Mitsubishi Elevator Nexway VFGH High-Speed Commissioning Guide

1. Installation & Adjustment of Critical Components

1. Door System Configuration:

   • Install and adjust landing and car door operators (including car-top station settings).

2. Leveling Sensor Setup:

   • Position and calibrate magnetic plate for precise floor alignment.

3. Terminal Safety Switches:

   • Install and adjust deceleration, limit, and final limit switches at shaft terminals.

4. Landing Station Devices:

   • Mount hall call buttons/displays and configure related potentiometers.

2. Pre-Commissioning Preparations

2.1 LED Status Verification

• Confirm normal illumination of all board LEDs.

2.2 FMS Layer Data Initialization

Required before automatic operation to prevent "selector deviation" faults:

1. Manual Mode Setup:

   • Move the car to the bottom floor leveling zone via manual control.

   • Hold the FMS toggle switch downward for 2 seconds to activate layer data writing.

2. Continuous Upward Run:

   • Manually drive the car upward to the top floor until UL switch activates.

   • Critical: Do NOT stop mid-travel.

   • Success: Floor number display stops blinking at the top floor.

3. Failure Recovery:

   • If interrupted, restart from Step 1.

2.3 High-Speed Operation Sequence

1. Independent Mode (Optional):

   • Set the car operation panel’s "Independent" switch to ON if equipped.

2. Automatic Mode Activation:

   • Set ALL maintenance panel switches (car-top, car, landing) to AUTO.

   • Confirm LED 60 illuminates (extinguishes if any switch remains in MANUAL).

3. Call Button Test:

   • Press hall/car call buttons to verify indicator lights activate.

3. High-Speed Calibration Procedures

3.1 Balance Factor Adjustment

1. Load Setup:

   • Place 50% of the rated load in the car, centralized at the midpoint.

   • Position the car at the bottom floor.

2. Upward Run Measurement:

   • Run the elevator to the top floor in AUTO mode at rated speed.

   • Record the motor current when the car reaches the mid-shaft position.

3. Downward Run Measurement:

   • Repeat the test in the downward direction at rated speed.

   • Record the motor current at mid-shaft.

4. Counterweight Optimization:

   • Adjust counterweight blocks until current difference between upward/downward runs is ≤±1A.

3.2 Brake System Calibration

1. Plunger Stroke Adjustment:

   • Set brake plunger stroke to 0.6±0.1mm.

2. Brake Contact Gap Test:

   • No activation when inserting a 0.5mm feeler gauge.

   • Must activate with a 1.0mm feeler gauge.

3. Brake Slip Distance Verification:

   • Load the car with 110% rated load.

   • Configure P1 board settings:

     • Set R/M-MNT-FWR toggle to MNT.

     • Adjust potentiometers: SET1=0, SET0=B.

     • Press SW1▽ to confirm.

4. Manual Downward Run Test:

   • Press SW1▽ again.

   • Manually drive the car downward via machine room controls.

   • Monitor 7SEG display for real-time speed.

   • Emergency stop when speed reaches 20 m/min.

5. Slip Distance Validation:

   • Confirm 7SEG displays a brake slip value ≤300 (unitless metric).

3.3 Load Weighing System Calibration & Data Initialization

3.3.1 Differential Transformer Calibration

1. Empty Car Preparation:

   • Ensure no load in the car.

   • Technician 1 adjusts the differential transformer at the car bottom.

   • Technician 2 measures voltage at the car-top TSD box.

   • Safety Note: Stand on crossbeams/door operator frames – DO NOT stand directly on the car roof.

2. Voltage Adjustments:

   • TM1 (V1/V3 ↔ TM2 0V): DC2.2V ±0.2V

   • LIR-220 R02 Potentiometer (VB ↔ 0V): DC0.3V ±0.1V

   • VF ↔ 0V: DC-2.0V ±0.2V

3.3.2 Flash-Memory Data Initialization

 Empty Load Data (0%)

1. Set P1 board: SET1=0, SET0=2 → Press SW1▽.

   • 7SEG displays current load data.

