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Motion Control Engineering Motion 3000ES User Manual

Escalator control
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Motion Control Engineering, Inc.
11380 White Rock Road
Rancho Cordova, CA 95742
voice 916 463 9200
fax 916 463 9201
www.mceinc.com
User Guide,
Motion 3000ES Escalator Control
Manual # 42-02-E001, Rev B9, May 2017

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Questions and answers

Rick Knemeyer
March 12, 2025

On our new Escalator controller Mod, I’m unable to get the bottom Missing Step Device to work. We have 24vdc at bottom and unit just bypassing bottom sensors and only stop on top Missing Step Device.

-1
2 comments:
Mr. Anderson
March 12, 2025

To troubleshoot the bottom Missing Step Device on the Motion Control Engineering Motion 3000ES Escalator controller, follow these steps:

1. Check Parameter Settings:
- Confirm that F3-05 is set to the same value as DSP1.
- If not, refer to the Escalator Learn Operation to re-learn parameter F3-05.

2. Verify Sensor Inputs:
- Ensure that S6 input on J1 of EC-SCB is properly connected.

3. Inspect Sensor Placement:
- Verify that sensors are spaced less than 1/2 tread width apart.

4. Check Mechanical Integrity:
- Inspect the escalator for mechanical issues that may affect step detection.

5. Check Connection and Function:
- Ensure that the input device is functioning correctly and properly connected.

If issues persist, repeat the Escalator Learn Operation and inspect for hardware faults.

This answer is automatically generated

0
R Knemeyer
March 12, 2025

@Mr. Anderson thank u very much. I believe i have checked all that but I will double check DSP 1 parameter.

0

Related Manuals for Motion Control Engineering Motion 3000ES

Summary of Contents for Motion Control Engineering Motion 3000ES

  • Page 1 Motion Control Engineering, Inc. 11380 White Rock Road Rancho Cordova, CA 95742 voice 916 463 9200 fax 916 463 9201 www.mceinc.com User Guide, Motion 3000ES Escalator Control Manual # 42-02-E001, Rev B9, May 2017...
  • Page 2 Limited Warranty Motion Control Engineering (manufacturer) warrants its products for a period of 15 months from the date of shipment from its factory to be free from defects in workmanship and materials. Any defect appearing more than 15 months from the date of shipment from the factory shall be deemed to be due to ordinary wear and tear.
  • Page 3 Make certain that power line fluctuations are within plus or minus 5% of proper value. In This Guide: This guide is the installation, adjustment, and troubleshooting guide for the Motion 3000ES escalator control. When viewed online as a pdf file, hyperlinks link to related topics and infor- mational websites.

  • Page 4: Table Of Contents

    About Motion 3000ES ........
  • Page 5 Operating Adjustments ..........29 Controller Parameters .

  • Page 7: About Motion 3000Es

    Escalator controls are available in VVVF Variable Speed, Across-the- Line, or Wye/Delta Direct Line Control versions. Motion 3000ES is fully ASME A17.1-2010, CSA B44.10, BS EN 115, and AS 1735.5 compliant, with independent, redundant safety string inputs, signal path, and processing to ensure safe operation.
  • Page 8 Motion 3000ES Escalator Control The standard Motion 3000 shipment contains two enclosures for non-VVVF drive units or three enclosures for VVVF drive units. This configuration allows simpler installation and reduces wire runs. Main Upper entry cabinet Drive cabinet (if used) 24”...

  • Page 9: Installation

    Installation Installation This section contains: • Equipment grounding • AC connections • Initial power up • Field connections Equipment Grounding For good grounding, quality wiring materials and methods must be used. Grounding must con- form to all applicable codes. Proper grounding is essential for system safety and helps to reduce noise-induced problems.

  • Page 10: Ac Voltage Verification And Wiring

    Motion 3000ES Escalator Control AC Voltage Verification and Wiring The AC wiring instructions in this section describe wiring from commercial power. The majority of technical information is contained in the MCE job prints package and referenced here as nec- essary. As shown in the job prints (if specified), an isolation transformer may be used to clean up “dirty”...

  • Page 11: Check Before Applying Power

    Installation Check Before Applying Power Escalator control enclosures are light weight. During shipping, they can be roughly handled, sometimes jarring connections and even socketed board components loose. To avoid damage, ensure reliable performance, and avoid troubleshooting expense: 1. Verify that no factory wiring connections have become loosened. 2.

  • Page 12: Controller Parameters

    Motion 3000ES Escalator Control Controller Parameters A simple keypad and display allow access to controller parameters. Your controller may have the optional LCD display. The LCD display is capable of displaying full text status and error messages. • ESC button: Press to exit parameter settings without saving changes.
  • Page 13 Installation Parameter setting example — Setting automatic oiling duration: • Check the table to see that oiling duration is parameter F2-02. • Press OK to access parameters. • Press UP until FUN2 is displayed. • Press OK to select FUN2 parameters. •...

  • Page 14: Drive Parameters

    Motion 3000ES Escalator Control Drive Parameters If you have a VVVF Control, selected drive parameters should be checked at this time. One of two drives may be used. Controllers equipped with CT Emerson drives use dynamic braking resistors installed in a sepa- rate resistor cabinet.

  • Page 15: Ct Emerson

    Installation CT Emerson The drive uses a direct entry, LED display and keypad. The display is a two- row display with the upper row showing drive status or the current menu and parameter num- ber being viewed. The lower row shows the value of the displayed parameter number or, if the drive has tripped, the specific fault indication.

  • Page 16: Ct Parameter Entry

    Motion 3000ES Escalator Control CT Parameter Entry The graphic below provides the parameter editing sequence. Status mode, Edit mode, display not flashing character to edit in lower line flashing to change Press value Parameter mode, upper display flashing Press to exit edit mode when ready...

  • Page 17: Keb F5

    Installation KEB F5 The KEB F5 drive uses an LED display and a membrane keypad. Parameters are displayed and changed as shown below. Display Parameter Group Display Parameter Number Parameter Display The blinking point determines the active (changeable) part of the parameter change between parameter group and...
  • Page 18 Motion 3000ES Escalator Control 12 Manual # 42-02-E001...
  • Page 19 Installation At this point, shut down the controller before making field connections.

  • Page 20: Field Connections

    Motion 3000ES Escalator Control Field Connections This section contains: • Motor connections • Brake connections • Safety and I/O connections Checking the Motor If this job reuses existing rotating equipment, the equipment must be checked for insulation breakdown before proceeding.

  • Page 21: Brake Resistance; Dc Brake Only

    Installation Brake Resistance; DC Brake Only Large resistors with slip-ring adjusters are used to adjust brake drop time. Resistor RB1 adjusts primary brake output. Resistor RB2 adjusts the auxiliary brake output. Check sheet -1 of your job prints for detailed information.) 1.

  • Page 22: Proximity Sensors / Rail And Step Speed

    Motion 3000ES Escalator Control Proximity Sensors / Rail and Step Speed The proximity sensors used to check rail speed and step speed/presence are listed below. Con- nect sensors as shown in the job prints. Each sensor has three or four wires (system depen- dent): •...
  • Page 23 Installation Figure 3. Sensor Spacing Timing Diagram When sensors S1 and S2 are spaced less than 1/2 step width apart, the time from leading edge of S1 to lead- ing edge of S2 is shorter going up and longer going down (dotted lines).

