AM-01.01.300_main_en.A.1

KONE ReSolve 200 Installation Instruction

KONE RESOLVE 200,  SINGLE / FLEXIBLE MAN INSTALLATION INSTRUCTION KONE © AM-10.65.001 All (D) 2009 rights 2013-04-17 ReSolve KONE reserved. Corporation 200

1067629.wmf

© 2009 KONE Corporation All rights reserved.

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AM-10.65.001 (D) 2013-04-17


Confidentiality Notice This proprietary and confidential document is provided to you only for purposes of installing and/or maintaining KONE products and it may not be used or its contents disclosed for any other purpose without KONE's prior written permission. Neither this document nor its contents may be copied or disclosed to third parties for any reason. KONE reserves the right to prosecute any breach of this obligation.  Authorization Notice This publication is for informational purposes only. All persons participating in the installation and/or maintenance of KONE equipment and using these instructions must be qualified to perform such work, are required to have received equipment specific training as specified by KONE and must have KONE Corporation's authorization to install and maintain KONE equipment.  DISCLAIMER OF WARRANTIES AND LIABILITIES KONE reserves the right at any time to alter the product design, specifications and procedures reflected in this document. NO STATEMENT CONTAINED IN THIS DOCUMENT IS TO BE CONSTRUED AS A WARRANTY OR CONDITION, EXPRESS OR IMPLIED, AS TO ANY PRODUCT, SPECIFICATION OR PROCEDURE, ITS MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE OR QUALITY, OR AS A MODIFICATION OR REPRESENTATION OF THE TERMS OF ANY PURCHASE AGREEMENT.  KONE DISCLAIMS ANY LIABILITY RESULTING FROM OR IN CONNECTION WITH THE USE OR DISCLOSURE OF INFORMATION IN THIS DOCUMENT. KONE HAS NO LIABILITY FOR TYPOGRAPHICAL OR OTHER ERRORS OR OMISSIONS CONTAINED IN THIS DOCUMENT OR ANYONE'S INTERPRETATION OF THE INSTRUCTIONS. THE USER OF THIS DOCUMENT ASSUMES ALL RISKS ASSOCIATED WITH THE USE OR DISCLOSURE OF THIS DOCUMENT.  Trademark Notice "KONE, MonoSpace, MiniSpace, EcoDisc, TranSys, Alta, KoneXion, KONE ECO3000 and all other product names are trademarks or registered trademarks of KONE Corporation in various countries."

Copyright Notice Copyright © 2009 KONE Corporation All rights reserved. No part of the contents of this document may be copied, reproduced or transmitted in any form or by any means, or translated into another language or format, in whole or part, without prior written permission of KONE Corporation.


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TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Special things about the method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 One fitter / two fitters working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Conditions for safe operation of elevator control system . . . . . . . . . . . . . . . . . . . . . 14 Installation method safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Protecting work areas with safety fences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Public safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Safety signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Determining need for car top balustrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Pit access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Safe access to all work areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SITE REQUIREMENTS AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride comfort measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 19 20 22

1

RECEIPT AND CONTROL OF MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Checking of packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Transporting materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Unloading materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 24 24 27

2

PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Safety fences and signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Checking the power sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Checking safety gear operation and overspeed governor. . . . . . . . . . . . . . . . . . . . . 2.4 Checking overtravels and safety spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Marking the sling and car position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Measuring travelling cable loop length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Checking the car and counterweight balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 Preparing the access for the travelling cables and the shaft bundle . . . . . . . . . . . . . 2.9 Installation of shaft lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 29 29 30 31 32 32 33 34 35

3

INSTALLING TRAVELLING CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Installing travelling cable: Machinery below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Installing travelling cables: Machinery above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Dismantling old car equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 37 41 44


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3.4 3.5 3.6 3.7 3.8 3.9

Installing car top connection box and inspection drive unit . . . . . . . . . . . . . . . . . . . . Routing cables to car top connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the travelling cable in the car top connection box . . . . . . . . . . . . . . . . . Temporary wiring of car top connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixing sensor unit to car roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the wire hanger and limit switch in top of the shaft. . . . . . . . . . . . . . . . . . .

45 45 47 48 49 50

4

INSTALLING TOP SERVICE LIMIT RAMP (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 55 4.1 Installing top service limit ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5

DISMANTLING OLD MACHINE ROOM EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 5.1 Marking the wires in the old control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 5.2 Removing old equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

6

INSTALLATION AND WIRING OF MACHINERY / CONTROL PANEL . . . . . . . . . . . . . . . 6.1 Position the control panel according to the site survey . . . . . . . . . . . . . . . . . . . . . . . 6.2 Re-use / installation of trunking for travelling cable and elevator shaft wiring . . . . . . 6.3 Routing of wiring between controller panel and machinery . . . . . . . . . . . . . . . . . . . . 6.4 Snelis devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Specific routing for V3F motor supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 Connecting the extension tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 Connecting travelling cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 Connecting machine room equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 Installing and connecting power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10 Wiring other machine room equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 60 63 64 64 65 66 67 68 75 79

7

COMMISSIONING FOR SERVICE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Preparations before turning the power on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Reset button at KMI (KONE Maintenance Interface) . . . . . . . . . . . . . . . . . . . . . . . . 7.4 Example of setting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Checking of inverter parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 Non-rotational autotuning of K1000 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 Driving the elevator for the first time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Preparation for driving the elevator on the car roof . . . . . . . . . . . . . . . . . . . . . . . . . .

80 81 81 83 84 86 87 89 90

8

INSTALLATION OF SHAFT LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 8.1 Installing elevator shaft lighting, if applicable (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . 93 8.2 Installing elevator shaft lighting, if applicable (PU) . . . . . . . . . . . . . . . . . . . . . . . . . . 94

9

REMOVING OLD ELEVATOR SHAFT EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Removing of old levelling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Remove old limits and floor switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 Remove landing bands / support wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 Removing old travelling cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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10

INSTALLING THE HANGING WIRES AND POSITIONING MAGNETS . . . . . . . . . . . . . . 10.1 Hanging the wires at top of the shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Fixing the wires in the pit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 Installing bottom service limit ramp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 Installing positioning magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

INSTALLATION OF SHAFT BUNDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 11.1 Installation of shaft bundle and trunking (serial, machinery above). . . . . . . . . . . . . .110 11.2 Installation of shaft bundle and trunking (serial, machinery below) . . . . . . . . . . . . . .114 11.3 Installation of shaft bundle and trunking (parallel, machinery above) . . . . . . . . . . . .119 11.4 Installation of shaft bundle and trunking (parallel, machinery below) . . . . . . . . . . . 122 11.5 Finalising new elevator shaft lighting (if included) . . . . . . . . . . . . . . . . . . . . . . . . . . 126 11.6 Finalising the travelling cable installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 11.7 Re-connecting travelling cables, if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 11.8 Taking the shaft bundle to the machine room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 11.9 Connecting shaft bundle (safety chain) in to the control panel . . . . . . . . . . . . . . . . 130

12

CONNECTING LANDING DOORS LOCKS AND BUTTONS . . . . . . . . . . . . . . . . . . . . . . 12.1 Positioning of the car. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2 Connection of landing door lock (serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 Wiring of landing call buttons (serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 Connection of landing door lock (parallel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 Wiring of indicators and optional landing devices (parallel) . . . . . . . . . . . . . . . . . . 12.6 Connecting shaft bundle (signalization) in to the control panel . . . . . . . . . . . . . . . .

13

REMOVING THE OLD SHAFT BUNDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

14

INSTALLATION AND WIRING OF ALL CAR EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . 14.1 Dismantling old car equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2 Installation of door control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3 Installation of parallel I/O box (only with parallel signalization) . . . . . . . . . . . . . . . . 14.4 Installation of ACU box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 Wiring of car top connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6 Wiring of old car light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7 Wiring of old car fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.8 Wiring of ADV door operator (Isola 96, Athena 96, Renova 96) . . . . . . . . . . . . . . . 14.9 Wiring of retiring ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.10 Wiring of door inverter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.11 Wiring of contactor control door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12 Wiring of Starlift door operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.13 Wiring of ADF - ADX door operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14 Wiring of AMD door operator (Drive 1, 1.5 and 2). . . . . . . . . . . . . . . . . . . . . . . . . . 14.15 Wiring of DC2000 door control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.16 Wiring of KOF230V, C-type door control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17 Wiring of ADT 3PH 125V door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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100 101 102 105 106

131 132 133 135 136 144 154 156 158 159 160 160 161 163 163 164 168 169 171 173 175 178 182 185 187

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14.18 14.19 14.20 14.21 14.22 14.23 14.24 14.25 14.26 14.27 14.28 14.29 14.30 14.31 15

Wiring of close command door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring of FIAM B/S door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring of Sabiem C door operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring of ACC 230V door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring of general 24V electronic control door operator . . . . . . . . . . . . . . . . . . . . . . Wiring of Selcom 1PH 220V automatic door operator. . . . . . . . . . . . . . . . . . . . . . . Wiring of no car door, EMO N, AT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring of BOF unit for non-automatic doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring of new COP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring of old COP and display (if any, parallel I/O module). . . . . . . . . . . . . . . . . . . Connection of ACU, if applicable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection of KRM, KSS ReVive signalization. . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection of KRM, parallel signalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring of car extension door (CED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189 191 193 195 197 199 201 202 203 204 207 208 208 209

FULL SPEED ADJUSTMENT / COMMISSIONING / SAFETY INSPECTIONS . . . . . . . . 210 15.1 Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211 15.2 Selecting roll call type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 15.3 Selecting LWD type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 15.4 Shaft setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 15.5 Connecting FRD / FID (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 15.6 Adjusting motor no load current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 15.7 Checking creeping time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 15.8 Motor slip compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 15.9 Floor level adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 15.10 Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 15.11 External options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 15.12 Commissioning of the car door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 15.13 Check the parameters for door inverter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 15.14 Checking KCE board versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 15.15 Testing landing door locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 15.16 Testing safety contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 15.17 Measuring insulation resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 15.18 Measuring earth continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 15.19 24 VDC ground fault test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 15.20 Testing operation of RCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 15.21 Speed measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 15.22 Current measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 15.23 Testing the final limit switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 15.24 Drive time supervision (DTS) test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 15.25 Buffer tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 15.26 Overspeed governor test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 15.27 Safety gear test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237


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15.28 Ride comfort /Special V3F10 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 15.29 Setting the elevator to normal use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 15.30 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 16

HANDLING WASTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

17

HANDOVER TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2 Handover form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3 Autocontrol form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4 Ride comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5 Installation quality checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

242 242 242 244 244 244

18 APPROVALS AND VERSION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 APPENDIX A. Changing the characteristics / V3F10 K1000 LED user interface . . . . . . . . . . . . 250 APPENDIX B. Control panel introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 APPENDIX C. Locking and unlocking Yaskawa parameter menus . . . . . . . . . . . . . . . . . . . . . . . 256 APPENDIX D. Estimating the mass of the counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 APPENDIX E. Speed parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258


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GENERAL This installation method is designed to guarantee not only the working efficiency but also the safety of the fitter and other people in the building. This manual includes several variations for the elevator configuration, but on site is delivered only the pages that suit the actual installation. The selected variation is depending on: • • • • •

Machine room position Drive type Door type Position of the limit switches (on the car or in the elevator shaft) Local options

Follow the method that is described in the documentation delivered on your site. Do not make your own short cuts of the method. Do the installation in the same order as described in the instruction that you get for each job.

Validity This instruction is valid for installations of elevators with KCE electrification and V3F10 drive. In case of alternatives in the described method, select the correct way according to the location of the site.

Installation method With this installation method, it is possible to: • Identify easily the equipment in the packages. The material is grouped together according to different phases and work places. • Wire and connect easily, without the circuit diagram. • Know the future phases of work and if necessary, to arrange the assistance of another technician. If there are several MMS packages, the best moments to install them are: Phase Phase 14:

Phase 5: Phase 12:


MMS package New car interior New car door New signalization in car New machinery New landing signalization

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Special things about the method This work must not disturb the normal operations or elevator users in the building. The working times must be agreed with the building owner carefully. If the elevator is a member of an elevator group the operation of the existing group control must be guaranteed during the works. When the connections between the old group and/or the other elevators and this elevator are disconnected, agree with the customer about the procedure and timing. Follow local rules. In case the elevator is connected to external alarm systems (KONEXION), the forwarding of alarms must be inhibited for the installation time. Temporary connections for landing locks and service drive limit switch are needed. To ensure public safety and your own safety, this method uses a special tool to connect the old and new safety circuits in series by overconnecting the landing door locks. Installation of shaft light can be done first if the elevator has a car inspection box.