2. Hold SW1▽ >1 sec until display stops blinking → Data saved.

3. Reset: SET1=0, SET0=6 → Press SW1▽.

 Half-Load Data (50%)

1. Place 50% rated load near mid-shaft.

2. Set P1: SET1=0, SET0=3 → Press SW1▽.

   • If 7SEG shows "A300" or "AE00":

     • Adjust TSD R01 to VB ↔ 0V = DC+1.8V ±0.1V.

3. Hold SW1▽ >1 sec → Save data.

4. Reset: SET1=0, SET0=6 → Press SW1▽.

 Overload Data (110%)

1. Place 110% load and adjust car-bottom stopper gap to 2mm.

2. Set P1: SET1=0, SET0=4 → Press SW1▽.

3. Hold SW1▽ >1 sec → Save data.

4. Reset: SET1=0, SET0=6 → Record OLWT on control panel nameplate.

3.3.3 Overload & Compensation Adjustments

 Overload Action (29W)

1. Set P1: SET1=4 → Press SW1▽.

2. Adjust SET0 until 7SEG shows "oL" → Confirm doors remain open with alarm.

 Compensation Deviation Correction

1. Place 50% load at bottom floor.

2. Set P1: SET1=8, SET0=3 → Press SW1▽ (auto-speed: 60m/min).

3. Press SW1▽ → SW2△ for upward run → SW2▽ for downward run.

4. Post-test:

   • Read compensation data via MON1=A, MON0=8/9 → Record CUWT.

   • Adjust HWLG (MON1=9, MON0=6) if startup jerks persist.

3.3.4 Startup Gain & Brake Slip Optimization

 Startup Gain Fine-Tuning

1. For empty-car startup jerks:

   • Set car to mid-shaft in IND mode (SPA/IND switch).

   • Set P1: MON1=9, MON0=C → HTOP=0 (7SEG1).

   • Adjust WGHG (SET1=3 + SET0) until car remains stationary after brake release.

   • Reset HTOP=5.

 Brake Slip Correction

• Upward Slip (Fig 2-6):

  • Set SET1=3 → Increase SET0 (F direction) → Confirm with SW1.

• Downward Slip (Fig 2-7):

  • Set SET1=3 → Decrease SET0 (1 direction) → Confirm with SW1.

4. TSD Switch Position Verification & High-Speed Testing

4.1 TSD Action Position Check

Temporary Parameter Setup

1. Safety Precheck:

   • Confirm no "selector deviation" fault (blinking floor display) during empty-car terminal runs.

2. TSD Check Mode Activation:

   • Set P1: SET1=8, SET0=1 → Press SW1▽ (speed auto-sets to 60m/min).

3. Full-Shaft Test:

   • Press SW1▽ → SW2△ for upward run.

   • At top floor, press SW2▽ for downward run.

   • 7SEG displays TSD switch deviations sequentially (see table below):

4. Reset: Restore P1 parameters to defaults.

4.2 High-Speed Auto-Run Validation

1. Manual Mid-Shaft Positioning:

   • Drive the car to a mid-floor leveling zone via manual control.

2. Auto-Mode Configuration:

   • Set SPA/IND (P1) to center position.

   • Set AUTO/HAND (R1) to AUTO.

   • Ensure all car-top/car switches are in AUTO.

3. Multi-Floor Test:

   • Register adjacent floor calls for short auto-runs.

   • Verify smooth deceleration and leveling at each stop.

4. Full-Shaft Auto-Run:

   • Test multi-floor and terminal-to-terminal runs for consistent performance.

4.3 Magnetic Pole Position Learning

1. Empty Car Setup:

   • Position the car at the bottom floor.

2. Learning Mode Activation:

   • Set P1: SET1=0, SET0=d → Press SW1▽ (speed: 60m/min).

3. Data Initialization:

   • Press SW2△ → Car auto-runs to top floor.