  • Page 24: Rail Speed Sensors

    Motion 3000ES Escalator Control 6. Drill mounting holes in the lateral truss member. 7. Install the upper step sensors. Set the running clearance to 1/16” (1.59 mm) max. Tighten the hardware. 8. Connect cables (PN 33-20-0012) to the sensors. Extend the cables from the sensors to the top escalator pit.
  • Page 25 Installation Table 2. EC-MCB Input Connector Descriptions: J1, J2, J3, J4, J5, J6, J11 Terminal Function Remark Spare speed sensor input Not used Step Sensor #1 S2 and S3 monitor direction, step speed, and miss- ing steps for Sensors #1 and #2 respectively. Step Sensor #2 Left handrail speed monitoring Pulse input.
  • Page 26 Motion 3000ES Escalator Control Table 3. EC-MCB Output Connector Descriptions: J7, J8, J9, J10 Terminal Wye/Delta drive mode ATL and VVVF drive mode Wye contactor Power contactor Delta contactor Running contactor Brake contactor Brake contactor T1 - T3 common T1 - T3 common...
  • Page 27 2. Press N until Device Type is displayed. 3. Press S to select. 4. Verify/set the Device Type to Motion 3000ES Escalator Controller. 5. If the Device Type was changed, reset the USN board by pressing the RSTA button. 6. After the device reboots, confirm new device type is selected.
  • Page 28 Motion 3000ES Escalator Control An escalator connection has additional parameters that need to be configured. Please note: each escalator must have its own unique lift number. Note For an escalator to work with USN, it must be an LCD (not LED) model. Verify that the escala- tor versions are the following, or higher: •...
  • Page 29 Configuration The processor boards, EC-MCB and EC-SCB can each use up to four (optional) display boards. The last display board in each chain must have an impedance matching resistor to properly ter- minate the CAN bus. Jumper J1 on the display board (EC-DISP) is used to enable or disable the impedance matching resistor.
  • Page 30 Motion 3000ES Escalator Control Table 6. EC-SCB Input Connector Descriptions: J1, J2, J3, J4 Terminal Function Remark Step Sensor #1 S6 and S7 monitor direction, step speed, and missing steps for Sensors #1 and #2 Step Sensor #2 respectively. Left handrail speed monitoring Impulse input.
  • Page 31 Configuration Table 7. EC-SCB Output Connector J9 Terminal Wye/Delta drive mode ATL and VVVF drive mode Active when Up or Down contactors are Active when UP or DOWN contactors are active active or when inverter output is active. common common Spare output Not used common...

  • Page 32: Initial System Startup

    Motion 3000ES Escalator Control Initial System Startup This section describes initial startup and adjustment. • Prestart check • Initial startup Prestart Check Before system startup: • Check and correct any hazardous conditions • Check/adjust installed components for: • Smooth operation •...

  • Page 33: Initial Startup

    Initial System Startup Initial Startup The initial startup procedure requires: • Power up • Drive (if used) parameter check/set • Inspection operation Power Up 1. Press the controller Stop button so power is removed from the machine. 2. Set the Norm/Insp switch to the Inspection position. 3.

  • Page 34: Remote Inspection Control Connection

    Motion 3000ES Escalator Control Remote Inspection Control Connection Special sockets for connecting remote inspection controls are provided. The sockets are covered and, as soon as a socket cover is opened, the escalator is placed in Inspection mode and stopped. Depending on job require- ments, these sockets may be mounted on the control enclosure and/or remotely in locations specified by the customer.

  • Page 35: Escalator Braking Distance Feature

    Initial System Startup Escalator Braking Distance Feature This feature (not available in all versions of software) measures the stopping distance of the escalator by monitoring the output of the hand- rail proximity sensors at S4 and S5 of the MCB. Immediately upon receiving a stop signal, the MCB counts the number of pulses received at S4 and S5 and determines whether or not the escalator has stopped within a user-defined tolerance.

  • Page 36: Escalator Learn Operation

    Motion 3000ES Escalator Control Escalator Learn Operation Before performing the learn operation, you should be comfortable with the operation of the escalator. You must use a hand held tachometer to check the escalator step and handrail speeds and verify that all adjustments are correctly made.

  • Page 37: Operating Adjustments

    Operating Adjustments Operating Adjustments Both the controller and the VVVF drive (if used) allow adjustment of many operating character- istics. You will need to adjust each for optimal performance of the escalator installation. This section contains complete controller and drive parameter tables. Keypad Refresher •...
  • Page 38 Motion 3000ES Escalator Control Table 10. Controller Parameters Param Name Description Value Default FUN1-Logic Input Settings 0=NC Set the correct polarity of Brake Con- F1-01 Contact on Brake 1=NO tact or to disable this feature 2=Disable 0=NC Set the correct polarity of Auxiliary...
  • Page 39 Operating Adjustments Table 10. Controller Parameters Param Name Description Value Default PM Contactor and Brake drop delay set- ting. Program to 900msec for VVVF drive/ F2-12 Stop Delay 0-5000Msec ATL and 0 sec for Wye/Delta. If system is equipped with Motor Effi- ciency Controller, set to 200.
  • Page 40 Motion 3000ES Escalator Control Table 10. Controller Parameters Param Name Description Value Default Set Upper and Lower speed limit for S6 F3-13 Speed error on S6 0-99% using the percentage of value of F3-05. Set Upper and Lower speed limit for S7...
  • Page 41 Operating Adjustments Table 10. Controller Parameters Param Name Description Value Default Rev detect enable Applied reversal detection on EC-SCB 0=No F4-07 on EC-SCB or not 1= Yes Pulse phase difference on EC-MCB. Pulse phase dif- Automatically set when a self-learn Set automati- F4-08 ference on EC-...
  • Page 42 Motion 3000ES Escalator Control Table 10. Controller Parameters Param Name Description Value Default Programmable error message: 1. Pit Flooded 2. Tandem Fault 3. Broken Belt F4-19 P37 Enable 4. Brake Wear 5. Broken Step Chain 6. Brake Overheat Not available on all software versions.
  • Page 43 Operating Adjustments Note Parameters in the preceding table that reference this note are set by entering a number (1 - 7) in the displayed digit that corresponds to the group of switches you want to set. For example, entries shown in the tables below would result in the settings shown in the shaded area below the entry.

  • Page 44: Displaying Parameters In Real Time

    Motion 3000ES Escalator Control Displaying Parameters in Real Time When the escalator is running, you can cycle through parameters to check their settings by pressing the UP or DOWN buttons on the display/keypad. The system must be running in Nor- mal mode for the parameters to be viewed in real time.

  • Page 45: Ct Drive Parameters (Vvvf Drive Only)

    Operating Adjustments CT Drive Parameters (VVVF Drive Only) Status In status mode, the drive display shows the operating status of the drive: • Auto tune: Auto tune in progress. • inh: Inhibited; enable input is inactive. • rdY: Ready; enable closed but inverter not active. •...

  • Page 46: Editing Drive Parameters

    Motion 3000ES Escalator Control Editing Drive Parameters To change drive parameters: 1. Display the parameter. 2. Use the mode button to select parameter edit mode (lower line flashing in drive dis- play). 3. Use up and down arrows on rocker switch to change value.

  • Page 47: Ct Drive Reset/Parameters Table

    Operating Adjustments CT Drive Reset/Parameters Table If the drive has tripped or a reset is necessary for other reasons (refer to the drive manual), the drive may be reset in one of two ways: 1. Stop button: If the drive has been set up such that the stop button is not operative, then the key has a drive reset function only.
  • Page 48 Motion 3000ES Escalator Control Table 13. CT Drive Parameters 0.30 Parameter Cloning ---- None None 0.31 Drive Voltage Rating Voltage 400/200 0.32 Maximum Heavy Duty Rating (Read Only) Amps 0.33 Catch a Spinning Motor ---- 0.34 User Security Code ---- 0.35...

  • Page 49: Keb Drive Parameters (Vvvf Drive Only)

    Operating Adjustments KEB Drive Parameters (VVVF Drive Only) Normal Mode (Single Speed): Up Going: Drive is always in control. Energy savings are realized when the escalator has a light load because the drive can provide less voltage and current while maintaining contract speed. When the load increases, the drive automatically increases voltage and current (only 2 modes—...
  • Page 50 Motion 3000ES Escalator Control 44 Manual # 42-02-E001...
  • Page 51 Operating Adjustments...
  • Page 52 Motion 3000ES Escalator Control Table 14. KEB F5 Parameters for Escalator Applications WARNING: Do not change drive parameters while escalator is running. Incorrect drive parameters can cause erratic operation. WARNING: Parameters with an asterisk (*) must be set correctly for your specific motor/machine/job.
  • Page 53 Operating Adjustments Table 14. KEB F5 Parameters for Escalator Applications WARNING: Do not change drive parameters while escalator is running. Incorrect drive parameters can cause erratic operation. WARNING: Parameters with an asterisk (*) must be set correctly for your specific motor/machine/job. Param Description Unit...
  • Page 54 Motion 3000ES Escalator Control Table 16. KEB Function Selection Value State Value State Value State Energy Saving Up all Speeds Line Contactor Enabled for No Function Active Active High Speed Up Operation. Energy Saving Down Low Line Contactor Enabled for...