Related documents For more information, see: • • • • • • • • • • • • • • • • • • • • • •

AM-01.03.001 Take 5 - Electrical safety when working on elevators AM-01.03.010 Safe working in elevator shaft and machine room areas AM-01.01.085 Planning guide and general instructions for low-rise elevator dismantling AM-12.20.005 KONE signalization system (KSS) installation AS-11.65.004 Replacement of V3F10 and V3F10CL drive module (V3F inverter unit) AS-10.60.001 Site reference guide for KONE MMS Resolve 10 and 20 electrification AS-10.65.006 Diagnostic guide for KONE ReSolve 200 commissioning AS-10.65.007 Fault finding instruction for KONE ReSolve 200 AS-12.02.001 Instruction for handling electrostatic-discharge-sensitive-devices on site UM-10.65.001 User manual for KCE removable user interface UM-10.65.002 KONE Maintenance Interface, European Norm Version 1374567 KCE parameter list 958174D01 KCE fault code list 773556D01 Door inverter instructions 873805 V3F10/K7/K1000 Yaskawa drive parameter list 878327 V3F10 fault codes 834948 Tool for calculating V3F open loop parameters TC000034 KCE Electrification, Core learning guide TC000035 KONE ReSolve 200 Electrification Core Training Guide TC000036 V3F10 Drive Core Learning Guide TC000037 KCE Electrification, Special Technology TC000123 KCE KONE Maintenance Interface, Core learning guide


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One fitter / two fitters working The table below indicates in which phases of the installation two fitters are required and when the installation can be undertaking by a single fitter. This is indicated using symbols in the beginning of the chapters.

= One fitter working

= Two fitters working

1

Installation phases Receipt and control of material (two fitters for transportation of new material)

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Preparations Installing travelling cables Dismantling old machine room equipment Installing and wiring of machine room equipment Start-up Installing top service limit ramp Installing shaft lighting Removing old elevator shaft equipment Installing hanging wires Installing shaft bundle and positioning magnets Connecting landing door locks and buttons Removing old shaft bundle Installing and wiring of car equipment Installing floor level flags Full speed adjustment / commissioning Removing old equipment


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SAFETY To ensure your safety and the safety of those around you, it is important that you read, understand, and follow ALL the safety precautions relative to a particular task. In particular it is important to read and understand any risk assessed method statements made at the time of the safety survey. Related safety instructions: • AM-01.03.001, Use of fall prevention systems when working on elevators and escalators Fall prevention planning is a mandatory requirement whenever either employees or the general public are at risk of injury from falling during equipment installation, removal or maintenance operations. Fall arrest systems must be used in accordance with local code requirements when there is a risk of falling and it is not possible to remove the risk by other means (e.g. balustrades). Use of harnesses must always be considered as a final resort if it is impossible to remove the hazard by other means. Serious injury or death may still be sustained after a fall wearing a harness in an enclosed space. • AM-01.03.002, Take 5 - Electrical safety when working on elevators • AM-01.03.003, Take 2 - Double security safety practice when using Tirak hoist for manriding purposes Take 2 is the workplace protective practice of double-securing to prevent risk of falling when using either a temporary platform or the elevator car for man riding when using the Tirak hoist. The requirement to enforce this practice is part of KONE Safety policy. The suitability of this method for a particular site requires inspection by a trained person. The safety survey must be documented, completed and visible before hoist usage is allowed. • AS-01.01.004, Take Care, End user safety focal points in elevator maintenance • AM-01.03.009, General instructions for material handling, using transportation and lifting equipment • AM-01.03.010, Safe working in elevator shaft and machine room areas • Site safety audit Take time to familiarise yourself with the elevator. This is particularly important when working on other manufacturer’s equipment where the level of training and information available may vary and circuit diagrams are in an unfamiliar style.


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Ensure you have adequate information to do the work and fully understand all the possible effects of your actions. - IF IN DOUBT - ASK. Talk to your supervisor if you have any doubts about the working method or safety related issues. Any local variations to the method must be supported by a local method statement and risk assessment. Additional electrical safety measures: • Use an approved multimeter (Fluke 179 or equivalent) on all circuits. Use fuse pullers to change or remove fuses. NEVER use fingers, pliers or screwdrivers. Covers on exposed electrical devices or wires MUST be installed to protect personnel from injury or shock. • ALL landing doors, car and sling, connection boxes, switch boxes, transformer casings, controller and tank must be verified for effective grounding to prevent shock to personnel and to ensure that protective fuses operate (particularly where protection is provided using residual current device (RCD)). • When using a portable electric meter, DO NOT connect one wire and leave other wires dangling loose. • Before powering up a circuit, make sure that all is clear. This is necessary in order to protect personnel from injury and to prevent damage to the equipment. • Avoid accidental contact with equipment or conductors which are known to be live or are NOT known to be de-energised. If it is necessary to work on equipment while it is hot, extra care must be observed. • TAKE TIME TO BE CAREFUL! Following safety precautions and using common sense will prevent injury, mutilation, or death. • During the safety survey the salesman/engineer will have made a detailed analysis of the existing installation and will have detailed notes concerning which parts of the electrical system need to be over-connected and which circuits must be isolated for the dismantling operation, if the powered car system is to be used.


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General safety • Introduce yourself to site agent or person responsible for the building. • Read the comments from the site safety survey. • When working in buildings that are occupied, ensure therefore that your work cannot cause a safety hazard to other people in the building. • Place warning and information signs as required. • Use barriers whenever necessary. • Take care that the communication between fitters and between the fitters and other building users is effective. • When two or more persons are working on the same elevator, one person should be in charge of control and access keys and safe and appropriate car movements. When the car must be moved, the responsible person must inform the other(s) of the intended car movements beforehand. • Ensure that the main supply is locked and tagged. • Report any defects or other dangerous conditions to your supervisor. • Ensure that ALL DOORS (machine room, pit, access and inspection doors) are locked at all times when unoccupied by authorised personnel. • Cover any unused holes in the machine room floor with steel plates. • Install temporary screens in common elevator shafts and machine rooms, where adjacent elevators are running and there is no dividing screen. • In machine rooms where adjacent elevators are running ensure that all work areas are protected with barriers. • Liaise with the building owner or his representative in cases where there are elevator groups where adjacent elevators are running and passenger traffic in the lobby area may interfere with your work. Ensure that all work areas are protected with barriers and that access routes for other building users are safe. Refer to the site safety survey. • If you suspect that hazardous materials are present, stop the work. Inform your supervisor who will arrange for a specialist to check the installation. Disposal of hazardous material is always a specialist’s job. Never attempt to do this yourself. Refer to the site safety survey. • Hot work should be avoided wherever possible by applying tools and methods that do not cause risk of fire. If hot work (disc cutting, flame cutting and so on) cannot be avoided, local work procedures for the necessary routines and equipment shall be followed. Refer to the site safety survey.


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Conditions for safe operation of elevator control system Installation conditions: • It needs to be ensured by the selection of an appropriate place of controller and car roof box that environmental influences like water, conductive dust and condensation don’t have a negative impact to the safety circuit (KCEMSC, KCEFUI, KCECCG). • It shall be ensured that all cabinet and enclosure doors and lids are closed when lift is put in service. 24 Vdc system: • Only 24Vdc power supplies approved by KONE shall be used in order to guarantee electric safety and safety circuit reliable operation. • In order to detect first ground fault of the safety circuit, the minus (-) of 24Vdc circuit shall be connected protective earth (PE). Connection to protective earth is made with connection of KCECPU PE terminal to control panel PE. The minus (-) of 24Vdc circuit shall not be connected to PE in any other location of the system. Safety contacts and related wiring: • Only safety contacts in conformance with EN 81-1, clause 14.1.2.2 or switching elements with at least the same safety level shall be connected to the safety inputs of the system. Contacts shall be forcibly guided. Use of magnetically operated reed switches or similar is forbidden. • Safety contact wiring shall fulfill the requirements for short-circuit-proof. When safety circuit wiring is installed in same conduit or trunking with other circuits, safety circuit conductors shall be insulated for the highest nominal voltage present.

Installation method safety Ensure that the safety of all lifting points has been verified in accordance with local regulations.


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Personal protective equipment Safety gloves, safety footwear, safety helmets, eye protection, dust masks, hearing protection and fall protection equipment are supplied for your personal protection. USE THEM AS REQUIRED. Safety item Safety harnesses and associated equipment. Refer to AM-01.03.001. Dust mask, suitable for working with mineral wool insulation in landing doors. First aid kit. Eye protection. Safety gloves. Rubber gloves for protection when cleaning rails. Hearing protection. Safety helmet. Work clothes / overalls. Safety footwear with ankle protection. Special precautions to limit injury in the event of a fall

WARNING If the safety harness and its associated equipment are not used correctly you may still sustain severe injury or death during a fall.

Requirements Always use the harness attached to an approved fixing point when there is a risk of falling and you are working 1.8 m or more above a lower level. Refer to AM-01.03.001. It is recommended that you attach the harness to a fixing point at least 2.0 m above the working height. Where this is not possible keep the lanyard AS SHORT AS POSSIBLE to minimize your free fall. (Be aware of the effect of rope and harness stretch when estimating the likely drop area and consider the risk from possibly dangerous striking points like guide rail brackets.) If you are likely to fall down the side of the car you must try to minimize the free fall distance to 300 mm or less. If you have attached the harness to a guide rail bracket or other fixed point in the elevator shaft you must ensure that there can not be any unwanted movement of the working platform. When your safety harness is not secured to a life line or other approved fixing point, ensure that the lanyard does not cause a catching or tripping hazard.


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Protecting work areas with safety fences Entrance protection must be: • Lockable • Openable without key from inside • Imperforate or at minimum preventing contact with exposed components that can be a safety risk.

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When not working at the landing. Closed landing door or fence covering the whole door opening.

Working on the car roof. Closed landing door or car at landing and fence closing the landing door area.

Public safety • • • •

Keep the working area closed to the public at all times. Keep the area outside the working area clean. Store materials in designated storage areas. Not on landings or in working area. In residential buildings keep to the agreed daily working schedules to avoid unnecessary disturbance to residents. • When transporting material into the elevator shaft, use additional safety fences or guarding.


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Safety signs The following safety signs are used in this instruction as highlights.

Turn main power OFF

Lock and tag the switch

Verify deenergization

Push the stop button OFF

Fall prevention measures

Determining need for car top balustrade When working on car roof the need for car top balustrade must be determined. When there is a risk of falling from height that can cause injury, car top balustrades/railings must be fitted and raised before accessing or man riding on an elevator car top. Possible differences between this instruction and local safety regulations must be considered. Dimensions and rules in this instruction fulfil requirements set in EN 81-1. If local requirements are at a higher level than described in this chapter, then they must be followed. In case of conflict between requirements, follow the local legal requirements. If working on old equipment where no balustrade exists then additional protective measures must be taken as defined by risk assessment. Solutions may be based on use of temporary portable balustrades/rails or fall restraint solutions. If fall arrest is used then special care must be taken to define rescue measures, in case of fall.


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Step 1

2 3 4

5

Action Measure the distances between the car wall and the elevator shaft wall. If the gap is less than 300 mm the balustrade is not needed. If the gap is 100 mm to 299 mm, fix the kick plate. If the gap is 300 mm to 850 mm, use at least 0.7 m high balustrade. If the gap is larger than 850 mm, use a 1.1 m high balustrade. If the clearance between the balustrade top bar and the lowest obstruction in the headroom when the counterweight is on the buffer or when the cylinder is fully extended (hydraulic elevators) would be less than 300 mm, temporarily increase the height of counterweight buffer or use props. If the landing doors have been removed, the gap on the landing side may exceed 300 mm. In that case, install an extra detachable handrail (provided locally) to the balustrade on the landing side. Refer to site survey if available.

Note

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NOTE!For hydraulic elevators, prevent upwards movement before working on car roof by disconnecting the up direction solenoid.

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6

If it is not possible to use a balustrade, fall arrest equipment must be available.

Pit access See AM-01.03.010, Safe working in elevator shaft and machine room areas.

Safe access to all work areas See AM-01.03.010, Safe working in elevator shaft and machine room areas.


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SITE REQUIREMENTS AND TOOLS

Site requirements Familiarise yourself with the data that is collected earlier from this elevator site. Read the order form for the positions and critical dimensions of the elevator (machine room, car roof and elevator shaft equipment). In addition to the normal survey made when the quotation is prepared a site safety audit is essential before any work can commence. • Machine room and car roof layout documents must be available. • Transportation of equipment to the machine room must be planned. Transportation routes, transportation loadings and lifting point loadings must be planned. • Suitable secure material storage areas must be agreed with building owner, adjacent to the elevator shaft. • Clear and unobstructed access routes must be defined. • Suitable provision for disposal of waste materials must be available, according to local requirements. • Adequate lighting, temporary or permanent, must be installed. • Lifting points must be correctly positioned in the machine room and marked with the safe working loads. • All building work must be planned and agreed with the building owner. • All required electrical work, for example new main supply, must be done. • Installation of shaft light can be done first if the elevator has a car inspection box.

WARNING Ensure that the car and counterweight are balanced to 50%.


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Tools • Normal hand tools • 2x PERI adjustable multi prop 250. See APPENDIX D., Estimating the mass of the counterweight. • 2x Pit prop fixing • Two chains for securing the car according to mass of car + 200 kg. • Manual chain hoist for lifting of control panel to the machine room (200 kg capacity). • Multimeter (Fluke 179 or equivalent) and long insulated test probes (minimum length 100 mm) • Electrostatic Discharge (ESD) kit, KM857505 • RUD eye bolts (optional) • Working stool / scaffolds • Insulation resistance meter • Handheld tachometer • Electric drill • Portable crane • Extension tool KM796238G10050 for landing 1072347.wmf doors • Pull rope, minimum length = Elevator shaft height + 5 m. • KONE MiniConsole NOTE! These tools can be used in several KCE installations, store them for later use. • Group of parts, cabinet trolley adapt KM5002834R01 including: • lifting handles KM796643H51 (see 6.1.1, Transporting and hoisting the control panel) • stair-climber wheels and frame KM50012010G01 • Extension tool KM796238G10050 (see 6.6, Connecting the extension tool) • Installation tool, plug KM796239G10070 (see 6.6, Connecting the extension tool) • Shaft light installation tool KM796237G10300 (see 8, Installation of shaft lighting) • 24V DC ground fault test wire KM796185G10100 • Magnet installation tool (optional) KM50086979G01


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Required checkings and measurements To ensure trouble free operation of the remaining elevator components, the condition and operation of them must be checked or discussed with the service technician. Discuss also the service history and repairs. Inform the service technician about the start of the modernization. If any of the existing elevator components should be adjusted or repaired to guarantee proper operation, contact your supervisor. Start corrective actions when needed.

Doors If the existing landing doors or car door remain, check that the doors are in good condition and works properly and smoothly: • No visible damage to door panels or frames. Shake the door panels and identify any loose fixings. • Good condition of locks and bottom guide shoes. Worn out bottom guide shoes must be replaced. • Clearances between the door panels and frames. • Panels are not scratching each other or the frames. • Function and condition of the door contact and lock contact. • Function and condition of lock rollers, top track and ropes and the car door coupler. • Function and condition of lock (swing landing door). • Fixing of the landing door closer (dictator) and door contact bridge (swing landing door). Check that the door closer and the door contact bridge are properly fixed and the door closes properly. • Hinges of the swing landing door. Open the door fully against the limiter / buffer and check function of the hinges. Lubricate hinges if needed.

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Car guide shoes Check that the existing car guide shoes are correctly adjusted (total gap C is 2-5 mm) and in good condition.

C

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Ride comfort measurements To record the ride comfort of the existing elevator and to find out the reasons for a possible bad ride comfort, use DT-5 measuring device for ride comfort and ride quality measurements. Analyze the reasons for bad ride comfort if necessary. Repeat the ride comfort measurement after completing the installation. For more information, refer to AM-01.05.014, DT-5 USER INSTRUCTIONS.


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1

RECEIPT AND CONTROL OF MATERIAL PHASE: 1 LOCATION: Unloading/storage area

1057961.wmf

1015363.wmf

Heading 1.1, Checking of packages 1.2, Transporting materials 1.3, Unloading materials


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AM-10.65.001 (D) 2013-04-17


1.1

Checking of packages Step 1

Action Check the number and the condition of packages during unloading.

Note

1057961.wmf

1.2

Transporting materials

WARNING Transportation of the control panel is not described in this instruction. A safe working method and risk analysis detailing all the required risk reduction measures must be obtained from the supervisor responsible for your installation.

Step 1

Action Ensure that all packages are intact.

2

Check that packages match the packing list (quantities). Store the material inside the machine room or a specifically designated storage place (refer to site survey).

3


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Note Take digital pictures of any damaged components that need to be replaced.

• Take the pit material box into the pit. • Leave the material needed on the car roof (car top connection box, travelling cable fixing, sensor unit, hanging wires, magnets etc.) onto the topmost floor.

AM-10.65.001 (D) 2013-04-17


B

D C E m ax

60

C A

E

E

A

1070809.wmf


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AM-10.65.001 (D) 2013-04-17


A: Transporting the control panel to topmost floor • • • •

use a transport cart to transport the control panel use U-beams or plywood when transporting control panel on rough surfaces or on stairs transport the control panel to topmost floor with old elevator if possible use stair climber if necessary, check load limitations of the stairs

B: Testing the lifting hooks • test existing lifting hooks (if any) using Hilti Anchor Tester 28 • install new lifting hooks if necessary, test using Hilti Anchor Tester 28 C: Lifting the control panel to machine room • enlargen the hole in machine room floor if necessary, cover and lock the hole properly • no-one is allowed to be under suspended load D: Moving the control panel in machine room • the control panel can be lifted manually by two persons • use chain hoist stand if it is not possible to use hoist hooks at the machine room roof • no-one is allowed to be under suspended load E: Isolating the transporting area • • • •

common machine room must be divided if other elevator(s) are in normal service segregate other building users from the transportation route with safety fences or guarding store materials in designated storage areas, keep the area outside the working area clean protect the floors on transporting area

F: Checking the lifting equipment • chains: chain rings must not be stretched, bent, cut, cracked or worn, do not use knots or bolts to shorten the chain

1066227.wmf

• shackles: do not replace shackle pin with bolt, ensure that the pin is totally locked  *) if the load shifts, the sling can unscrew the shackle pin

1066228.wmf


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AM-10.65.001 (D) 2013-04-17


• eye bolts: the angle of lifting must not be less than 45 degrees when using shoulder eye bolts

1066229.wmf

• hooks: use only hooks with safety latches, use hooks with swiwels to allow the load to revolve

1066230.wmf

1.3

Unloading materials See AM-01.03.010, Safe working in elevator shaft and machine room areas. Remove the cardboard to access material inside the package.

1074399.wmf


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2

PREPARATIONS

OR

PHASE: 2 LOCATION: Shaft

Heading 2.1, Safety fences and signs 2.2, Checking the power sources 2.3, Checking safety gear operation and overspeed governor 2.4, Checking overtravels and safety spaces 2.5, Marking the sling and car position 2.6, Measuring travelling cable loop length 2.7, Checking the car and counterweight balancing 2.8, Preparing the access for the travelling cables and the shaft bundle 2.9, Installation of shaft lighting


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2.1

Safety fences and signs Step 1

Action Place warning and information signs and safety fences as required.

Note

1013729.wmf

2.2

Checking the power sources WARNING Ensure that electrical equipment and conductors are safely de-energized before working on them. Measure that there is no supply power before starting any electrical work. Some supply units / controllers may still contain high capacitive voltages after power is switched off. Carry out checks with a test instrument to prove equipment is safe to work on when switched - off, (allow enough time for stored energy to be discharged).

Step 1

2

Action Ensure that there are no energy storage devices or alternative power supplies in the elevator under work. Always study the existing documentation of the elevator carefully.


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Note For example lightning supply, emergency battery drive, backup power supply or emergency generator. WARNING! The accuracy of the existing documentation must be considered, because the documentation may not be up to date, if for example an old installation was modified or modernized.

AM-10.65.001 (D) 2013-04-17


2.3

Checking safety gear operation and overspeed governor If the overspeed governor is not OL35, refer to manufacturer’s instructions.

WARNING Before changing machine and ropes it is very important to check the function of the safety gear. If safety gear has not lately been activated, wedges and links can be stuck when the overspeed governor trips.

Step 1 2

3

Action Ensure that the overspeed governor and safety gear operates correctly. If TSS brake is delivered check that the overspeed governor is electrically bidirectional. Replace the overspeed governor if necessary (for example OL35). Check that the overspeed governor contact (A) is operational.

Note

TSS = Traction Sheave Shaft.

A

Ensure manually that the tripping direction is correct.

1080994.wmf


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2.4

Checking overtravels and safety spaces Check the safe spaces of the elevator in the order form / site survey. Check that the distances A-H are according to EN81.

If the safe spaces are not adequate in accordance with the elevator code, limit the travel of the counterweight to guarantee the safe space on the car roof. Use counterweight props, if needed. Refer to site survey. Secure the props to the guide rails using pit prop fixings.

* *

1032581.wmf 1063102.wmf


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2.5

Marking the sling and car position NOTE! If there are no drive buttons at the car roof and marking might cause any danger (for example in case of long floor to floor distance) this can be left undone. Marking at this point is not mandatory but will increase the efficiency of the installation. Step 1

Action Position the car at the lowest landing level. Mark the position of the car or the car sling to the shaft wall or to the guide rail.

Note

Repeat the marking at each landing level while driving to top of the elevator shaft. These markings will be used later to position the limit switch ramps and positioning magnets. 1060414.wmf

2

2.6

Check the best place for the positioning system (DZS). Refer to site survey.

The travelling cable location may be changed if necessary.

Measuring travelling cable loop length NOTE! Take these measurements in case of machinery below. Step 1

2 3

Action A: Measure the distance between travelling cable fixing below the car and car top connection box. B: Measure the length of existing travelling cable loop below the car. C: Measure the car height.

Note

A

C

B 1066910.wmf


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2.7

Checking the car and counterweight balancing Step 1

Action Load 50 % of the rated load into the car. Check from the layout drawings which weight the elevator is balanced to. Most of the elevators are balanced to 50 %.

Note The counterweight to be balanced to empty car weight + 50 % of the rated load. In some old elevator installations this figure may vary.

1012226.wmf

2

Drive car and counterweight to the same height in the elevator shaft.

1041126.wmf

3 4

Open the brake and check the traction sheave to see if the car moves. Drive the car a little upwards.


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The car should not move if car and counterweight are at same level.

AM-10.65.001 (D) 2013-04-17


Step 5

6 7

8

2.8

Action Open the brake for a few seconds and check the traction sheave to see if the car moves. Do the same in the other direction. If the counterweight is not balanced to empty car weight + 50 %, plan how to correct the balance before the end of the motor/drive commissioning. Remove the test weights from the car.

Note The car should not move.

The method must be planned in design phase or by supervisor.

Preparing the access for the travelling cables and the shaft bundle CAUTION Agree with the builder / building owner before making holes to the wall or floor. Any alterations to building structure require the approval of a qualified builder or building surveyor or a structural engineer. Agree with your supervisor and the building owner.

Machinery below From machine room to pit From pulley room to elevator shaft

1057965.wmf


Machinery above From machine room to elevator shaft

1057966.wmf

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Step 1 2

3

4

2.9

Action Note Check that there is room enough for the travelling cables and shaft bundle to go from machine room to elevator shaft and to the pulley room, if any. If necessary, enlarge the access. (See SWITCH THE POWER OFF. Use dust mask, gloves and goggles. picture above, machinery below/ above).

Remember to place a plastic container in the elevator shaft to prevent the waste material falling when enlarging the hole. (See picture above). Fix a minimum 6 mm nylon pull rope for pulling wiring into machine room.

