RST FRC-Q Series User manual

9.581.140-6 Page: 1
VVVF Controller
for
Elevators
)
FRC-Q
FRC-F
IMD

9.581.140-6 Page: 2
Issued by: RST Elektronik GmbH
Tannenstraße 11
74229 Oedheim
Phone: +49 7136 / 9912-0
Fax: +49 7136 / 9912-10
www.rst-elektronik.de
Copyright: © 2017 RST Elektronik GmbH
All rights reserved by the publisher, including reprinting and copying of extracts of
the present manual.
No part of this manual shall be reproduced or copied using electronic reproduction
systems in any way, unless the publisher approved of such reproduction or copying
in writing before.
RST Document No.: 9.581.140-6
Valid as from software: 18.080.18
Subject to change

9.581.140-6 Page: 3
xContents
1 General......................................................................................................................... 9
1.1 Information about this manual .........................................................................................................9
1.2 Co-applicable documents .................................................................................................................9
1.3 Signs and symbols ..........................................................................................................................10
2 Important Notes......................................................................................................... 11
2.1 Safety Tips........................................................................................................................................11
2.2 Retrofitting old systems..................................................................................................................11
2.3 Installation of the VVVF controller .................................................................................................11
2.4 Installation of the Brake Resistor...................................................................................................12
2.5 See to sufficient ventilation of the cabinet....................................................................................13
2.6 Connection of contactor coils ........................................................................................................13
2.7 Contactor mounting plate ...............................................................................................................13
2.8 Earthing.............................................................................................................................................13
2.9 Shielding...........................................................................................................................................14
2.10 Earth-leakage circuit-breaker......................................................................................................14
2.11 Motor protection by ptc-thermistor ............................................................................................14
2.12 Motor protection switch...............................................................................................................14
2.13 Mains feedback.............................................................................................................................15
2.14 Energy recovery ...........................................................................................................................15
2.15 Reactive current compensation..................................................................................................15
3 Warranty..................................................................................................................... 15
4 Technical Specification............................................................................................. 18
4.1 Connection to power supply...........................................................................................................18
4.2 Sizes..................................................................................................................................................18
4.3 Ambient conditions .........................................................................................................................19
4.4 Mains voltage cut-in frequency ......................................................................................................19
4.5 Inputs/outputs ..................................................................................................................................20
4.6 Device options .................................................................................................................................21
4.6.1 Optional circuit board for use with sine encoders.......................................................................21
4.6.2 Optional circuit board for USB host ............................................................................................21
4.6.3 External display ..........................................................................................................................21
4.6.4 RS422 transducer for shaft copy outputs ...................................................................................21
4.6.5 Relay module RM3 .....................................................................................................................21
4.7 Scope of supply / accessories .......................................................................................................22
4.8 Dimensions.......................................................................................................................................22
5 Installation ................................................................................................................. 30
5.1 Shaft installation ..............................................................................................................................30
5.1.1 Deceleration distance / leveling switches...................................................................................30
5.1.2 Direct landing..............................................................................................................................30
5.2 Connection of VVVF controller.......................................................................................................32
5.2.1 Power connections .....................................................................................................................32
5.2.1.1 Protective conductor..................................................................................................................32
5.2.1.2 Connection to power supply......................................................................................................32
5.2.1.3 Fans...........................................................................................................................................32
5.2.1.4 Motor phases.............................................................................................................................32
5.2.1.5 Braking resistor..........................................................................................................................32
5.2.2 Low-voltage connections ............................................................................................................33
5.2.2.1 Encoder .....................................................................................................................................33
5.2.2.1.1 Square wave encoder.........................................................................................................33
5.2.2.1.2 Sine encoder.......................................................................................................................33
5.2.2.2 Drive command inputs...............................................................................................................36
5.2.2.2.1 General ...............................................................................................................................36
5.2.2.2.2 Overview.............................................................................................................................36