  • Page 55: Commissioning Tests

    Commissioning Tests Commissioning Tests Overspeed and reversal errors may need to be demonstrated during commissioning tests. Step Overspeed Error 1. After completing a learn run at contract speed, record the values for parameters F3-01, F3-02, F3-05, and F3-06. They should all be very close to the same number. (They are learned speeds from the four step sensors.) 2.

  • Page 56: Fault Conditions

    Motion 3000ES Escalator Control Fault Conditions Both the controller and the VVVF drive (if used) will display fault condition codes. This section contains complete controller and drive fault condition tables and descriptions. Controller Faults Note To reset a latched fault, press both UP and DOWN buttons and hold them down for two sec- onds.
  • Page 57 Fault Conditions Table 18. Controller Fault Displays Fault Description Troubleshooting Motor overheat fault. P10 E-10 Check input device to P10 terminal. input on J2 of EC-MCB. Upper left missing skirt fault. E-11 Check input device to P11 terminal. P11 input on J3 of EC-MCB. Upper right missing skirt E-12 fault.
  • Page 58 Motion 3000ES Escalator Control Table 18. Controller Fault Displays Fault Description Troubleshooting Lower step upthrust fault. E-34 Check input device to P34 terminal. P34 input on J3 of EC-SCB. Check connection and function of input device. Underspeed fault. Right Confirm that F3-04 is set to the same value as USP4. If not, refer to E-35 handrail speed monitoring.
  • Page 59 Fault Conditions Table 18. Controller Fault Displays Fault Description Troubleshooting Check input device. Brake contactor fault. P8 E-51 Check setting of parameter F1-01. Verify that setting matches physical input on J2 of EC-MCB. characteristic of break contact. Seismic fault. P24 input on J4 Check input device to terminal P24.

  • Page 60: Ct Drive Faults

    Motion 3000ES Escalator Control CT Drive Faults Note The drive faults listed here are current as of publication of these tables. If you believe that a description is not accurate, please consult the manufacturer manual shipped with the drive. The numeric codes listed below each alphabetic fault code in the table may be input to drive Pr10.38...
  • Page 61 Fault Conditions Table 20. CT Drive Fault Displays EEPROM data corrupted - Drive mode becomes open loop and serial comms will time out with remote keypad on the drive RS485 comms port. This trip can only be cleared by loading default parameters and saving parameters EnC1 Drive encoder trip: Encoder power supply overload Check encoder power supply wiring and encoder current requirement.
  • Page 62 Motion 3000ES Escalator Control Table 20. CT Drive Fault Displays Hardware fault - return drive to supplier HF05 Data processing error: Undefined exception Hardware fault - return drive to supplier HF06 Data processing error: Reserved exception Hardware fault - return drive to supplier...
  • Page 63 Fault Conditions Table 20. CT Drive Fault Displays Reduce drive switching frequency Reduce duty cycle Decrease acceleration / deceleration rates Reduce motor load O.ht2 Heatsink over temperature Check cooling fans, ventilation path, and filters. Increase ventilation. Decrease acceleration / deceleration rates. Reduce drive switching frequency.
  • Page 64 Motion 3000ES Escalator Control Table 20. CT Drive Fault Displays OIAC.P Power module over current detected from the module output currents Acceleration / deceleration rate is too short. If seen during autotune, reduce voltage boost Pr 5.15 Check for short circuit on output cabling...
  • Page 65 Fault Conditions Table 20. CT Drive Fault Displays Ph.P Power module phase loss detection Ensure all three phases are present and balanced Check input voltage levels are correct (at full load) Internal power supply fault Remove any Solutions Modules and reset Check integrity of interface ribbon cables and connec- tions (size 4,5,6 only) Hardware fault - return drive to supplier PS.10V 10V user power supply current greater than 10mA...
  • Page 66 Motion 3000ES Escalator Control Table 20. CT Drive Fault Displays Uflt Multi module drive: Unidentified fault Check all interconnecting cables between power modules Ensure cables are routed away from electrical noise sources UP div0 Onboard PLC program attempted divide by zero...