   • Success: 7SEG stops blinking.

4. Reset: Restore SET1/SET0 to defaults.

4.4 Inertia Identification Run

1. Temporary Parameter Setup:

   • Apply parameters from TSD Check Step 1.

2. Test Mode Activation:

   • Position empty car at bottom floor.

   • Set P1: SET1=8, SET0=2 → Press SW1▽ (speed: 60m/min).

3. Terminal-to-Terminal Runs:

   • Press SW1▽ → SW2△/▽ → Car auto-runs between terminals.

   • Validate 7SEG3 displays "0–9" without blinking after two round trips.

4. Failure Recovery:

   • If 7SEG3 blinks, repeat TSD Check before retesting.

5. Reset: Restore all parameters.

5. DC-CT Gain Calibration & Leveling Precision Optimization

5.1 DC-CT Gain Identification

*Resolve motor current imbalance causing empty-car jerks (requires properly adjusted brakes):*

1. Preparation:

   • Set R/M-MNT-FWR to MNT.

   • Manually position the car mid-shaft at low speed.

2. Compensation Mode Activation:

   • Set P1: SET1=8, SET0=4 → Press SW1▽ twice.

3. Manual Upward Run (Simulated):

   • Hold manual UP switch for ≥50 seconds (brakes remain engaged; car stationary).

   • Success: 7SEG displays cumulative compensation count; data saved to memory.

4. Precision Optimization:

   • Repeat Step 3 3+ times for accuracy.

5. Reset: Restore SET1/SET0 to defaults.

5.2 Leveling Error Adjustment

 5.2.1 PTSH Parameter Tuning

• Symptom: Over-leveling or failure to reach leveling position.

• Procedure:

  1. Set P1: SET1=1 → Press SW1▽.

  2. Adjust SET0 to modify PTSH → Press SW1▽ to confirm.

5.2.2 Magnetic Plate Repositioning

• Recalibrate leveling sensor plate installation for alignment accuracy.

 Load Compensation (WGCPN)

1. Default Setup: SET1=6, SET0=8 (factory default = 0.0mm).

2. Adjust SET0 → Press SW1▽ to apply.

5.2.3 Brake Timing & Re-Leveling (LTB/RLPT)

1. LTB (Brake Engagement Timing):

   • Too early: Increase LTB (F direction).

   • Too late: Decrease LTB (0 direction).

   • Tool Required: Service computer for E2PROM modification.

   • 

2. RLPT (Re-Leveling Precision):

   • Critical: Adjust only with micro-recorder/accelerometer for ride comfort compliance.

6 TSD Mode Calibration & Load Performance Validation

6.1 TSD Mode Delay Constant (TSSH) Setup

1. Initial Configuration:

   • Position empty car at bottom floor.

   • Set TSSH = DELY (retrieve DELY via MON1=9, MON0=E → check 7SEG2).

2. TSSH Adjustment:

   • Set P1: SET1=5 → Press SW1▽ → Adjust SET0 → Confirm with SW1▽.

3. Terminal Run Test:

   • Press SW2△/▽ → Run car between terminals at rated speed.

   • Increment TSSH until 7SEG1 blinks during deceleration → Stop (max TSSH reached).

6.2 TSD Operation Check

1. Mid-Shaft Setup:

   • Position empty car at mid-floor door zone.

   • Set TSSH = (Current Value – 2).

2. Test Mode Activation:

   • Set P1: SET1=0, SET0=F → Press SW1▽ twice.

3. Terminal Run Validation:

   • Press SW2△/▽ → Car runs terminal-to-terminal at rated speed.

   • Post-test:

     • Confirm car stops within door zone at bottom floor.

     • Validate 7SEG3 displays 3–5.

4. Over-Travel Correction:

   • If car overshoots terminal, increase TSSH by 1.

5. Reset: Restore P1 to SET1=0, SET0=6.

6.3 Load Performance Testing

Validate elevator operation across 0%–110% load: