2)
The levelling distance is pre-set at 180mm to allow 3 seconds of levelling at a typical level speed of 60mm/s
(0.06m/s). It is recommended to have at least 3 seconds of level speed to allow the lift to consistently settle
on level speed for differing load / oil conditions, thus maintaining floor level accuracy.
a. Run the lift UP to a floor (preferably a middle floor to avoid terminal / over-travel limits).
b. Record the time on level speed. If it is more than 3 seconds increasing the parameter
POSITIONING SYSTEM PARAMETERS ->DECEL RATE will decrease the level distance and
hence time. Similarly reducing the DECEL RATE will increase the level distance and hence time.
9. ADJUSTING THE LEVEL TO ZERO DISTANCE UP/DN (FROM THE CONTROL PANEL) (see Fig 2)
For example the 3 floor lift as Fig1.
a. Run the lift UP to a floor (preferably a middle floor to avoid terminal / over-travel limits).
b. Make a note of the position it stops at (e.g. 3995).
c. Run the lift DN to the same floor. Make a note of the position it stops at (e.g. 4007).
d. The results show in the UP direction the lift stopped LOW by 5mm and stopped HIGH in the DN
direction by 7mm. To compensate for this the parameters POSITIONING SYSTEM
PARAMETERS ->LEVEL TO ZERO DIST UP/DN have to be adjusted accordingly. Thus
reducing the UP distance by 5mm and the DOWN distance by 7mm will compensate. Increasing
the distance compensates for overshooting floor level. Reducing the distance compensates for
stopping short of floor level.
e. Try again to the same floor until the target value of 4000mm ±2mm is achieved. This procedure
only has to be done for one floor, the other floors will be accurate according to these settings.
f. For a 2 floor lift adjust LEVEL TO ZERO DIST UP/DN for the top /bottom floors respectively.
10. PUT THE LIFT ON PREPARE TO TEST CONTROL (DOORS PARK OPEN).
a. As 7(a/b/c/d), but Press DN ARROW to display “PARK OPEN”; Press ENTER
Level
Distance
Level to 0 dist UP
Level to 0 dist DN
Floor Level
Door Zone
DZ
Level
Distance
Fig 2
Fig 1
Typical Table of Results (3m floor heights)
Floor 3 = 7000mm
Floor 2 = 4000mm
Floor 1 = 1000mm
Typical Settings (0.5m/s)
Level To 0 Dist UP = 25mm
Level To 0 Dist DN = 25mm
Level Distance = 180mm
Decel Rate = 200mm/s sqrd
0
1
2
Fig 3
0
1
2
0
1
2
0
1
2
0
1
2
0
1
2
0
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2
2
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0
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0
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11. SET FLOOR LEVELS.
Up to this point the actual physical floor levels should NOT have been set. The aim was to setup the
positioning system to stop at the learned values rather than the actual floor levels. NOW is the time to
set the actual floor levels from within the lift car!
a. Travel to each floor in turn, making a note of the position error in mm. Travelling to each floor in
both directions IS NOT NECESSARY as the system should be the same for both UP and DOWN.
b. From the menu POSITIONING SYSTEM PARAMETERS->FLOOR LEVELS, select each floor
in turn and use the selection wheels to adjust the absolute position in millimetres as Fig 4 below.
12. SETTING UP RE-LEVELLING.
Only setup re-levelling when the floor levels are correctly set otherwise the position point will be inaccurate
thus the re-levelling operation will most likely report warnings and errors. As can be seen from Fig 5 the
distances are short so accurate floor levels in the first place will ensure trouble free operation.