SWITCH THE POWER ON.

Installation of shaft lighting Step 1 2

Action If there are drive buttons at the car roof, install the shaft lighting at this phase. Connect the lighting cable temporarily to a suitable power supply. Use shaft light installation tool KM796237 included in installation tool set. Ensure that the supply is protected by either a suitably rated earth leakage circuit breaker or an isolation panel.


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Note For more information, see section 8, Installation of shaft lighting.

1069951.wmf

AM-10.65.001 (D) 2013-04-17


3

INSTALLING TRAVELLING CABLES

OR

PHASE: 3 LOCATION: Shaft, car roof

1015363.wmf

1072248.wmf

Note: Two persons may be needed to lower the travelling cable, when the elevator travel is more than 40 meters. Heading 3.1, Installing travelling cable: Machinery below 3.2, Installing travelling cables: Machinery above 3.3, Dismantling old car equipment 3.4, Installing car top connection box and inspection drive unit 3.5, Routing cables to car top connection box 3.6, Connecting the travelling cable in the car top connection box 3.7, Temporary wiring of car top connection box 3.8, Fixing sensor unit to car roof 3.9, Installing the wire hanger and limit switch in top of the shaft


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3.1

Installing travelling cable: Machinery below WARNING Ensure that the inspection drive and stop buttons on the car roof operate correctly.

CAUTION Use helmet, hearing protection, dust mask, gloves and goggles as required.

At the middle of the elevator shaft Action Install 2 fixings for the travelling cable a bit above the mid point of elevator shaft on the guide rail or on the wall. Refer to the old travelling cable fixing positions. • The final fixing (1). • The temporary fixing (2) about 500 mm lower.

Note

1. 1.

2. 500

Step 1

500

3.1.1

2. 1048542.wmf

2

Check that the text on the cable faces the elevator shaft wall.

1048543.wmf


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Step 3

Action Lower the travelling cable: • 1: Unroll the travelling cable on the landing. • 2: Fix the car side end (plug marking XT) of the travelling cable temporarily to the car roof. • 3: Lower the travelling cable as a loop down to the elevator shaft until the loop is at the same level than old travelling cable loop. Check that the travelling cable runs free without getting stuck to the elevator shaft equipment. • 4: Fix the travelling cable both to the temporary and final fixings.

Note

1060605.wmf

4

Repeat step 3 for the second travelling cable if delivered. Fix the travelling cable first to the temporary fixing (1) and then to the final fixing (2).

2 1

1048545.wmf

5

D: Measure new car cable loop width from the car roof.

D

1066911.wmf

6

Calculate the total length (A + B - C - D) of travelling cable needed for the loop and up to the car top connection box.


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For dimensions A, B and C see section 2.6, Measuring travelling cable loop length.

AM-10.65.001 (D) 2013-04-17


Step 7

Action Tape a piece of self-adhesive tape (1) as reference on the travelling cable for that length.

Note

1 1048547.wmf

8

Adjust the travelling cable in the final fixing according to the reference.

11 1048548.wmf

9

Detach the travelling cable from the temporary fixing. Straighten the travelling cable. Lower the machine room end of travelling cable down behind the guide rail line. 1048549.wmf

3.1.2

Finalising the travelling cable installation Step 1

Action Remove the temporary fixing.

Note

1048554.wmf


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3.1.3

Passing the travelling cables to the machine room Step 1

Action Press the stop button down and go to the pit:

Note

Pass the control panel ends of the travelling cables to the machine room. Use a pull rope (1) if necessary.

1060713.wmf

2

Pull the travelling cable to the machine room using the rope. Check that the travelling cable reaches to the new control panel. Fix the travelling cable and shaft bundle into the pre-installed trunking or clips.

3

Pass spare length of cables back into the pit. Place the spare shaft bundle into the trunking. Fix the travelling cables to the wall in the pit.


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3.2

Installing travelling cables: Machinery above Step 1

2

Action Position the car so that there is access to the car roof from the topmost landing. Install the travelling cable hanger at the top of the elevator shaft.

Note

NOTE!Ensure that the position of the travelling cable hanger is at a straight angle relative to the car top.

3

1039502.wmf

Check the distance L between final position of the control panel and travelling cable fixing. Refer to site survey. Unwind length L of the travelling cable onto the top landing.

L

1039343.wmf

4

Fix all the travelling cables provided to the new fixing. NOTE! Check that the text on the cable faces the elevator shaft wall.

xx

xx

1039344.wmf

5

Fix the pull rope to the machine room end (plug marking XC) of the travelling cable.


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Step 6

Action In the machine room:

Note

Lift the travelling cable up to the machine room using the pull rope. Lay out the travelling cable. Lower the pull rope back into the shaft. It will be reused later for lifting the shaft bundle.

1065864.wmf

7

On the car roof: Readjust the travelling cable length at the travelling cable hanger, if necessary.

1039347.wmf

8

Unroll the first travelling cable onto the top level landing.


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Step 9

Action Lower the travelling cable as a loop down to the elevator shaft.

Note

NOTE!Do not let the cable twist around itself. Check that the travelling cable runs free without getting stuck to the elevator shaft equipment. Repeat for the second travelling cable if delivered.

1060118.wmf

10

Fix the travelling cable to the car roof edge. Ensure that the cable cannot be damaged by the sharp edge of the car roof.

1039533.wmf


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3.3

Dismantling old car equipment Step 1 2

3

4

Action Park the car so that you have access to the car roof from the topmost landing. Ensure the adequate lighting at the car roof for installation purposes. Connect the lighting to socket at machine room if necessary. Switch the mains power OFF. Lock and tag the switch. Isolate the car light supply. This may be separate. Verify de-energisation of mains supply and lighting supply (if separate).

Note Car roof approximately 0.8 m above the topmost landing level. Additional lighting may be needed if the main switch switches OFF also the car top and shaft lighting or the old elevator does not have lighting at all.

0V

1070189.wmf

5

6

Check the strength of the car roof. Temporarily support the car roof, if necessary. Remove from the car roof all old car equipment that will not be re-used and all possible shaft equipment at the location of the new service limit switch.

Refer to site survey.

1060242.wmf


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3.4

Installing car top connection box and inspection drive unit Step 1

Action Install the car top connection box and inspection drive unit on the car roof.

Note

The best place to fix car top connection box is above the travelling cable.

2

3

3.5

1 = Advised position of the inspection drive unit 2 = Possible positions of the car top connection box 3 = Travelling cable Fix a piece of plastic trunking close to the car top connection box. Place extra length of the cables to the trunking.

1

3

2 1067459.wmf

Route the inspection drive unit cable to car top connection box. Connect to XB20 on KCECCG board.

Routing cables to car top connection box Step 1

Action Remove the DIN rail with connection boards. Remove the end plate.

Note

2

1

1074431.wmf


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Step 2

Action Fix a piece of plastic trunking close to the car top connection box. Store the extra cable lengths inside the trunking.

Note

1080342.wmf

3

Fix the cables with cable ties. Leave approximately 10 cm cable ends after cable ties.

Note the cable earthing points.

XB9 + XB13 + 1074433.wmf

4 5 6 7

Fix the end plate. Fix the DIN rail with the boards. Connect the cables. Close the car top connection box.


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3.6

Connecting the travelling cable in the car top connection box Step 1 2

Action Fix the travelling cable inside the box. Connect travelling cable: • XT1 on KCECCG board • XT3 on KCEREL board • green/yellow wire to PE bar • all unused wires to PE bar to prevent risk of the electric shock • do not connect XT20 (for KRM) at this phase.

Illustration

XT1

PE XT3 1067599.wmf

3

In case of 3PH car door or retiring ramp connect the wires to terminal X49 and/or KCEREL board. Refer to circuit diagrams.


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3.7

Temporary wiring of car top connection box Step Action Note 1 Check that there are jumpers on the plugs XS1, XS2, XS3, XS4, XS5, XS6, XS7, XS8, XS9 and XS10 on KCECCG board as the safety devices have not been connected yet. NOTE! Each over connection plug has different pin order. Check plug markings carefully and connect the plugs accordingly.

XS1 XS2 XS3 XS4 XS5 XS6 XS7 XS8 XS9 XS10 1069958.wmf

• • • • • • • • • •

XS1 Final limit switch on car roof (51) XS2 Safety gear contact on car roof or buffer contact on car roof (52/58) XS3 Emergency exit contact in car/emergency stop switch on car roof (57/41) XS4 Slack rope contact on car roof or safety sill contact in car (53/54) XS5 Front car door contact or car door gate contact (87/55) XS6 Rear car door contact or rear car door gate contact (B87/B55) XS7 Buffer contact on car roof (58:N) or extendable car top balustrade contact XS8 Buffer contact on car roof (58:U) or extendable car top balustrade contact XS9 Service limit (68:U) XS10 Service limit (68:N)


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3.8

Fixing sensor unit to car roof Step 1

2 3

4 5

Action Fix C-profile to the car sling or to the car roof with screws according to site survey. Connect the sensor cable to the sensor unit. Fix sensor fixing plate to the C-profile using T-bolts according to the site survey results. Fix the front door and rear door (if any) sensor to the fixing plate. Fix service limit switches 68:U and 68:N (if any) to the fixing plate.

Note

1067582.wmf

Examples of sensor and limit switch positioning:

1070022.wmf

6

Route and connect the cables to the KCECCG board at the car top connection box: • door zone sensor cable to XB9 • rear door zone sensor (if any) to XB13 • service limit switch 68:U (if any) to XS9 • service limit switch 68:N (if any) to XS10. Fix the door zone sensor cable shields by clamps.

XB13 XB9 XS9 XS10 1069959.wmf


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3.9

Installing the wire hanger and limit switch in top of the shaft

3.9.1

Preparations Action Measure the dimension ”X” (distance between the car sill and the landing sill).

2

Measure and mark up the upper limit switch magnet position X + 100 mm up from the sensor unit at the car roof. This guarantees that the final limit switch operates 100 mm above top floor.

Note

X+100

Step 1

1069961.wmf


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3.9.2

Wire hanger in top of shaft NOTE! Magnetic force may cause magnet movement when car is passing the magnets if distance between the positioning magnets and the car (metallic conductive parts) is less than 70 mm. In such cases additional intermediate fixing is required at each floor to prevent position magnets swaying. Guide rail fixing Recommended:

>30 40 >70

Wall fixing

>70

>110

Distance between the positioning magnet and car is minimum 70 mm. Additional fixings per 16 m intervals.

>140

>180

1080378.wmf

Distance between the positioning magnet and car is > 15 mm and < 70 mm.

>30 40 >15 <70

1080379.wmf

>110

>15 <70

An additional intermediate fixing at each floor is required.

>85 1080380.wmf


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AM-10.65.001 (D) 2013-04-17


Step 1

2

Action Fix the upper guide rail fixing or wall fixing so that the lower edge of the fixing is at the marked height (*). Fix the piano wire fixing bracket and Tbolts. Select correct fixing holes according to site survey / layout drawings / delivery documents. Hanger fixed on the guide rail: Pre-assemble the hanger on the car roof.

Note

Ensure that there will be room to fix the service limit ramp (if any) later. For more information, see section 4, Installing top service limit ramp (optional).

* 1070386.wmf

Hanger fixed to the shaft wall: Install the hanger according to site survey / layout drawings / delivery documents. Measure and record the distance from the guide rail to the bracket. You will need the measurement to position the bottom wall fixing.

1070028.wmf


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Step 3

Action If the hanger is fixed to the guide rail, secure the fixing by pinning the hanger in position.

Note

1072281.wmf

4 5 6 7

Slide the C-profile ramp to T-bolts. Fix security bolt to top of the ramp. Place the topmost floor magnet 130:U to bottom end of the ramp. Place top final limit magnet(s) 151:U above the top floor magnet so that there is no gap in between. When counterweight is on fully compressed buffer, sensor must read magnet. Place all the delivered final limit magnets to create a ramp.

All the magnets must be placed so that the Kone logo is at the top end of the magnet. C-profile must not be visible below or between the magnets. This might cause errors in positioning. Each magnet has its own ID.

151:U

130:U 1070026.wmf


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Step 8

Action Position the ramp so that the bottom end of the final limit magnet is at the marked height (= 100 mm up from topmost landing).