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5.2.2.2.3 Setting the direction ............................................................................................................36
5.2.2.2.4 Control via floating contacts, internal control voltage .........................................................37
5.2.2.2.5 Control via floating contacts, external control voltage ........................................................37
5.2.2.3 Signal procedures......................................................................................................................38
5.2.2.3.1 Signal procedure at normal operation (example: up-travel at V4)......................................38
5.2.2.3.2 Signal procedure at inspection ...........................................................................................39
5.2.2.3.3 Signal procedure for levelling operation .............................................................................39
5.2.2.3.4 Signal procedure with signal „motor magnetized “ .............................................................40
5.2.2.3.5 Faults / interruptions of safety circuit ..................................................................................41
5.2.2.4 Digital inputs ..............................................................................................................................42
5.2.2.5 Motor PTC input ........................................................................................................................42
5.2.2.6 Digital outputs............................................................................................................................42
5.2.2.7 Relay outputs.............................................................................................................................42
5.2.2.7.1 Connection contacts ...........................................................................................................42
5.2.2.7.2 Switching statuses ..............................................................................................................42
5.2.2.8 Incremental encoder signals for shaft copying of the elevator control ......................................43
5.2.2.9 RS-485 interface for DCP mode or external display .................................................................43
5.2.2.9.1 Connection for DCP mode:.................................................................................................43
5.2.2.9.2 Connection of external display............................................................................................43
6 Use of the VVF controller.......................................................................................... 45
1.1 Control elements ..................................................................................................................................45
1.2 Entering parameter values...................................................................................................................45
1.3 Selecting settings from parameter lists .............................................................................................46
1.4 Navigation in the menu ........................................................................................................................46
7 Error messages ......................................................................................................... 47
1.5 Acknowledging faults...........................................................................................................................47
7.1.1 Manual acknowledgement using the unit's keyboard.................................................................47
7.1.2 External acknowledgement by a +24V signal.............................................................................47
7.1.3 Acknowledgement by the unit itself by auto-fault reset ..............................................................47
8 Commissioning ......................................................................................................... 48
8.1 Switching on the power supply......................................................................................................48
8.2 Selection of operating mode...........................................................................................................48
8.2.1 Vector control with asynchronous machine................................................................................48
8.2.2 Open Loop4 ................................................................................................................................48
8.2.3 Vector control with synchronous machine..................................................................................48
1.6 Adaptation of the controller parameters to the system....................................................................49
8.2.3.1 Open Loop operating mode.......................................................................................................49
8.2.3.2 Operating Mode "Vector control with synchronous machine" ...................................................49
8.2.3.3 Operating Mode "Vector control with asynchronous machine" .................................................49
1.7 First travel operation ............................................................................................................................50
8.3 Setting of the load application .......................................................................................................51
9 The Menu.................................................................................................................... 52
9.1 Menu overview .................................................................................................................................52
9.2 Selection of units .............................................................................................................................56
9.3 Setting – programming the converter............................................................................................57
9.3.1 Setting speeds ............................................................................................................................57
9.3.2 Setting the times/distances.........................................................................................................59
9.3.3 Setting the speed controller........................................................................................................60
9.4 Display/Scanning operating variables...........................................................................................62
9.4.1 Display of actual and set values .................................................................................................62
9.4.1.1 Speed ........................................................................................................................................62
9.4.1.2 Motor current and torque...........................................................................................................62
9.4.1.3 Other variables ..........................................................................................................................62
9.4.1.4 Bar graph display of deviation between required and actual speeds........................................63
9.4.2 Inputs/Outputs ............................................................................................................................63
9.4.2.1 Drive commands........................................................................................................................63
9.4.2.2 Digital inputs ..............................................................................................................................63
9.4.2.3 Digital outputs............................................................................................................................63
9.4.2.4 Relay outputs.............................................................................................................................64