13. LIMITS (SLOWING/STOPPING) AND BUFFER TESTS
A set of dedicated buttons are available to assist in the testing of the slowing limits, stopping limits and lift
buffers (i.e. buffer test). To make the buttons appear press and hold the shaft area of the screen for 5
Seconds. Once the buttons appear they need to be held under “constant pressure” to invoke the function. If
the buttons are not pressed for a period of 20 minutes they will disappear. Also to clear the buttons, simply
press MENU and press LIFT/GROUP VIEWER to re initialise the lift viewer. (see Fig 6).
a. TESTING THE SLOWING LIMITS
Press TOP button to register a top car call and, then press SLOW LIMIT TEST button under constant
pressure to inhibit the STEP signal, thus forcing the lift to slowdown via the slowing limit. Press BOT
to register a bottom car call and repeat the above process.
b. TESTING THE TERMINAL LIMITS
Press TOP button to register a top car call and then press STOP VANE TEST button under constant
pressure to inhibit the stopping signals, thus forcing the lift to stop on the terminal limit. Press BOT to
register a bottom car call and repeat the above process.
c. TESTING THE OVERTRAVEL MECHANICAL BUFFERS (BUFFER TEST)
Note this function is to be used only by responsible Lift Test Engineers!
Press TOP button to register a top car call and then press BUFF TEST button under constant pressure
to inhibit the slowing, slowing limits and stopping signals, thus forcing the lift to crash stop onto the
lift buffers on HIGH SPEED! Press CPB to register a bottom car call and repeat the above process.
14. CAN/CANopen INFORMATION
a. The Positioning system is designed for use with Position Devices incorporating CAN or the
industry standard CANopen communication protocol. Therefore information can be transferred
from the device and viewed by selecting option MENU->POSITIONING SYSTEM INFO->
CAN/CANOPEN INFO. In particular the error information can be viewed as below:
i. Schmersal USP: = USP wire Errors / Warnings / CANopen information.
ii. Hengstler AC58: = Contains Alarm / Warnings / CANopen information.
a. Ensure Re-level vane is set 15mm above / below floor level
as shown in fig 5. Test for Re-level UP as follows:
b. Lower the lift down until it actuates the re-level vane.
c. Ensure the lift re-levels UP on level speed.
d. Make a note of the position where it stops, e.g. 3997.
e. The result shows in the UP direction the lift stopped LOW
by 3mm. Therefore decrease POSITIONING SYSTEM
PARAMETERS ->RELEV UP STOP DIST by 3mm to
compensate.
f. Increasing the distance compensates for overshooting
floor level. Reducing the distance compensates for
stopping short of floor level.
g. Repeat the procedure for relevel DN (if reqd). Adjust
parameter POSITIONING SYSTEM PARAMETERS -
>RELEV DN STOP DIST to compensate.
Relevel Up Stop Dist
Floor
Door Zone
DZ
Fig 5
Re Level Vane
UP / DN (LV1)
15mm
15mm
Relevel Dn Stop Dist
Level =
4000mm
0
1
2
Fig 4
0
1
2
0
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2
0
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2
0
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iii. CEDES = APS Status / Errors /Warnings / CAN Information
15. FURTHER INFORMATION FOR USE WITH AN OVERSPEED GOVERNOR ENCODER (If fitted)
a. Resetting the Absolute Position:
It may be necessary to reset the absolute position of the lift for the following reasons:
i. Excessive Correction: See below
ii. Clear Correction Levels: With the lift physically at the bot flr level, select to clear.
Select option MENU->POSITIONING SYSTEM INFO-> RSET ENCODER POSITION ->YES to
reset the absolute position of the encoder to the position of the bottom floor level.
b. Correction Point Moved: It is vital that correction points do not move once set after a learn run.
IT IS STRONGLY RECOMMENDED THAT CORRECTION SENSOR / POINTS ARE FIXED
SO THAT THEY DO NOT MOVE. If they do move they will affect floor levels to the amount
moved (i.e. 30mm UP if moved 30mm UP etc). Rectify by (v) “Corr Fault Info” (as below)
c. Correction Point Missing: If a correction point is not found the event “CORRECT POINT
MISSING" is generated in the event logger, and the position error will NOT be corrected! This can
be caused by (i)-(v) as “Corr Fault Info” (as below).