Note

1071057.wmf

Align the sensor unit at the car roof according to the magnets. Take reference measurements from the guide rail.

A B

9

B+15

The gap between the sensor unit and magnet must be 15 ± 5 mm.

A 1070027.wmf

10 11

Check the distance between the magnet and sensor unit (X + 100 mm). Turn the inspection drive unit on the car roof 42:DS to NORMAL.

1 = Normal, 2 = Inspection

1


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NORMAL

I N S P E C T I O N

2

NORMAL

I N S P E C T I O N

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4

INSTALLING TOP SERVICE LIMIT RAMP (OPTIONAL) PHASE: 7 LOCATION: Shaft

1072256.wmf

1015363.wmf

Heading 4.1, Installing top service limit ramp


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4.1

Installing top service limit ramp Step 1

Action Assemble the service limit ramp if necessary.

Note

NOTE: Install the ramp extension kit if applicable.

1070100.wmf 1082067.wmf

2

Fix the ramp to top guide rail bracket using T-bolts. For correct height refer to delivery documents. The service limit switch must operate when the car is 1 m below the topmost floor to remain exit route from the car roof.

3 4

There must be minimum 1.8 m space left between the car roof and the elevator shaft ceiling when the limit switch operates. Fix the guide rail bracket to the lower end of the ramp. Ensure that the ramp is correctly aligned.

1070097.wmf

5

Check the operation of the service limit switch.


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5

DISMANTLING OLD MACHINE ROOM EQUIPMENT

OR

PHASE: 4 LOCATION: Machine room

1060688.wmf

WARNING Ensure that the power is switched off at the main switch. Check if the old limit switch is 3 phase type.

Heading 5.1, Marking the wires in the old control panel 5.2, Removing old equipment


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5.1

Marking the wires in the old control panel Step 1

Action Find and clearly mark on the old control panel the old lock wires (and door contact wires if swing door is used). • Door lock wire = 1 • Door lock wire = 2 • Door contact wire = 3 • Door contact wire = 4 • Door earth wire = 5

Illustration

5 4 3

2

5.2

2 1

Use the corresponding references (see table below) and mark them on the wires. Function Ref. Landing door lock Door wire: 1 Door wire: 2 Landing door contact Door wire: 3 Door wire: 4 Earth Door wire: 5

Removing old equipment Step 1 2 3 4

Action For more information on dismantling, see AM-01.01.085. Disconnect and protect the marked door wires in the old control panel. Disconnect all old equipment. Remove the old control panel.

Note

1015365.wmf


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6

INSTALLATION AND WIRING OF MACHINERY / CONTROL PANEL OR PHASE: 5 LOCATION: Machine room

1067612.wmf

1072125.wmf

1015363.wmf

WARNING Ensure that the power is switched off at the main switch. Check if the old limit switch is 3 phase type.

Heading 6.1, Position the control panel according to the site survey 6.2, Re-use / installation of trunking for travelling cable and elevator shaft wiring 6.3, Routing of wiring between controller panel and machinery 6.4, Snelis devices 6.5, Specific routing for V3F motor supply cable 6.6, Connecting the extension tool 6.7, Connecting travelling cable 6.8, Connecting machine room equipment 6.9, Installing and connecting power supply 6.10, Wiring other machine room equipment


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6.1

Position the control panel according to the site survey Two possible locations: On the wall or on the floor.

6.1.1

Transporting and hoisting the control panel Step 1

Action Use stairclimber assembly for electrification panels to transport the control panel in stairs if necessary.

Note

1073726.wmf

1074502.wmf

2

Install new lifting hook above the control panel location if necessary. Test the lifting hook using Hilti Anchor Tester 28. Refer to manual delivered with the tester.

1072123.wmf


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Step 3

Action Keep the control panel door locked when lifting or transporting it. Lifting the control panel with chain hoist attached to lifting eye.

Note The weight of the KCE control panel is 50 - 80 kg. Two people lifting the control panel.

o

60 max

1070072.wmf

6.1.2

1070076.wmf

On the floor Step 1

2 3 4

Action Mark and drill the control panel fixing holes to the floor. Use control panel stand as drilling template.

Note Use hearing protection, dust mask, gloves and goggles.

For correct location refer to the site survey and delivery documents. Fix the stand to the control panel. Tilt the control panel to the upright position. Lift and fix the control panel to the floor. Safety Gloves must be worn.

1


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6.1.3

On the wall Step 1

Action Fix the controller fixing bracket (1) to the wall using stroke anchors delivered with the bracket. Check the correct location from delivery documents.

Note

1

Use hearing protection, dust mask, gloves and goggles.

1067617.wmf

2

Lift the panel in position on the fixing bracket using manual chain hoist or manually (two persons).

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3

Drill a hole in the wall through the fixing hole at bottom end of the panel. Fix with screw. 1067627.wmf

4 5 6

Fix the stand (if any) to the control panel. Fix the bottom plate to the stand. Position and fix the THD filter as planned in the site survey (if THD filter is not pre-installed in the control panel).

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6.2

Re-use / installation of trunking for travelling cable and elevator shaft wiring Step 1

Action Re-use or install the trunking between the control panel and the elevator shaft hole or machinery (travelling cable and elevator shaft wiring).

Illustration

Refer to the order form for possible optional systems that may require space in the machine room (e.g. Konexion). WARNING! If the drive type is V3F10 and there is metal floor in machine room, the elevator shaft wiring and travelling cable must be placed at least 0.5 m above the floor.

1057978.wmf


WARNING! Before starting the installation in elevator shaft, the motor cable shield must be connected to earth.


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6.3

Routing of wiring between controller panel and machinery Step 1

2

3 4

Action See marking on the floor and on the walls, done at the time of the site survey, or see the file saved by the supervisor. Continue with the cables between the control panel and the main power supply. Continue with the cables between the control panel and the machinery.

Note

1067643.wmf

Use metal trunking if the wiring runs on the floor across machine room.

1015367.wmf

6.4

Snelis devices Step 1

Action If there are Snelis devices (for example extra lighting, ladders, balustrades) to be installed to the machine room, install them now.


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Note

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6.5

Specific routing for V3F motor supply cable

KCE

1 0

M 20 cm

1067711.wmf

Step 1

2

3

Action Note Route motor cable shortest This cable must have minimum distance possible way from the control panel to of 20 cm to any other parallel cables or the machinery. must cross them at 90°. Peel the V3F motor cable to expose the cable shield and change the cable gland to metal one. Route the motor cable into the motor connection box Ensure that the shield has reliable contact with the gland. 1058144.wmf CAUTION! If the motor has plastic junction box, connect the cable shield directly to earth terminal. Pass V3F motor cable through the sprung cable clamp in the control panel. Ensure that the braided shield comes into contact with the clamp. V3F


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6.6

Connecting the extension tool The extension tool (KM796238G10050) connects old door lock wiring in series with the new door lock wiring. This ensures that the elevator cannot drive while a door is open or unlocked.

S4, S5

A

S5 S4 XH1 PE1

B

XH1

122

12

1

XH1 PE

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A = New controller; B = Old controller Step 1 2

3

Action Note Connect the extension tool plug to the connector XH1 on the KCEMSC board and earth wire to PE bar. Connect the extension tool to the door and landing contacts of the old wiring. The landing door lock: Wires 1 and 2 Terminal 122 The landing door contact (if swing door): Wires 3 and 4 Terminal 121 Earth: Wire 5 PE bar Put a temporary jumper on the extension tool XH1.

DIP switch S4 and S5 settings according to landing door type ON OFF S4/3, S5/3, front door type Manual door (swing door) Automatic door S4/4, S5/4, rear door type Manual door (swing door) Automatic door S4/6, S5/6, through type car 2 doors, (through type car) 1 car door


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6.7

Connecting travelling cable WARNING Ensure that the power is switched off at the main switch.

Step 1

Action Connect the travelling cable plugs to the KCE control panel: • XC1 on KCECPU board • XC3 to connector below KCECPU board • XT20 to connector below KCECPU board (in case of alternative travelling cable)

Note Connect shield of serial transmission twisted pairs to ground by fixing clamp* on back plate of control cabinet.

XC1 XC3

XT20

*

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6.8

Connecting machine room equipment

6.8.1

Connecting stop button and overspeed governor

XM1

XOSG1 2 PE1

1

1067688.wmf

1. = Stop button 2. = Overspeed governor Step

1

Action Note WARNING! Ensure that the power is switched off at the main switch. Connect the plugs of the machine room cables to the KCE control panel. KCEMSC board: XM1 Stop button (optional, if not applicable, place jumper to XM1) XOSG1 OSG switch PE bar PE1


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6.8.2

Installing machine room lighting (LMR, optional) Step 1

2 3

Action Install the machine room lighting unit if applicable.  If machine room > 12 m2, two lighting units are used. Connect the machine room lighting to adapter cable (XH157/2). Connect the adapter cable (XH157) to the control panel.

Note XH157 XH157/1 XH157/2

NOTE! The shaft lighting will be connected to the adapter cable (XH157/1) later. 6.8.3

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Using spring loaded terminal Step 1

Action Use right size of screw driver when connecting wires to spring loaded terminals.

Note

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6.8.4

Connecting machinery V3F

A = Motor V3F B = Fan C = Brake D = EMC clamp

XMF/ 1, 2, 3, 4, 5 XBR/+, PE

Refer to the old and new elevator circuit diagrams and component instructions.

D A C B Component connections 1 Motor V3F: Phase 1 Phase 2 Phase 3 Earthing (green/yellow) 10 Fan (1 phase): Controlled phase Continuous phase Neutral Earthing (green/yellow) 10 Fan (2 or 3 phase): Controlled phases

Thermal contact Earthing (green/yellow) 11 Brake: Brake wire (+) Brake wire (-) Earthing (green/yellow)


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1067708.wmf

Control panel connections terminal U terminal V terminal W terminal PE terminal XMF/1 terminal XMF/2 terminal XMF/3 terminal PE terminal XMF/1 terminal XMF/2 terminal XMF/3 terminal XMF/4 terminal XMF/5 terminal PE terminal XBR/+ terminal XBR/terminal PE

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6.8.5

Connections of THD filter (if external)

PE 1U1 1V1 1W1 1U2 1V2 1W2

1067714.wmf

For more details, refer to site-specific elevator circuit diagrams. Control panel Mains cable 1 1U1 1U1 1V1 1V1 1W1 1W1 PE PE


THD filter (pre-wired) 1U2 1V2 1W2

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Control panel Mains cable 2 1U2 1V2 1W2

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6.8.6

Connections of MAS-M (main switch located on the machine room wall, optional)

1L1 1L2 1L3 1N1 PE 2L1 2N1 PE MAS-M

1067723.wmf

For more details, refer to site-specific elevator circuit diagrams. MAS-M Mains power supply cable Connection to MAS-M must be done according to section 6.9.2, Connecting power supply cables to control panel (new cables) obeying the safety rules! Lighting supply cable


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Control panel 1L1 1L2 1L3 1N1 PE 2L1 2N1 PE

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6.8.7

Connecting the machinery (using old cables) A) Marking of the wires in the old control panel. • Mark each wire of the different functions (see table). • Identify each wire by numbered bands of marking tape and register this number in the space corresponding (column A) to the function found. B) Wiring in the control panel. • Wire each numbered wire on the terminal block (see table). • Tick in column B, once each function has been re-connected. NOTE! ***) If V3F: New shielded motor cable must be used (see section 6.5, Specific routing for V3F motor supply cable)

A = Motor V3F B = Fan C = Brake D = EMC clamp

XMF/ 1, 2, 3, 4, 5 XBR/+, PE

Refer to the old and new elevator circuit diagrams and component instructions.


D A C B

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Component connections 1 Motor:

A

Control panel connections

B

terminal U terminal V terminal W terminal PE 10 Fan (1 phase): Controlled phase Continuous phase Neutral Earthing (green/yellow) 10 Fan (2 or 3 phase): Controlled phases

terminal XMF/1 terminal XMF/2 terminal XMF/3 terminal PE terminal XMF/1 terminal XMF/2 terminal XMF/3 terminal XMF/4 terminal XMF/5 terminal PE

Thermal contact Earthing (green/yellow) 11 Brake: Brake wire (+) Brake wire (-) Earthing (green/yellow)


terminal XBR/+ terminal XBR/terminal PE

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6.9

Installing and connecting power supply

6.9.1

Installing new external main switch unit (MAS-M, if included)

WARNING Ensure that the building main supply to the machine room is switched off and isolated.