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9.4.3 Errorstack ...................................................................................................................................64
9.4.4 Statistical data ............................................................................................................................65
9.4.5 Encoder diagnosis ......................................................................................................................65
9.4.6 Current errors .............................................................................................................................65
9.5 System settings ...............................................................................................................................66
9.5.1 Unit password protection ............................................................................................................66
9.5.2 Setting the language...................................................................................................................67
9.5.3 Selecting the unit mode (U/min or m/sec) ................................................................................68
9.5.4 Unit operating modes..................................................................................................................68
9.5.5 Selection of device control..........................................................................................................69
9.6 Information menu.............................................................................................................................69
9.7 Extended menus ..............................................................................................................................70
9.7.1 Extended Drive Curve.................................................................................................................70
9.7.1.1 Setup of start-up behaviour .......................................................................................................70
9.7.1.2 Additional intermediate speeds .................................................................................................71
9.7.1.3 Floor-to-Floor Correction ...........................................................................................................72
9.7.1.4 Speed transitions.......................................................................................................................73
9.7.2 Extended control settings ...........................................................................................................74
9.7.3 Selection of works-setting...........................................................................................................75
9.7.4 Configuration of inputs and outputs............................................................................................75
9.7.4.1 Encoder/Motor...........................................................................................................................76
9.7.4.2 Digital inputs ..............................................................................................................................77
9.7.4.2.1 External fault acknowledgement.........................................................................................77
9.7.4.2.2 Monitoring drive contactors.................................................................................................77
9.7.4.2.3 Monitoring of opening brake upon start ..............................................................................77
9.7.4.2.4 Brake monitoring as per EN81/A3 ......................................................................................77
9.7.4.2.5 Emergency power...............................................................................................................77
9.7.4.3 Drive Commands.......................................................................................................................78
9.7.4.3.1 Encoding .............................................................................................................................78
9.7.4.3.2 Configuration of direction signals........................................................................................78
9.7.4.4 Outputs ......................................................................................................................................78
9.7.5 Further supervisions ...................................................................................................................79
9.7.6 Special functions.........................................................................................................................80
9.7.6.1 Loosening cabin from safety catch............................................................................................80
9.7.6.2 Automatic measurement of motor characteristic.......................................................................80
9.7.6.3 Automatic test of motor connection upon the start of drive.......................................................80
9.7.6.4 Determination of angle offset in synchronous machines...........................................................80
9.7.6.5 Evaluation of an analogue load measuring unit ........................................................................81
9.7.6.5.1 Calibration with empty cabin...............................................................................................81
9.7.6.5.2 Calibration with load in cabin ..............................................................................................81
9.7.6.5.3 Further information on calibration .......................................................................................81
9.7.6.5.4 Enabling the function ..........................................................................................................81
9.7.6.6 Counter for capturing travel direction changes .........................................................................82
9.7.6.6.1 General ...............................................................................................................................82
9.7.6.6.2 Programming the counter and activating the function ........................................................82
9.7.6.6.3 Menu structure....................................................................................................................82
9.7.6.6.4 Setting the counter interval and activating the function......................................................83
9.7.6.6.5 Display of counter values....................................................................................................84
9.7.6.6.6 Signaling before reaching the programmed counter value (pre-warning) ..........................84
9.7.6.6.7 Reaching / exceeding the programed counter value..........................................................84
9.7.7 Monitoring of power brakes as per EN81-A3 .............................................................................86
9.7.7.1 Field of application.....................................................................................................................86
9.7.7.2 Basic function of self-monitoring system...................................................................................86
9.7.7.2.1 Brake element as per EN81/A3 ..........................................................................................86
9.7.7.2.2 Monitoring inputs on the VVVF controller ...........................................................................86
9.7.7.3 Function of self-monitoring system............................................................................................86
9.7.7.3.1 Monitoring at start of travel operation .................................................................................86
9.7.7.3.2 Monitoring at end of travel operation: .................................................................................87
9.7.7.4 VVVF controller settings............................................................................................................87
9.7.7.4.1 Configuration of digital inputs .............................................................................................87
9.7.7.4.2 Activation of monitoring function.........................................................................................87
9.7.7.4.3 Adjustment of monitoring times for special cases ..............................................................88
9.7.7.4.4 Resetting the fault...............................................................................................................88
9.7.7.5 Functional check........................................................................................................................89