d. Correction Point exceeded: If the level of correction is exceeded, the event “POS DEV CORR
EXCEEDED" is generated in the event logger, and the position error will NOT be corrected! The
level in the software is typically set to 50mm. This can be caused by (iv) or (v) as “Corr Fault Info”
(as below).
e. Correction Fault Info: When the lift has arrived at its destination it looks for a correction point
before stopping. If missing / exceeded the lift will still operate as normal but floor levels will
slowly drift over time (due to rope slip) until the appropriate action [as below] is taken.
i. Corr Point missing [re fit corr point]
ii. Corr Sensor Failed [new sensor]
iii. Floor Level adjusted > half corr vane length (i.e. >150mm for a 300mm vane) [move corr
point central then new learn run].
iv. Excessive OSG Rope Slip i.e. the OSG trips and the rope slips [move rope back, or reset
abs posn, or new learn run]
v. Corr Sensor Moved [Move back, or new learn run]
f. Correction information: Select option MENU->POSITIONING SYSTEM INFO->
CORRECTION INFO to view the current correction information. From this menu correction levels
can be viewed for each floor. A test would be to run the lift to each floor and the current level
should be similar for each floor. If one is vastly different to all the rest then typically the correction
point for that floor has moved.
g. Position Device Power Output: Typically the position encoder will be powered through a relay
output from the micro processor. This is to reset the encoder under communications failure by re-
cycling the power. If a communications lost condition is detected this output will de-energise every
10 seconds for 2 seconds to re-cycle the power.

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16. PRE-CHECK INFORMATION:
A. Door Zone Sensor / Door Zone Actuators Fitted At Each Floor Level.
a. Ensure Door Zone Actuators (DZA’s) are fitted at each flr lev and operate the Door Zone Sensor
(DZS) fitted on the lift car. Also the DZA’s are clear of any obstructions of the lift car and DZS.
b. Also ensure the signal from the Door Zone Sensor can be seen in the lift controller. This can be
achieved by pressing MAIN MENU then LIFT/GROUP VEIWER on the Almega keypad which
will display the screen as Figs 6/7 below:
B. Motor Wiring / Speed
a. Ensure motor windings and valves are wired correctly. Ensure the motor runs at the correct /
expected speed when on Inspection, Normal and Level Speed. E.g. for 0.3m/s, the Almega LCD
display will show “S = 0.30”, and is the actual measured speed.
C. Almega Parameters
a. TRAVEL SETUP (Press Menu-> PARAMETERS->TRAVEL TIMES)
STOP TIME = 0 Milliseconds
BRAKE RELEASE TIME = 0 Milliseconds
b. POSITIONING SYSTEM SETUP (Press Menu-> PARAMETERS->POSITIONING SYSTEM SETUP)
SPEED PROFILE CONTROL = NO
WITHIN FLOOR LEV DISTANCE = 35mm
LEVEL TO ZERO DISTANCE UP = 25mm
LEVEL TO ZERO DISTANCE DN = 25mm
LEVELLING DISTANCE = 180mm
ACCEL RATE = 1500mm/s^2
SLOW DIST CALC NON PROF CTRL = TRAVEL SPEED PAR
OVRSPEED GOV DIAMETER = Diameter of OSG (i.e. 300mm for Atwell VG OSG)
D. Slowing Limits
a. Ensure slowing limits are set as the backup slowing distances (BSD) as below. (Also see shaft
wiring drawing). Setting the distance too great may generate events "SLOWED: UP/DN SLOW
LIMIT" and result in inaccurate floor levels at the terminal floors!
b. Speed (m/s) BSD (mm) Speed (m/s) BSD (mm) Speed (m/s) BSD (mm)
0.2 = 250 1.0 = 900 2.0 = 2150
0.5 = 450 1.25 = 1200 2.5 = 3000
0.75 = 700 1.6 = 1600 3.0 = 3900
E. Overspeed Governor Encoder (if fitted)
a. Ensure Correction Sensor/Points are firmly fixed and cannot move. Also central to floor level.
b. Ensure the encoder coupling to the OSG is fitted correctly and all the grub screws are tightened.
n
U
L
D
L
n
D=
NORMAL
8
7
6
5
4
3
2
1
Lift 1
DZ sensor / Input must be ON!
If the software terminal limit parameter is
set, the terminal limits will appear in the
lift viewer as shown.
Filled RED = no position value assigned
Filled GREEN = limit is ok
Not Filled = limit is broken (on the limit)
Fig 6
Note for special Buttons
Press and Hold the shaft Area for 5
seconds to make the test buttons appear.
MOTION:
RSU: ○
RSD: ●
RUN: ○
Z: ●
DEST: 1
S=1.600 ACC
P=4000
MENU
15:03:45
ENTER
CALLS
TOP
BOT
EMER
CARL
LANL
PLEL
5VC: ●
5VIO: ●
24IO: ●
SLOW
LIMIT
TEST
STOP
VANE
TEST
BUFF
TEST
3 Test Buttons appear in the area
dedicated for extra door operators.

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17. SOFTWARE SLOWING LIMITS (Using Cedes Dual Positioning System):
A. Almega2 Parameters
Note: When non-profile setup (Hydraulic), only the parameters underlined and in BOLD apply.
a. POSITIONING SYSTEM (Press MENU->POSITIONING SYSTEM PARAMETERS)
i. SOFTWARE SLOW LIMITS = YES
ii. SLOW LIMIT DECEL RATE = 1700
iii. SLOW LIMIT JERK RATE = 1700
iv. CALC SLOW LIMIT DIST HS = ( READ ONLY)
v. SLOW LIMIT RESET DIST = 750
vi. SLOW LIMIT DIST ADJUST = -50
b. TRAVEL SPEEDS (Press MENU->PARAMETERS->TRAVEL SPEEDS)
i. SLOW LIMIT COMMS LOST SPEED = 0.5 m/s
B. RSU and RSD status with software slowing limits.
a. Ensure Bottom and Top floors are assigned.
C. Wiring
a. Ensure CEDES channel 1 connected to Position Encoder CAN
b. Ensure CEDES channel 2 connected to CAR CAN
D. Calculated Slowing Limit Distance HS
This can be viewed from the parameter (POSITIONING SYSTEM PARAMETERS->CALC SLOW LIMIT DIST
HS). This parameter is updated every 1s for the speed HS. It's also updated when running with the HS value.
E. Non-profile setup
a. When using non profile control and slow dist calc=Travel Speed PAR, i.e. hydraulic, adjust the
backup slowing limit by setting the ‘SLOW LIMIT DIST ADJUST’ by x value.
e.g. when it is set to default -50, it puts the backup slowing limits -50mm behind the actual slowing
distance. (Press MENU->POSITIONING SYSTEM PARAMETERS-> SLOW LIMIT DIST ADJUST)
b. The debug screen will show the last up/down slow distance.
(Press MENU->POSITIONING SYSTEM INFO-> DEBUG INFO)
EL
EH
E-
E+
CCL
CCH
C1 L (Blue)
C1 H (Grey)
GND (Green)
+24 V (White)
GND (Black)
+24V (Pink)
C2L (Brown)
C2H (Yellow)
CEDES
APS
If the SOFTWARE SLOW LIMITS
parameter is set, the RSU/RSD will
indicate the software slow limit status as
below.
Filled RED = Top/Bottom floor not assigned
Filled ORANGE = Slow limit comms lost
Filled GREEN = Activated
Not Filled = Not Activated
D=
NORMAL
8
7
6
5
4
3
2
1
Fig 3
MOTION:
RSU: ○
RSD: ●
RUN: ○
Z: ●
DEST: 1
S=1.600 ACC
P=4000
MENU
15:03:45
ENTER
CALLS
TOP
BOT
EMER
CARL
LANL
PLEL
5VC: ●
5VIO: ●
24IO: ●
Lift 1
n
U
L
D
L
n