Step 1

Action Warn all concerned persons: janitor, syndic, users and others.

2

Switch the mains power OFF. Lock and tag the switch.

3

Isolate the lighting supply. This may be separate. Verify de-energisation of mains supply and lighting supply (if separate).

Illustration

0V

1070189.wmf

4

6.9.2

Install the new main power supply and power supply for car light.

Connecting power supply cables to control panel (new cables) Table 1: Safety precautions. Step 1

2

Action Switch the mains power OFF. Lock and tag the switch. Isolate the lighting supply. This may be separate. Verify de-energisation of mains supply and lighting supply (if separate).

Note

0V

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Table 2: Connection.

1L1 1L2 1L3 1N1 PE

2L1 2N1 PE 1070323.wmf

Step 1

Action Connect the mains supply cable: • L1 (brown) to 1L1 • L2 (black) to 1L2 • L3 (grey) to 1L3 • N (blue) to 1N1 • PE (green/yellow) to PE

2

Connect the lighting supply cable (3x1.5 mm2): • L (brown) to 2L1 • N (blue) to 2N1 • PE (green/yellow) to PE Connect the additional earth wire (if required) from PE to PE.

3


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Note Label on cable: 20 When MAS-M is used, the THD filter connection must be done before the mains supply connection. The connection may have already been prepared in section 6.8.6, check the THD filter connection at this stage. Label on cable: 20:1

With adjustable speed drive systems additional protective conductor is needed when riser cable protective conductor has a cross-sectional area of less than 10 mm2 Cu. The additional protective conductor of at least the same cross-sectional area shall be provided up to a point where the protective conductor has a cross-sectional area not less than 10 mm2 Cu or 16 mm2 Al.

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6.9.3

Connecting power supply cables to main switch unit (MAS-M) Step 1

2


Note

0V

1070189.wmf

3

4

6.9.4

Connect the mains supply cable: • L1 (brown) to Q20/1 • L2 (black) to Q20/3 • L3 (grey) to Q20/5 • N (blue) to N • PE (green/yellow) to PE Connect the lighting supply cable (3x1.5 mm2): • L (brown) to Q29/1 • N (blue) to Q29/3 • PE (green/yellow) to PE

The THD filter connection must be done before the mains supply connection. The connection may have already been prepared in section 6.8.6, check the THD filter connection at this stage.

Connecting power supply cables to control panel (old cables) Table 3: Safety precautions. Step 1

2


Note

0V

1070189.wmf


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Table 4: Marking and connection of old wires in the new panels.

1L1 1L2 1L3 1N1 PE

2L1 2N1 PE 1070323.wmf

Step 1 2 3

Action Note Mark each wire of the different functions (see table). Refer to the elevator circuit diagrams. Identify each wire by numbered marking bands and register this number in the space corresponding (column A) to the function found. Connect wires to the new control panel as shown in the table below. Tick in column B, when each function has been re-connected.

Functions Mains supply cable: Phase 1 Phase 2 Phase 3 Neutral Earth Lighting supply cable: Phase Neutral Earth Lighting supply cable Phase (in case of 230 VAC Phase mains supply): Earth Additional PE wire Earth (if required)


A

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Control panel terminal 1L1 1L2 1L3 1N1 PE 2L1 2N1 PE 2L1 2N1 PE PE

B

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6.10

Wiring other machine room equipment Step 1

Action Note Route and connect the cables for rest of the machine room equipment: • LIL, Elevator link • EAQ, Earthquake feature • CIC, Corridor illumination control For more information on wiring the machine room equipment, see wiring diagrams.


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COMMISSIONING FOR SERVICE SPEED PHASE: 6 LOCATION: Machine room, car roof

SPEED m/s

TESTS

STOP

0.6 0.3 0.02

RUN OFF

263

INSPECTION UP

NORM

SB-1 SB-2

TEST

STOP

SB-COMM DZI

0.02 0.3 0.6

261

Unlocking zone

7

CALLS

TESTS

TOP CALL

SETUP

SB-3 SB-4

BOOST

RUN INSP

DOWN

TERMINAL STOP BYPASS

BOTTOM CALL

OSG

FAULTS Self check

ETS Bypass NTS Bypass Normal Decel Bypass

Overspeed SELECT

RESET

Unintended movement Run time limiter

SB-1 = Car Doors ( C5, C6 ) SB-2 = Car ( C1-C4, C7-C10, S1, S2 ) SB-3 = Landing Doors ( H3, H4 ) SB-4 = Pit, OSG ( H1, H2, H5, H6 )

PENDANT SERVICE REMOTE

Safety chain open

Use jumpers SB-1 to SB-4 for safety chain bypass

TESTS 261 = inhibit landing calls 263 = enable tests, inhibit door opening

1069928.wmf

NOTE! If any problems during the commissioning, for more information on fault finding and diagnostics, see AS-10.65.006 Diagnostic guide for KONE ReSolve 200 commissioning and AS-10.65.007 Fault finding instruction for KONE ReSolve 200. Heading 7.1, Safety measures 7.2, Preparations before turning the power on 7.3, Reset button at KMI (KONE Maintenance Interface) 7.4, Example of setting parameters 7.5, Checking of inverter parameters 7.6, Non-rotational autotuning of K1000 drive 7.7, Driving the elevator for the first time 7.8, Preparation for driving the elevator on the car roof


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7.1

Safety measures The following safety items must be carried out before starting actual work: • • • • •

7.2

Check the connections of drive module, if any. Ensure that the cover of drive module is closed, if any. Check that nobody is working in the elevator shaft or on the elevator. Inform other members of working team that the power is switched ON. Ensure that all covers of electrical components are in place before switching the power ON.

Preparations before turning the power on Ensure that the elevator is balanced to 50%.

7.2.1

On the car roof Step 1 2

Action ENSURE THAT THE POWER SUPPLY IS SWITCHED OFF. Check that the inspection drive unit on the car roof in switched to normal.

Note

1 = Normal, 2 = Inspection

1


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NORMAL

I N S P E C T I O N

2

NORMAL

I N S P E C T I O N

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7.2.2

In machine room Step 1 2

Action Turn the elevator to RDF drive (INSPECTION switch to low position). Ensure that the STOP switch is set to run. The STOP LED must not be lit.

Illustration STOP

TESTS

RUN OFF 261 263 TEST

STOP INSPECTION NORM

CALLS UP

TOP CALL

RUN INSP

3

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Open the cover of the drive unit. Verify the setting of the jumpers. ESC

LO RE

RESET

ENTER

RUN

STOP

1070101.wmf

4

SWITCH THE POWER ON from control panel or external main switch unit.

1

Q220

0

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5

Check the status of the LEDs and display at the drive unit: • bb blinking on display • ALM LED blinking ESC

LO RE

RESET

ENTER

RUN

STOP 1069826.wmf

6

7

Only the INSP LED at the KMI should be lit.

If the elevator is on the door zone the Unlocking zone LED is lit.

NOTE! Ensure that the safety chain is not broken. The Safety chain open LED must not be lit. Check that the 24V OK LED on both KCECPU and KCEMSC board is lit.


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7.3

Reset button at KMI (KONE Maintenance Interface) Step 1

Action Turn test switch to position 263 and push the Reset button at KMI if any of the LEDs beside the reset button is lit.

Note TESTS

OFF 261 263 TEST

Reset button does not work if KCEMSC is in the Safe Mode. Make a power break (both 24 V and battery) for KCEMSC. Push the Reset button within 10 minutes after power break.


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KCEMSC may go to Safe Mode if the elevator has been in fault more than 10 hours. Fault code 1175 appears on display.

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7.4

Example of setting parameters The following example explains how to set the parameter A1-02 value to 2. Step 1

Action At the beginning bb is blinking on display.

Display

1069865.wmf

2

3

4

5

6

7

8

9

10

Press the key until PAr  appears on display. Press the key to view the  ENTER parameter setting display. Press the key until 01 is  RESET blinking on the display. Press the key until A1-02  appears on display. Press the key to view the  ENTER current parameter value. Press the key until the digit to  RESET be changed is blinking on the display. Press the key until 2  appears on display. Press the key to confirm the  ENTER change. End blinks on display. The display automatically returns to show A1-02.

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11

12

Press the

ESC

key until F0.00

appears on the display. Otherwise the elevator will not run. bb starts blinking on display after a while if any buttons are not pressed.

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7.4.1

Menu structure for digital LED operator

Description of Key Operations

:

DRV light is on. *Pressing RUN will start the motor.

Turn the power on

* Forward Selection

:

Reverse Selection

: :

Output Frequency

Output Current

Output Voltage

Note: “XX” characters are shown in this manual. The drive will display the actual setting values.

XX Monitor Display

XX XX XX

XX

XX XX

XX

DRV light is off. *Drive cannot operate the motor.

Verify Menu

XX Set Up Mode

XX XX

XX XX

Parameter Setting Mode

XX

Auto-Tuning

XX


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7.5

Checking of inverter parameters Check the parameters described in the table below. For correct parameter values, see wiring diagrams. For more information on user interface, see APPENDIX A., Changing the characteristics / V3F10 K1000 LED user interface. For more information, see sections 7.4, Example of setting parameters and 7.4.1, Menu structure for digital LED operator. For more information on parameters, see 873805 V3F10/K7/K1000 Yaskawa drive parameter list and APPENDIX E., Speed parameters. Step 1 2 3 4 5 6 7 8 9 10 11 12

Action Set the following parameters: Control method selection (A1-02) parameter to 2. MA-19-20 Terminal function selection (H2-01) parameter to 61. Inverter input voltage (E1-01) parameter. Inverter input current (E2-01) parameter. KONE control selection (D1-18) parameter to 11. Nominal speed (D1-01) parameter. Inspection drive speed (D1-02) parameter to 15. Correction drive speed / Inspection slow speed (D1-04) parameter. Levelling speed (D1-17) parameter to 4. Acceleration time (C1-01) parameter Deceleration time (C1-02) parameter Press the key until F0.00

Note Value 2 = Open loop vector control Value 61 = KCE Controller (Volt) According to main supply voltage. (A) Refer to machine data plate. Value 11 = KCE Controller (Hz) Refer to machine data plate (50 or 33). (Hz) 15 corresponds 0.3 m/s if nominal speed is 1 m/s and D1-01 is 50 Hz. (Hz) (Hz) (s) See table below.

ESC

appears on the display. Otherwise the elevator will not run.


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Speed (m/s) Light flywheel Medium flywheel Heavy flywheel

7.6

Acceleration / deceleration time (C1-01 / C1-02) 0.3 0.4 0.5 0.63 0.7 0.8 0.6 0.8 0.9 1.0 1.2 1.4 0.9 1.1 1.2 1.3 1.5 1.6 1.2 1.3 1.4 1.6 1.8 1.9

0.9 1.4 1.7 2.0

1.0 1.5 1.8 2.1

Non-rotational autotuning of K1000 drive Step 1

2

Action Note Press the key until ATun  1071358.wmf appears on display. Press the key to view the autotuning parameter setting display. ENTER

3 4

Set the parameter T1-01 value to 01 to perform Stationary Auto-Tuning. Set the following parameters to the motor values given on the motor nameplate: T1-02 “Mtr Rated Power” kW (if noted in HP, multiply the number by 0,746) T1-03 “Rated Voltage” V T1-04 “Rated Current” A T1-05 “Rated frequency” Hz T1-06 “Number of Poles” 4 for 1500 rpm or 33 Hz Kone motor, 6 for 1000 rpm motor T1-07 “Rated Speed” Motor Rated RPM: 1440 for 4 poles 960 for 6 poles NOTE! The slip adjustment will be done later in chapter 15.8.

5

Press the key until Tun11  appears on display.


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Step 6

Action Press simultaneously RUN and UP (or RUN and DOWN) RDF buttons on KMI. Wait until the main contactor energise (contactor makes “clank“ sound). Press the key on the drive RUN  unit once. Tun11 is blinking on the display and the green light on the RUN key is lit.

7

When END appears on the display, release the RDF buttons.

8

Press the

ESC

INSPECTION NORM

CALLS UP

TOP CALL

RUN INSP

DOWN

BOTTOM CALL

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Keep the RDF buttons pressed down until the whole autotuning procedure is over. If something else than END appears on the display (for example END1), the autotuning did not succeed. Refer to V3F10 fault codes 878327.Correct the problem and repeat non-rotational autotuning.

key until F0.00

appears on the display. Otherwise the elevator will not run.


Note

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7.7

Driving the elevator for the first time Step 1 2

3 4 5

6

7

8

Action If there is a retiring ramp, block it mechanically. Ensure that the car door can not open when driving the elevator, as the car door is not electrically connected yet. Block the door manually, if necessary. Ensure that the elevator is on RDF mode. Check the safety chain using KONE KMI (KONE Maintenance Interface). Check motor rotation direction in RDF mode. • Push simultaneously RUN and DOWN buttons to drive the car downwards a short distance only. • Observe the rotation direction. If the car moves in the wrong direction, • Switch the power off • Swap two phases (U,V) in the motor supply cable. • Check the rotation direction again. Check visually the rotation of motor and operation of brake.

Note

For more information, see KONE fault code list 958174D02. INSPECTION NORM

CALLS UP

TOP CALL

RUN INSP

DOWN

BOTTOM CALL

1069938.wmf

If necessary, adjust the brake mechanically. Check also that the brake voltage is correct. Measures between terminals XBR/+ and XBR/-.

If there is a stop button in machine room, test it.


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7.8

Preparation for driving the elevator on the car roof

7.8.1

First: on the machine room Step 1

Action

Illustration

Switch ON: • Switch 290:1 (car lighting) • Switch 290:2 (socket in the pit and shaft lighting)

1 0

1069939.wmf

7.8.2

Second: on the car roof Step 1

Action Turn the inspection drive unit on the car roof 42:DS to INSPECTION.

Illustration 1 = Normal; 2 = Inspection

1

2

NORMAL

I N S P E C T I O N

2

NORMAL

I N S P E C T I O N

1069822.wmf

Check the socket power and earthing on the car top connection box using multimeter.

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7.8.3

Third: on the car roof Step 1 2 3 4 5

6

7.8.4

Action Note Push the stop button on the inspection drive unit. Try to drive the car to both down and up The elevator must not drive. directions. Release the stop button. Try to drive the car to both down and up The elevator should drive. directions. Check the final limit magnet operation: • remove the magnet from C-profile and hold it in front of the sensor unit • try to drive the car, the elevator must not drive • place the magnet back to C-profile • drive the car upwards until the final limit magnet stops the car NOTE! If there are pit props below the counterweight, you can not perform this test. Do not remove the pit props at this phase. Check the operation of all landing door The elevator must not run. contacts while driving down. Open each door individually and try to drive the elevator.

If the elevator will not run check following Step 1

2 3

Action If the car can not run in up direction, check the state of the inspection drive limit switch 68:U. If there is a retiring ramp, block it mechanically. Ensure that the car door cannot open when driving the elevator, as the car door is not electrically connected yet. Block the door manually, if necessary.


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Note

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8

INSTALLATION OF SHAFT LIGHTING PHASE: 8 LOCATION: Shaft

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Heading 8.1, Installing elevator shaft lighting, if applicable (PT) 8.2, Installing elevator shaft lighting, if applicable (PU)

Page 93 94

WARNING Ensure that the car roof is strong enough for two men and tools.

WARNING Ensure that the inspection drive and stop buttons on the car roof operate correctly.

Use hearing protection, dust mask, harness, helmet, gloves and goggles.


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Installing elevator shaft lighting, if applicable (PT)

2

Note

X

3

Action Fix the first light fitting to the elevator shaft wall so that: top of the light fitting is max. 0.5 m below the slab. Plug the cable on the light fitting. Tie the elevator shaft lighting cable to the pull rope. Continue by installing the other light fittings. Refer to layout drawings. Lower the last light fitting to the bottom of the pit.

max. 0.5m

Step 1

X

8.1

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5

6

max. 0.5m

X

4

X = 6 m for standard lighting X = 3 m for slim lighting Pull the elevator shaft lighting cable up to the machine room.

Make an adapter wire between the lighting unit and socket. Molex 1 - phase (black) Molex 2 - neutral (blue) Molex 5 - earth (green / yellow) Connect the lighting and pit supply cables temporarily to a suitable power supply. Use shaft light installation tool KM796237 in installation tool set. Ensure that the supply is protected by either a suitably rated earth leakage circuit breaker or an isolation panel.


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Installing elevator shaft lighting, if applicable (PU)

4

5

X = 6 m for standard lighting X = 3 m for slim lighting Do not install the last light in the bottom of pit yet. The last light fitting is fixed after shaft bundle installation. For more information, see section 11.5, Finalising new elevator shaft lighting (if included). Pass the cable into machine room with help of a pull rope if necessary.

max. 0.5m

On the car roof: Place elevator shaft lighting equipment on the car roof. Fix the first light fitting so that: top of the light fitting is max. 0.5 m below the slab. Plug the cable to the light fitting. Continue by installing the other lights. Use the car as a working platform.

1079689.wmf

6

7

max. 0.5m

3

Note

X

2

Action

X

Step 1

X

8.2

Make an adapter wire between the lighting unit and socket. Molex 1 - phase (black) Molex 2 -neutral (blue) Molex 5 - earth (green / yellow) Connect the lighting and pit supply cables temporarily to a suitable power supply. Use shaft light installation tool KM796237 in installation tool set. Ensure that the supply is protected by either a suitably rated earth leakage circuit breaker or an isolation panel.


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1069951.wmf

AM-10.65.001 (D) 2013-04-17


9

REMOVING OLD ELEVATOR SHAFT EQUIPMENT PHASE: 9 LOCATION: Shaft

Remove all old elevator shaft material, except the old shaft bundle. Heading 9.1, Removing of old levelling system 9.2, Remove old limits and floor switches 9.3, Remove landing bands / support wires 9.4, Removing old travelling cable

Page 96 96 97 98

NOTE! For more information on dismantling, see AM-01.01.085.


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9.1

Removing of old levelling system Check that the floor level positions have been marked and remove old levelling system.

9.2

Remove old limits and floor switches Step 1

Action Position the car at a convenient working height. PUSH THE STOP BUTTON

Illustration Ensure that the inspection drive unit on the car roof operates correctly. Use harness, helmet and gloves.

2 3

Cut the switch wires to the old elevator shaft wiring. Remove, if possible, the old switch and limit ramp. NOTE! If you have at the top on the elevator shaft 3 phases limit switch TURN OFF the main power supply before removing it (if applicable).

4

RELEASE THE STOP BUTTON Continue as above, level by level.


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9.3

Remove landing bands / support wires Step 1

2 3

Action

Illustration

Use harness, helmet and gloves. Dismantle, if existing, the intermediate fixing of the Landing bands. In the pit remove all the lower fixings of the Landing bands. Position the car to have access to the upper support of the Landing bands. PUSH THE STOP BUTTON DOWN

4 5 6 7 8

At the upper support, remove 1 Landing band from its support. Carefully pull up and roll the Landing band. Tie and arrange the band. Continue in an identical way for the other bands. Dismantle and remove the upper support. Remove chain of selector, if any. RELEASE THE STOP BUTTON


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Use harness, helmet and gloves.

AM-10.65.001 (D) 2013-04-17


9.4

Removing old travelling cable Step 1

Action

Illustration At the top of the shaft. Or at the middle of elevator shaft if a halfway box exists

Use harness, helmet and gloves. Position the car at a safe working height just below the old travelling cable support. PUSH THE STOP BUTTON

1015432.wmf

2

3 4

Pull up the old travelling cable to the landing and coil it. Tie up the travelling cable roll. Cut the old cable close to the fixing. Repeat for the other travelling cables. RELEASE THE STOP BUTTON Position the car to access to the travelling cable fixing. PUSH THE STOP BUTTON

1039604.wmf


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Step 5 6

Action Remove the old travelling cable fixing. The ends of travelling cable remain . Take out the old travelling cable fixing.

Illustration

1058200.wmf

7

RELEASE THE STOP BUTTON


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The old travelling cables may be temporarily stored in car.

AM-10.65.001 (D) 2013-04-17


10

INSTALLING THE HANGING WIRES AND POSITIONING MAGNETS OR PHASE: 10 LOCATION: Shaft

1072260.wmf

1015363.wmf

CAUTION Use gloves, goggles and helmet as required.

Heading 10.1, Hanging the wires at top of the shaft 10.2, Fixing the wires in the pit 10.3, Installing bottom service limit ramp (optional) 10.4, Installing positioning magnets


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Page 101 102 105 106

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10.1

Hanging the wires at top of the shaft Step 1

Action PUSH THE STOP BUTTON

2

Fix a weight (for example a spanner) to the piano wire. Unwind the piano wire until the weight touches the pit floor.

3

Note

1070121.wmf

4

5

Cut the wire, route and secure it in position. CAUTION! Be careful not to bend the wire. Repeat the lowering and fixing for the other wire. Keep minimum 1 meter distance between the wires while lowering to prevent them getting entangled. 1067773.wmf

6 7

Secure the piano wires to the bracket with cable ties. RELEASE THE STOP BUTTON

1070824.wmf


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10.2

Fixing the wires in the pit Step 1

2

Action Drive the car exactly to the lowest floor level according to the marking on wall or guide rail. Mark was made at the beginning of the installation. Mark the door zone sensor level to the guide rail.

Note

1070152.wmf

3 4 5 6 7 8

Drive the car down to the buffer. Fix upper end of the lower guide rail or wall fixing 300 mm above marked height. Position the wall fixing according to the measurement recorded at top of the shaft. Fix the piano wire fixing bracket. Hand tighten the piano wire and cut it to correct length. Leave approximately 150 mm free end below fixing bracket. Route and fix the wire end to the tensioning device (1). Leave the wire hand tight. Repeat the fixing for the other wire end. If the hanger is fixed to the guide rail, secure the fixing by pinning the hanger in position.

300

1

1067779.wmf


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10

Action Mark the wires at a distance f from the lower wire anchorage. For dimension f see following tables. Tighten the wires. For stretching force see following tables.

Note

f L

Step 9

1067780.wmf

Fixing distance L (m)

Wire extension f (mm) F=200N

Wire extension f (mm) F=300N

8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 45

15 19 23 27 31 34 38 42 46 50 53 57 61 65 69 72 76 80 84 86

22 28 33 39 45 50 56 61 67 73 78 84 90 95 100 105 110 115 120 125

Guide rail 70/49/16, 70/53/16, 89/62/15.9, (70/70/8) (90/65/14), 125/82/16, 125/89/15.9


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Permitted tensioning F 200N 300N

AM-10.65.001 (D) 2013-04-17


Step 11 12

13

14 15

Action One or two final limit magnets: Make an opening* to the ramp. One or two final limit magnets: Place the lowest floor magnet 130:N just below the opening* in the ramp.

Note Three or more final limit magnets: Do not make an opening to the ramp. All the magnets must be placed so that the Kone logo is at the top end of the magnet.

Three or more final limit magnets: Place the lowest floor magnet 130:N to the top edge of the ramp. Place bottom final limit magnets 151:N below the lowest floor magnet so that there is no gap in between.

C-profile must not be visible above or between the magnets. This might cause errors in positioning. Each magnet has its own ID.

When car is on fully compressed buffer, sensor must read magnet. Place all the delivered final limit magnets to create a ramp. Fix security bolt to top end of the ramp. Slide the C-profile ramp to T-bolts. Position the centre of the topmost magnet to the marked height.

*

130:N

151:N 1070153.wmf


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10.3

Installing bottom service limit ramp (optional) Step 1

Action Assemble the service limit ramp if necessary.

Note

1070100.wmf

2

3 4

Fix the ramp to bottom guide rail bracket using T-bolts. For correct height refer to delivery documents. Fix the guide rail bracket to the top end of the ramp. Ensure that the ramp is correctly aligned.

1070154.wmf

5

Check the operation of the service limit switch.


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10.4

Installing positioning magnets Step 1

Action Fix the lowest floor deceleration magnet 136:N to the piano wires.

Illustration For LD refer to the following table.

All the magnets must be placed so that the Kone logo is at the top end of the magnet.

