Mitsubishi UCMP Car Unexpected Movement Protection Technical Manual

Table of Contents

1. Device Function & Safety Specifications

2. Installation Configuration

3. Inspection & Maintenance

4. Stopping Distance Measurement

5. Brake Fault Simulation & Reset

6. Appendix: Key Diagrams & Tools

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1. Device Function & Safety Specifications

1.1 Core Functions

• Trigger Conditions:

  • Unlocked landing door AND open car door

  • Single component failure in drive system (excluding ropes/pulleys)

• Protection Action:

  • Force stop within 0.5 seconds after triggering

1.2 Safety Levels

Icon	Type	Content	Requirement
⚠️	Warning	Electric shock/mechanical hazards	Power off required
🔧	Note	Parameter errors	Certified personnel only
💡	Tip	Efficiency tips	Recommended priority

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2. Installation Configuration

2.1 External Device (ZFS-ELE100)

2.1.1 Machine Room Installation

1. Positioning:

   • Fix housing to control cabinet with M8 bolts (right side preferred)

   • Torque: 12±1N·m (calibrated torque wrench)

2. Wiring:

   • Power lines (red/black) → PAD terminal L1/L2

   • Signal lines (yellow/blue) → P1 board X9A-3/X9A-4

   • Secure cables with nylon ties every 30cm (bend radius >5× cable diameter)

Acceptance Criteria:

• Housing levelness ≤1mm/m

• Ground resistance <0.1Ω

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2.1.2 Machine-Room-Less Installation

Step-by-Step:

1. Auxiliary Cabinet Mounting:

   • Secure to right inner wall using M6 stainless bolts

   • Bolt spacing: 150mm horizontal, 200mm vertical

2. Top Entry Wiring:

   • Install rubber grommets in cable entry holes

   • Maintain ≥50mm separation between signal/power cables

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2.2 Embedded Device (KCA-1009A)

• Pre-Installed: Adjacent to P1 board in control cabinet (no field installation)

• Verification:

  • Check P1 board LEDs post-power-on:

    • Green steady: Power OK

    • Red flashing: Signal not ready (check X9 connector)

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3. Inspection & Maintenance

3.1 Periodic Inspection

Item	Frequency	Tools	Acceptance Criteria
Brake Force Test	6 months	Laser rangefinder	5-test average ≤ Table 1 limits
Contact Impedance	1 month	Multimeter (Fluke 87V)	NC contacts <0.5Ω

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3.2 Maintenance Protocols

Brake Force Deficiency Resolution:

1. Clean brake linings: Use 120-grit sandpaper on friction surfaces

2. Adjust spring pressure: Turn adjustment nut clockwise (1/4 turn per step)

3. Retest until compliant

⚠️ Warning:

• Record spring compression length during disassembly (photo documentation)

• Prohibit lubricants on friction surfaces

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4. Stopping Distance Measurement

4.1 Synchronous Motor System (Machine Room)

4.1.1 Pre-Test Preparation

1. Tools:

   • Laser rangefinder (±1mm accuracy)

   • Insulated gloves (CAT III 1000V)

   • Jumper wire (0.5mm² Y/G)

2. Parameter Setup:

   SET1=0 → SET0=8 → Press SW1 (enter Mode B)    
   MON1=0 → MON0=5 → Display current speed

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4.1.2 Operational Steps

1. Car Positioning:

   • Empty car at top floor (leveling error <2mm)

   • Manually close hoistway and car doors

2. Mode Switching:

   • Disconnect EDSW connector (control cabinet X10 terminal)

   • Set emergency operation switch to "Emergency"

3. Downward Movement:

   • Hold "DOWN" button until DZ LED extinguishes → Release immediately

4. Measurement:

   • Measure vertical offset (X) between car/landing sills using laser rangefinder

   • Formula: Stopping distance S=150-X (mm)

5. Reset:

   • SET1=0 → SET0=8 → Press SW1 (exit Mode B)

   • Reconnect EDSW and reset emergency switch

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4.1.3 Data Recording

Test Cycle	Offset X (mm)	Stopping Distance S (mm)	Pass/Fail
1	+25	125	✔️
2	+18	132	✔️

Pass Criteria: 5-test average ≤ Table 1 limits (e.g., ZBK-PMN ≤500mm)

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4.2 Asynchronous Motor System (HOPE-IIG)

4.2.1 Test Tool Integration

1. Tool Connection:

   • Power off → Connect P295057C000G02 tool in series with PAD-X3 interface

   • Confirm tool LED shows steady red

2. Signal Trigger:

   • Disconnect RLD (Down) connector → Car moves 10mm → System logs "90b" fault

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4.2.2 Distance Calculation & Reset

1. Measurement Rule:

   • Car sill below landing sill → X is negative (e.g., X=-20mm)

   • Formula: S=|X|+10=30mm

2. Reset Procedure:

   • Reconnect RLD → Power cycle → SET1=7 → SET0=E → Hold SW1 for 3s

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5. Brake Fault Simulation & Reset

5.1 Brake OFF Fault (Failure to Release)

Step 1: Locate Terminals

• BK1 Contacts: P1 board X5 terminal block

  • X5-1: BK1 NC input

  • X5-2: BK1 NC output

Step 2: Short-Circuit Operation

• Connect X5-1/X5-2 with jumper wire → Power on → System logs "F1-BK1 OFF"

Step 3: Reset

• Remove jumper → SET1=7 → SET0=E → Hold SW1 for 3s → Power cycle

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5.2 Brake ON Fault Simulation (Failure to Engage)

Step 1: Disconnect Monitoring Circuit

• Remove X5-3 connector → Power on → System logs "E2-BK1 ON"

Step 2: Reset

• Reconnect X5-3 → Hard reset (power cycle)

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6. Appendix: Key Diagrams & Tools

6.1 Brake Contact Locations

Diagram: X5 terminal block & shorting operation

6.2 Debugging Tool Connection

Diagram: Tool connection direction & LED status

6.3 Sill Gap Measurement

Diagram: Car & landing sill midpoint alignment

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Disclaimer:

• ⚠️ All operations require certified personnel. Unauthorized modifications void warranties.