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9.7.7.5.1 Check by RST following software modifications.................................................................89
9.7.7.5.2 Functional test during on-site commissioning.....................................................................89
9.8 Operation with CANopen-Interface ................................................................................................91
9.8.1 General information ....................................................................................................................91
9.8.2 Wiring..........................................................................................................................................91
9.8.3 Activating the CANopen-Lift Interface ........................................................................................92
9.8.4 Interface Settings........................................................................................................................92
9.8.5 Checking the connection ............................................................................................................92
9.8.6 Interface Settings........................................................................................................................92
9.8.7 Commissioning ...........................................................................................................................93
9.8.8 Operation in Velocity-Mode ........................................................................................................93
9.8.9 Operation in Position-Mode ........................................................................................................93
9.9 Operation with DCP-Interface.........................................................................................................95
9.9.1 General information on DCP operation ......................................................................................95
9.9.2 Wiring..........................................................................................................................................95
9.9.3 Activation of DCP control............................................................................................................95
9.9.4 DCP01 ........................................................................................................................................95
9.9.5 DCP03 ........................................................................................................................................95
9.9.6 DCP04 ........................................................................................................................................96
9.9.6.1 General information on DCP04 mode .......................................................................................96
9.9.6.2 Commissioning ..........................................................................................................................97
9.9.6.3 DCP4 Setup options..................................................................................................................97
9.9.7 DCP quick start function .............................................................................................................98
9.9.8 Monitoring of the DCP Connection .............................................................................................98
9.10 Use with synchronous machines / gearless ...........................................................................100
9.10.1 Entering the general plant data ................................................................................................101
9.10.2 Calibration.................................................................................................................................102
9.10.2.1 General..................................................................................................................................102
9.10.2.2 Calibration with synchronous machine turning......................................................................102
9.10.2.2.1 Requirements for the measurement without ropes.........................................................102
9.10.2.2.2 Requirements for the measurement with ropes putted on .............................................102
9.10.2.3 Procedure ..............................................................................................................................102
9.10.3 Checking the rotational sense assignment...............................................................................103
9.10.3.1 Calibration with synchronous machine stopped and brake applied......................................104
9.11 Open-Loop Mode........................................................................................................................106
9.11.1 Open-Loop4..............................................................................................................................106
9.11.1.1 Parameter overview...............................................................................................................106
9.11.1.2 Setup of converter .................................................................................................................106
9.11.1.2.1 Activating the operating mode ........................................................................................106
9.11.1.2.2 Entering the plant data....................................................................................................107
9.11.1.2.3 Automatic measurement of motor parameters ...............................................................107
1.8 Service menus for special applications ...........................................................................................108
9.11.2 Important information................................................................................................................108
9.11.3 Enabling service level...............................................................................................................108
9.11.4 Menu description ......................................................................................................................108
9.11.4.1 Service XC164 Gearless ......................................................................................................108
9.11.4.2 Converter...............................................................................................................................109
9.11.4.3 General configuration ............................................................................................................109
9.11.4.4 Error triggering.......................................................................................................................109
10 Emergency current evacuation with UPS.............................................................. 110
10.1.1 General .....................................................................................................................................110
10.1.2 Wiring........................................................................................................................................110
10.1.3 Dimensioning of UPS................................................................................................................111
10.1.4 Particularities of the VVVF-controller during evacuation ..........................................................112
11 Service and maintenance ....................................................................................... 112
12 FRC-Q with integrated drive contactors................................................................ 113
12.1 General ........................................................................................................................................113
12.2 Technical Specification .............................................................................................................113
12.2.1 Housing.....................................................................................................................................113
12.2.2 Fastening the cables.................................................................................................................116
12.2.3 Wiring........................................................................................................................................116

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13 Converter operation without travel contactors..................................................... 117
13.1 General ........................................................................................................................................117
13.2 Scope of application ..................................................................................................................117
13.3 Safety instructions.....................................................................................................................117
13.4 Function ......................................................................................................................................118
13.5 Requirements to be met by installation/components ............................................................118
13.6 Activation of STO function........................................................................................................119
13.7 Functional check........................................................................................................................119
13.7.1 Checking the GS signal ............................................................................................................119
13.7.2 Checking the STO signals ........................................................................................................119
13.7.3 Checking the contactor drop-out monitor .................................................................................119
14 USB module for long-term data recording............................................................ 126
14.1 Installation of USB module .......................................................................................................126
14.2 USB menu ...................................................................................................................................126
14.2.1 Call / Activation .........................................................................................................................126
14.2.2 Menu control .............................................................................................................................126
14.2.3 Saving VVVF controller parameters on USB stick ...................................................................127
14.2.4 Loading VVVF parameters from USB stick ..............................................................................127
14.2.5 Deleting VVVF controller parameters from USB stick..............................................................128
14.2.6 Activating travel curve recording on USB stick.........................................................................128
14.3 Error messages from the USB module ....................................................................................129
14.3.1 No USB-Modul !?!.....................................................................................................................129
14.3.2 Err: USB-Stick Init, Err: USB--Status, Err: USB-FP-Status ....................................................129
14.3.3 Err: SendParam ........................................................................................................................129
15 Errors and Warnings............................................................................................... 130
15.1 Error messages at the converter ..............................................................................................130
15.1.1 Encoder polarity........................................................................................................................130
15.1.2 No start-up ................................................................................................................................130
15.1.3 Overspeed ................................................................................................................................130
15.1.4 Control Deviation ......................................................................................................................130
15.1.5 Overcurrent...............................................................................................................................130
15.1.6 Overvoltage DC ........................................................................................................................131
15.1.7 Undervoltage DC ......................................................................................................................131
15.1.8 Motor adaptation.......................................................................................................................131
15.1.9 Motor temperature ....................................................................................................................131
15.1.10 Temperature KK. (Overtemperature)........................................................................................131
15.1.11 DCP-TimeoutErr .......................................................................................................................131
15.1.12 DCP-ChecksumErr ...................................................................................................................132
15.1.13 DCP04 Remaining distance .....................................................................................................132
15.1.14 Timout FastStart DCP...............................................................................................................132
15.1.15 Runtime error............................................................................................................................132
15.1.16 Contactor error..........................................................................................................................132
15.1.17 Power unit.................................................................................................................................132
15.1.18 Calibration.................................................................................................................................133
15.1.19 Earth fault .................................................................................................................................133
15.1.20 Motor overload..........................................................................................................................133
15.1.21 Sine amplitude ..........................................................................................................................133
15.1.22 CDAmplitude.............................................................................................................................133
15.1.23 Referencing error......................................................................................................................133
15.1.24 EnDat BUS_OPEN, EnDat Timeout , EnDat CRC ...................................................................134
15.1.25 EnDat ALARM ..........................................................................................................................134
15.1.26 EnDat STRICHZAHL ................................................................................................................134
15.1.27 SSI BUS_OPEN, SSI Timeout .................................................................................................134
15.1.28 n-Max Synchron........................................................................................................................134
15.1.29 Overload FU .............................................................................................................................134
15.1.30 Timeout ZS=Imot ......................................................................................................................135
15.1.31 SSC-Error .................................................................................................................................135
15.1.32 No calibration............................................................................................................................135
15.1.33 Overvoltage mains, low voltage mains, phase sequence mains..............................................135
15.1.34 Timeout Brake Start..................................................................................................................135
15.1.35 BRR_Overtemperature.............................................................................................................135

