Application of Hpmont HD5E escalator dedicated drive controller on escalators
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  • Application of Hpmont HD5E escalator dedicated drive controller on escalators

Application of Hpmont HD5E escalator dedicated drive controller on escalators

With the development of economy and advancement of science and technology, escalators are increasingly used. Currently, the number of escalators in China has exceeded 1 million. While the escalator system brings convenience and shortcuts to people, it also consumes a lot of electricity. With the advancement of energy conservation and emission reduction, it is imperative to save energy on escalators. The "Regulations on Energy Conservation in Public Institutions" promulgated by the State Council on October 1, 2008 was officially implemented, and it also guided the development trend of escalator energy conservation in the form of law.

Classification :


1 Introduction
With the development of economy and advancement of science and technology, escalators are increasingly used. Currently, the number of escalators in China has exceeded 1 million.
While the escalator system brings convenience and shortcuts to people, it also consumes a lot of electricity. With the advancement of energy conservation and emission reduction, it is imperative to save energy on escalators.
The "Regulations on Energy Conservation in Public Institutions" promulgated by the State Council on October 1, 2008 was officially implemented, and it also guided the development trend of escalator energy conservation in the form of law.
Escalators are widely used in public places such as shopping malls, airports, subways, etc. They run at rated speed after being turned on. When no one is on the escalator, the escalator still runs at high speed, consuming a lot of electricity and wearing out the mechanical parts of the elevator. If you can reduce the running speed of the escalator or even stop the escalator when no one is riding, you can save electricity, reduce the wear and tear of the elevator's mechanical parts, and extend the service life of the elevator.

2 Analysis of existing escalator system
2.1 Non-energy-saving escalator system
Most of the existing escalators use non-energy-saving escalator control systems. PLC or special control panel is used as the core of the escalator control system. After the control system receives the start signal, it controls the corresponding contactor action, and the power grid drives the escalator up or down. These systems have escalator protection logic, refueling and buzzer functions. Non-energy-saving escalators can only control the escalator to run at rated speed or to stop the escalator.

2.2 Y-△ step-down start energy-saving escalator system
In this scheme, when no one is riding the escalator, the contactor is disconnected, the motor is powered off, and the escalator stops; when there is someone riding the escalator, the Y-△ voltage reduction of the escalator starts and the escalator runs quickly. This kind of system can achieve the purpose of saving energy, but it starts and stops frequently. Although it starts with Y-△ voltage reduction, it will still have a big impact on the escalator power grid when it starts. Therefore, this solution has few applications.

2.3 Energy-saving escalator system with universal inverter The inverter has a speed regulation function, which can realize soft start of the motor and make the escalator run at different speeds according to needs. However, the general frequency converter itself does not have relevant logic for escalator control and needs to be used with other controllers, which complete the escalator control logic.
It receives up and down photoelectric signals and outputs fast or slow running commands to the inverter. The inverter drives the escalator to run fast or slow. Since it is always running with variable frequency, it generates electricity when the elevator goes down. At this time, the frequency converter needs to be equipped with a braking resistor. Although this type of system can achieve soft start and achieve low-speed energy saving, the system structure is complex and the cost is high.

3 HD5E Technical Features
HD5E escalator dedicated drive controller uses advanced customized design concepts, focuses on the needs of the escalator industry, and perfectly combines advanced motor control technology with escalator control logic. The product has a variety of escalator operation modes, excellent bypass frequency conversion technology, complete escalator control logic and escalator fault protection, which can meet all types of escalator renovation and new elevator applications.
3.1 Multiple escalator operation modes
(1) Bypass frequency conversion operation mode
When someone is riding the escalator, the drive controller controls the escalator to accelerate to the power frequency, and then the escalator switches from the variable frequency drive to the power frequency drive; when no one is riding the escalator, the escalator is driven by the variable frequency drive and runs at low speed.
(2) Full frequency conversion operation mode
Whether there is someone riding the escalator, the escalator is always running with variable frequency drive. When there are people riding the escalator, it runs at high speed, and when no one is riding the escalator, it runs at low speed and energy saving.
(3) Power frequency Y-△ operation mode
The escalator uses Y-△ voltage reduction to start, which reduces the impact on the escalator and the power grid. After the start is completed, the escalator is driven by the power frequency drive. When the frequency conversion output is abnormal, the escalator system can run in the power frequency Y-△ operation mode. One system provides two options.
(4) Maintenance operation
The maintenance operation is divided into frequency conversion maintenance and power frequency Y-△ maintenance. The input, output signals and operating status of the escalator system are checked in the frequency conversion state and the power frequency state respectively.

3.2 Excellent bypass frequency conversion technology
When the escalator switches from variable frequency to industrial frequency, the excellent phase locking technology makes the impact current small during switching and the escalator has no jitter.
When the escalator switches from power frequency to variable frequency, ultra-smooth speed tracking technology enables impact-free starting.

3.3 Three energy-saving operating modes
HD5E provides three different energy-saving operation modes: low-speed operation for unmanned elevators, low-speed operation for unmanned elevators and then stopping, and stop operation for unmanned elevators. It also provides forward express time, slow operation time, and express operation frequency. Functional parameters such as the slow running frequency and the slow running frequency can be set by users themselves, which can flexibly meet the energy-saving needs of different applications.

 

 

 

 

3.4 Perfect escalator fault protection
In addition to various protection functions of the frequency converter, HD5E also provides safety circuit disconnection protection, anti-reversal protection, drive chain breakage protection, motor speed measurement protection, handrail speed measurement protection, upper and lower step loss protection, and contact adhesion for the escalator system. Protection, contactor contact feedback disconnection protection, fire alarm protection and other complete escalator fault protection logic fully meet industry specifications and relevant national technical requirements to ensure safe and reliable operation of escalators.