  • Page 67: Keb Drive Faults

    Fault Conditions KEB Drive Faults Note The drive faults listed here are current as of publication of these tables. If you believe that a description is not accurate, please consult the manufacturer manual shipped with the drive. Table 21. KEB Drive Error Displays Display Description Cause...
  • Page 68 Motion 3000ES Escalator Control Table 21. KEB Drive Error Displays Display Description Cause • Input voltage wrong or too low. DC Bus charging error. Occurs for a short • High supply line resistance. E.LSF time during drive power up but clears auto- •...

  • Page 69: Brake Module

    Brake Module Brake Module In a typical escalator machine brake control circuit, a fixed voltage is abruptly applied or removed to control the position of the brake. There is no control of the rate at which the brake moves — the command is simply on, or off. Control voltages are provided to pick, hold, and drop the brake.

  • Page 70: Configuration

    Motion 3000ES Escalator Control Configuration The top board, TC-FCL, provides the controls to configure the module for job requirements. Such configuration is completed at the factory when the module is shipped installed in a con- troller. If the module is a modification to an existing control, check this instruction for proper settings.

  • Page 71: Reset Switch

    Brake Module The four switches of DIP switch SW3 function as two independent pairs. Switches 4 and 3 enable various software features. Switches 2 and 1 set the ID for the module. The ID identifies the module to the controller allowing it to be addressed and controlled independently of any other modules used (up to three).
  • Page 72 Motion 3000ES Escalator Control Table 24. LED Fault Indication Blinks Fault Description Reset Aux IGBT stuck closed If the voltage across the Aux IGBT does not go high Discrete: Proces- enough to trigger the Aux IGBT monitoring circuit sor reset.

  • Page 73: Module Connectors Per Board

    Brake Module Module Connectors Per Board Top Board, TC-FCL This section provides information about user-accessible module connections. Table 25. J1 Pin Assignment Function PICK Discrete Pick control input from controller (V AC/DC) HOLD Discrete Hold control input from controller (V AC/DC) RELEV Discrete Relevel control input from controller (V AC/DC) Overload fault output...

  • Page 74: Bottom Board, Tc-Fcp

    Motion 3000ES Escalator Control Bottom Board, TC-FCP The FCP board transforms AC input power (single or three phase) into the DC output voltage required to control the brake. The in-line connectors on the board are sized to handle higher voltage and current.

  • Page 75: Timing

    Brake Module Timing Figure 12. Brake Timing Diagram...

  • Page 76: Adjustment

    Motion 3000ES Escalator Control Adjustment Typically, the module will have been pre-installed and connected at the factory. If you are replacing an existing module, mount this module in the same location and follow the controller job prints to make electrical connections.

  • Page 77: Can Control Adjustment

    Brake Module CAN Control Adjustment 1. Apply power to the controller. Place the escalator on Inspection. 2. Pick a run direction. Verify that the brake picks cleanly. If not, readjust pick voltage and retry. 3. After the brake settles to hold position, verify that the brake is not dragging. If neces- sary, readjust hold voltage and retry.

  • Page 78: Typical Mbrake Installation

    Motion 3000ES Escalator Control Typical mBrake Installation Typical mBrake connection is illustrated below. Figure 13. mBrake Connection 72 Manual # 42-02-E001...
  • Page 79 E.nOL 59 E.OH2 60 AC wiring 4 E.OL2 59 Auxiliary Brake 15 E.PuC 1 60 E.PuCH 60 EEF 53 Bottom/top display board jumper 21 EnC1 53 Brake delay 30 EnC10 53 Brake module EnC2 53 LED fault indication 63 EnC3 53 Brake pick 26 EnC4 53 Brake resistance 15...
  • Page 80 PS.10V 57 S ramp enable 39 PS.24V 57 Security Status 40 rS 57 Serial Comms Address 40 SCL 57 Serial Comms Mode 40 th 57 Serial Comms Rate 40 thS 57 Smart/Cloning Card 39 tunE 57 Symmetrical Current Limit 39 tunE1 57 T28 digital input 5 destination 39 tunE2 57...
  • Page 81 Remote Inspection Control 26 Reset controller parameters 34 RFI 3 RFI/EMI 14 Run learn operation 28 Safety string 15, 28 Self-learn 33 Shorts 3 Speed mode 32 Step sensors 16 Step speed monitoring 16 Top/Bottom display board jumper 21 UP button 6 Verifying Main Line Power 4 Wiring the Brake 15 Wiring the Motor 14...

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