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15.1.36 BRR_Current ............................................................................................................................135
15.1.37 GS failure during travel.............................................................................................................136
15.1.38 EEPROM ..................................................................................................................................136
15.1.39 Timeout Brake Start..................................................................................................................136
15.1.40 STO failure during travel...........................................................................................................136
15.1.41 STO logic ..................................................................................................................................136
15.1.42 Brake-On EN81 ........................................................................................................................136
15.1.43 Brake-Off EN81 ........................................................................................................................136
15.1.44 DirChangeCounterMax.............................................................................................................137
15.1.45 CAN Timeout ............................................................................................................................137
15.2 Warnings at converter ...............................................................................................................137
15.2.1 Temperature .............................................................................................................................137
15.2.2 Motor data o.k. ?.......................................................................................................................137
15.2.3 No Refsignal .............................................................................................................................137
15.2.4 Load meas. error ......................................................................................................................137
15.2.5 No +5V +15 +24V .....................................................................................................................137
15.2.6 DCP connection........................................................................................................................137
15.2.7 DCP04 software........................................................................................................................137
15.2.8 Drive Commands !?..................................................................................................................137
15.2.9 Control Times !? .......................................................................................................................137
15.2.10 EEP write protection .................................................................................................................138
15.2.11 EEP-RAMaccess ......................................................................................................................138
15.2.12 EEPROM error..........................................................................................................................138
15.2.13 Config Device ...........................................................................................................................138
15.2.14 Measured values ......................................................................................................................138
15.2.15 MAXVALUE PARA ...................................................................................................................138
15.2.16 STO-Signal missing..................................................................................................................138
15.2.17 DirChangeCounterKrit ..............................................................................................................138
16 Factory Settings, Parameter Overview.................................................................. 139

9.581.140-6 Page: 9
1 General
1.1 Information about this manual
This assembly manual describes a recommended assembly method which has been implemented
successfully many times. However, RST Elektronik does not guarantee that this assembly variant can
also be applied to other lift plants. The Customer alone shall be responsible for complying with the
local regulations and adjusting the special circuitry features of each lift installation to the relevant
technical requirements. RST Elektronik shall not be held responsible for any loss and/or damage
resulting from the Customer's negligence during the execution of the assembly. This shall apply in
particular to any non-compliance with the Assembly and Commissioning Instructions/Manuals supplied
with our products.
Before starting the work, read these instructions carefully. Compliance with all safety instructions
contained in this manual is a prerequisite for safe working.
In addition to this manual, the applicable local accident prevention and safety regulations must be
complied with.
1.2 Co-applicable documents
In addition to this manual, the following documents shall also be complied with:
„Operation of KONE MonoSpace drive systems“ (RST-Dokument 9.639.xx)

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1.3 Signs and symbols
Important note! Comply in any case. Non-compliance may
result in malfunction or damage.
Danger due to electrical voltage! Danger to life and limb!
Useful tip.
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