4 HD5E application cases
4.1 HD5E energy-saving renovation application cases
In terms of transformation and application, it is first necessary to carefully analyze the composition of the original system. Currently, escalator control systems with PLC as the core or special control panels as the core are generally available on the market. During renovation, users generally require that no major changes be made to the original system. Completing the energy-saving renovation of escalators with minimal changes is a requirement for many renovation occasions.
In this kind of transformation situation, we choose the transformation plan of full frequency conversion operation mode.
The schematic diagram of the system composition is as follows:

 

 

 

The above scheme only needs to induce three signals: up command, down command and stop command from the original system. The protection logic of the escalator is still completed by the original system, but It turns out that the main power of the system is not output to the motor, and the motor is driven by HD5E variable frequency. The added upper photoelectric and lower photoelectric signals are installed at the upper and lower entrances of the escalator respectively to detect whether someone is taking the escalator. When someone is riding the escalator, the HD5E drives the escalator to run at high speed;

When no one is on the escalator, the HD5E drives the escalator to run at low speed and save energy or stop running.
This solution can easily realize the energy-saving transformation of escalators. Since it is fully variable frequency operation, when the escalator carries people down, energy is fed back to the HD5E. Generally, a braking resistor needs to be configured to discharge the feedback energy and prevent the HD5E from overvoltage failure. In addition, it should be noted that the original system is generally equipped with speed measurement protection, and the basis of the original system speed measurement protection is the rated elevator speed. When the escalator runs at low speed, the original system will report a speed measurement protection fault. At this time, the speed measurement protection of the original system needs to be disabled. Then the speed measurement signal is input into HD5E, and HD5E implements speed measurement protection. HD5E provides complete various speed measurement protections, which can completely protect the possible speed abnormalities of the escalator.

4.2 HD5E new elevator application case
In new elevator applications, HD5E’s advanced motor control performance and perfect escalator control logic can be fully utilized. HD5E can not only complete the escalator control logic but also complete the frequency conversion speed regulation of the motor. The escalator control system composed of HD5E no longer requires other control devices. The high degree of integration improves the reliability and maintainability of the system.
In the application of new elevators, the bypass frequency conversion operation mode is adopted, and Y contactors and △ contactors are equipped as backup. When the frequency conversion output is abnormal, it can be switched to the power frequency Y-△ operation mode to improve the reliability of the escalator system operation.

 

 

 

Among them: KM1 is the frequency conversion output contactor; KM2a is the power grid uplink contactor; KM2b is the power grid downlink contactor; KM3a is the Y contactor; KM3b is the △ contactor .

 

 

 

The escalator control system composed of HD5E escalator dedicated drive controller has the following advantages
(1) Realizing frequency conversion speed regulation of the motor saves energy, reduces the impact and wear of the escalator, and increases the service life of the escalator.
(2) The use of bypass frequency conversion technology reduces the working time of the HD5E variable frequency output and increases the service life of the HD5E; since the HD5E only produces variable frequency output at startup and low speed, it can be used in downshifts to save system costs; switching at high speed It operates at industrial frequency, so there is no need to configure a braking resistor, which saves space in the control cabinet and reduces heat generation.
(3) Integrating advanced motor control technology and complete escalator control logic simplifies the system structure and improves the reliability and maintainability of the system.
(4) The power frequency Y-△ operation mode is provided as a backup for the system. When the variable frequency output is abnormal, the escalator can be driven by the power frequency, further improving the reliability of the escalator system.
(5) Multiple energy-saving modes and flexible function parameter settings to meet the needs of different applications.

4.3 HD5E Energy Saving Analysis
The calculation formula of power P is as follows:

Hpmont HD5E

Where, U is the line voltage, I is the phase current, and Cosj is the power factor. Take an escalator driven by a 7.5Kw motor as an example. When the escalator runs at high speed at 50Hz without load, the output line voltage is 380V and the output phase current is 8A. When the motor is lightly loaded, the power factor is low, assuming it is 0.5. At this time, the power P is calculated as follows.

Hpmont HD5E

When the escalator is running at no-load 10Hz and at low speed, the output line voltage is about 80V and the output phase current is 8A. When running at low speed, the motor power factor increases slightly, assuming it is 0.7. The hourly power P is calculated as follows.

Hpmont HD5E

Compared with 50Hz operation, 10Hz low-speed operation can save nearly 2Kwh of electric energy per hour. Calculated by running at low speed for 5 hours per day, it can save 10Kwh of electric energy per day. The escalator can also run in a mode where no one is riding the escalator, first running at a low speed and then stopping, which can save more power when stopping. The above calculation illustrates the huge advantages of HD5E in energy saving. Of course, the energy-saving effect will be different in different applications, which is mainly related to the motor current and motor power factors when the escalator is no-load.

5 Conclusion
Practice has proven that the HD5E escalator dedicated drive controller has won recognition from customers for its excellent performance, rich and flexible functions, and reliable and stable performance, whether in the reconstruction of old elevators or in the application of new elevators. HD5E will definitely make its due contribution to the upgrade of escalator systems and the promotion of energy conservation and emission reduction.

With the development of the economy and the advancement of science and technology, escalators are increasingly used. Currently, the number of escalators in China has exceeded 1 million. While the escalator system brings convenience and shortcuts to people, it also consumes a lot of electricity. With the advancement of energy conservation and emission reduction, it is imperative to save energy on escalators. The "Regulations on Energy Conservation in Public Institutions" promulgated by the State Council on October 1, 2008 was officially implemented, and it also guided the development trend of escalator energy conservation in the form of law.

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