LD

136:N

NOTE! Minimum distance between floors is 2600 mm (136 must be positioned maximum 1000 mm from door zone and minimum distance between magnets is 400 mm).

130:N 151:N

1070294.wmf

6

NOTE! With long to floor distance: If the distance between the 131:U and 131:N deceleration magnets is more than 3.6 m, install position reference magnet 138 between the deceleration magnets.

LD

131:U 1070183.wmf

131:U =

5

130

138 =

4

131:N

LD

3

Drive the car to the next floor. Locate the car exactly at the floor level according to the marking made at the beginning of the installation. Mark the door zone sensor (centre line) level to the shaft wall or to the guide rail. Drive the car downwards. Fix the door positioning magnet 130 to the piano wires. Fix the deceleration magnets 131:U and 131:N to the piano wires. For LD refer to the following table. Continue installing the positioning and deceleration magnets at each floor while driving to top of the elevator shaft.

>3.6m

2

131:N 130 131:U


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1080305.wmf

AM-10.65.001 (D) 2013-04-17


Step 7

Action Fix intermediate supports (if any) to the guide rail or to the shaft wall. Ensure that the wires are aligned.

Illustration

There must be an intermediate support: • every 16 meters • one per floor if distance from positioning magnet to car wall is less than 70 mm. Install an intermediate support to middle of the shaft. In case of more than one intermediate supports, install them at equal distances.

8

Fix the topmost floor deceleration magnet 136:U to the piano wires.

151:U 130:U LD

For LD refer to the following table.

136:U

1070292.wmf

Speed (m/s) 0.50 0.63 0.70 0.80 1.00


Deceleration distance LD (mm) Light flywheel Heavy flywheel 410 700 540 800 660 950 800 1100 1100 -

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11

INSTALLATION OF SHAFT BUNDLE PHASE: 11 LOCATION: Shaft

1015363.wmf

1072268.wmf

Heading 11.1, Installation of shaft bundle and trunking (serial, machinery above) 11.2, Installation of shaft bundle and trunking (serial, machinery below) 11.3, Installation of shaft bundle and trunking (parallel, machinery above) 11.4, Installation of shaft bundle and trunking (parallel, machinery below) 11.5, Finalising new elevator shaft lighting (if included) 11.6, Finalising the travelling cable installation 11.7, Re-connecting travelling cables, if necessary 11.8, Taking the shaft bundle to the machine room 11.9, Connecting shaft bundle (safety chain) in to the control panel


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Page 110 114 119 122 126 127 128 129 130

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Principle of serial electrification

Principle of parallel electrification

*

*

FCB

FCB

FCB 1074490.wmf

1074491.wmf

*) Control panel in machine room


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11.1

Installation of shaft bundle and trunking (serial, machinery above) Step 1

Action If the old trunking is going to be used, remove the old shaft bundle from trunking. Fix the shaft bundle temporarily outside the trunking using cable ties.

Illustration

1070829.wmf

2

Fix the first length of trunking on the elevator shaft side wall. Find an optimum position as near as possible to entry hole from machine room to elevator shaft and the existing connection point of the door lock wiring. NOTE! If there is no car door, place the trunking so that it is possible to install an automatic door later. Fix each 2 meter piece of trunking with 3 or 4 fixings.

WARNING! Ensure that the inspection drive and stop buttons on the car roof operate correctly. Use hearing protection, dust mask, harness, helmet, gloves and goggles.

7 mm hole for soft concrete 8 mm hole for hard concrete

Ø7 Ø8

1039495.wmf


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Step 3

Action Estimate the amount of cable needed to reach the control panel and loop it. Hang the looped part of shaft bundle (1) temporarily in the pull rope at the elevator shaft top.

Illustration

1 4

Place the shaft bundle in the trunking. Locate the first FCB board approximately to the door lock level.

1057998.wmf

5

Select the floor branch cables for each floor: • Door lock wiring (1.) • Wiring for landing call buttons (2.) • Indicator wiring (if any) (3.)

p12 2

1 2 3 1058001.wmf

6

Fix the branch cables to the wall with the delivered fixing clips. • In this phase connect only P122 plug inside the elevator shaft trunking. • All the other cables (buttons, indicators, etc.) will be connected later.

1058002.wmf


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Step 7

8

Action Continue by installing simultaneously the trunking, shaft bundle and branch cables at each level. When arriving at the bottom floor, lower the remaining shaft bundle into the pit. Check that the shaft bundle end will not get damaged or stop the elevator moving.

Illustration

1058003.wmf

9

10

WARNING! PUSH DOWN THE STOP BUTTON ON THE CAR ROOF.


Go to the bottom of the pit: • Check that the shaft bundle will be free to move and will not get damaged when it is passed to machine room. Finish the trunking and shaft bundle installation. WARNING! In case of deep pit, use working stool or scaffolds.

1072137.wmf

11 12

Fix the pit switch unit and the cables to the wall. Connect the cables from the pit switch unit to the shaft bundle. • STOP BUTTON plug P112 • SOCKET plug XH157 NOTE! The XH157 will be connected to the lowest shaft light if elevator shaft lighting is applicable.


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Refer to the delivery documents / site survey. Switch unit: 2 1 = no elevator shaft lighting. 2 = elevator 1 shaft lighting is applicable.

AM-10.65.001 (D) 2013-04-17


Step 13

Action Illustration Insert the plug in the shaft bundle: • cable OR bridge plug marked 123:1, 123:2 (OSG tension weight contact) • cable OR bridge plug marked 125:1, 125:2 (buffer switch)

1 1

3

1

2 2

2 1071033.wmf

14

1. Shaft bundle 2. Cable 3. Bridge plug Place the plugs and cables inside the elevator shaft trunking.

1058058.wmf

15

Connect the overspeed governor tension weight and/or buffer switch, if used. • Disconnect old wires from the contact. • Connect new cables in the contact.

123/125

123/125

123:1 = overspeed governor tension weight contact (car) 123:2 = overspeed governor tension weight contact (counterweight) 125:1 = buffer switch 125:2 = buffer switch

123/125

123/125

123/125

123/125 1071034.wmf


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11.2

Installation of shaft bundle and trunking (serial, machinery below)

11.2.1

Installation of the stop switch near the access or trap door (serial, machinery below) Step 1

Action Pass the stop switch cable and overspeed governor cable (if applicable) through the cable entry between the elevator shaft and pulley room.

Note

Fix the cables and connect them.

1058007.wmf


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11.2.2

In top of the elevator shaft (serial, machinery below) Step 1


Note

1070829.wmf

2

Fix the first length of trunking. Place it to the side wall in top of the elevator shaft. NOTE! If there is no car door, place the trunking so that it is possible to install an automatic door later.

Elevator with pulley room

1058008.wmf


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WARNING! Ensure that the inspection drive and stop buttons on the car roof operate correctly. Use hearing protection, dust mask, harness, helmet, gloves and goggles. Elevator without pulley room

1058009.wmf

AM-10.65.001 (D) 2013-04-17


11.2.3

Installing shaft bundle (serial, machinery below) Step 1

Action WARNING! Ensure that the inspection drive and stop buttons on the car roof operate correctly.

Note

Use harness and helmet. Place the shaft bundle in the trunking. Place the first FCB board approximately to the door lock level. 1. 2. 3. 4. 5.

2

Stop switch Overspeed governor Door lock Landing call (FCB) Indicator (if existing)

3

1

4 5 1058011.wmf

2

Prepare the floor branch cables. Refer to the delivery documents for the devices on each floor. Connect only the door lock cable P122 plug in the shaft bundle. 1 •The door lock wiring (1)

P122

•The landing call wiring (2)

2 •The indicator wiring (3) (if existing).

3 NOTE! Connect the other cables (buttons,

1058012.wmf


indicators, etc.) later in phase 14 (see section 12, Connecting landing doors locks and buttons).

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11.2.4

Wiring pulley room devices (at the top of the elevator shaft) Step 1

Action Connect plug marked ”112” (stop button) in the new shaft bundle.

Note

P112 1071035.wmf

2

Connect the overspeed governor ”127” in the new shaft bundle. P 127

1058016.wmf

11.2.5

Continue the installation of shaft bundle and trunking to pit (serial, machinery below) Step 1

Action At the bottom floor, lower the remaining shaft bundle into the pit. Check that the shaft bundle end will not get damaged or stop the elevator moving.

Note

1071036.wmf

2

WARNING! Ensure that the inspection drive and stop buttons on the car roof operate correctly. WARNING! PUSH DOWN THE STOP BUTTON ON THE CAR ROOF.

3

4

Go to the bottom of the pit: • Check that the shaft bundle will be free to move and will not get damaged when it is passed to machine room. Push the stop button down when Use hearing protection, dust mask, entering the pit. gloves and goggles. Install the pit switch unit so that the pit stop switch can be operated both from the landing and from the pit. Fix the cables for the pit switch unit to the wall.


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Step 5

Action Connect the cables from the pit switch unit to the shaft bundle. • STOP BUTTON plug P112 • SOCKET plug XH157

Note

2

1 NOTE! The XH157 will be connected to the lowest shaft light if elevator shaft lighting is applicable.

6

Switch unit: 1 = no elevator shaft lighting. 2 = elevator shaft lighting is applicable.

Insert the plug in the shaft bundle: • cable OR bridge plug marked 123:1, 123:2 (OSG tension weight contact) • cable OR bridge plug marked 125:1, 125:2 (buffer switch)

1 1

3

1

2 2

2 1071033.wmf

7

1. Shaft bundle 2. Cable 3. Bridge plug Place the plugs and cables inside the elevator shaft trunking.

1058058.wmf


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Step 8

Action Connect the overspeed governor tension weight and/or buffer switch, if used. • Disconnect old wires from the contact. • Connect new cables in the contact.

123/125

123/125

Note 123 = car overspeed governor tension weight contact 123 = counterweight overspeed governor tension weight contact 125 = buffer switch 125 = buffer switch

123/125

123/125

123/125

123/125 1071034.wmf

11.3

Installation of shaft bundle and trunking (parallel, machinery above) Step 1 2

Action Move the car to the top of shaft. If the old trunking is going to be used, remove the old shaft bundle from trunking. Fix the shaft bundle temporarily outside the trunking using cable ties.

Illustration

1070829.wmf


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Step 3

Action Fix the first length of trunking on the shaft side wall. Find an optimum position as near as possible to entry hole between from machine room to shaft and the existing connection point of the door lock wiring. NOTE! If there is no car door, place the trunking so that it is possible to install an automatic door later.

Illustration Use hearing protection, dust mask, harness, helmet, gloves and goggles.

Fix each 2 meter piece of trunking with 3 or 4 fixings. 7 mm hole for soft concrete 8 mm hole for hard concrete

4

WARNING! Ensure that the inspection drive and stop buttons on the car roof operate correctly. Estimate the amount of cable needed to reach the control panel and loop it. Hang the looped part of shaft bundle (1) temporarily in the pull rope at the shaft top.

Ø7 Ø8

1039495.wmf

1 5

Place the shaft bundle in the trunking. Locate the first branching of shaft wires for topmost door approximately to the door lock level. Follow the color/text markings on the wires to identify the purpose of each branch wire. a10607ac


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mf

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Step 6

7

8

Action Route the branching of shaft wires in plastic tubes to the door. Fix the tubes to the shaft wall with the delivered fixing clips.

Illustration

NOTE! Wires will be connected later. Continue by installing simultaneously the trunking, shaft bundle and branch wires in plastic tubes at each level. When arriving at the bottom floor, lower the remaining shaft bundle into the pit. Check that the shaft bundle end will not get damaged or stop the car moving.

1058002.wmf

1058003.wmf

9

10

Go to the bottom of the pit. Check that the shaft bundle will be free to move and will not get damaged when it is passed to the machine room. Finish the trunking and shaft bundle installation.

WARNING! Push down the stop button on the car roof.

1072138.wmf

11 12 13

Cut the plug at the shaft bundle away and connect the wires to the new pit stop button. Route the new wires to the overspeed governor tension weight contact(s) and buffer switche(s). Connect the overspeed governor 123 = tension weight contact for car tension weight and/or buffer switch, if overspeed governor used. 123 = tension weight contact for • Disconnect old wires from the counterweight overspeed governor contact. 125 = buffer switch • Connect new cables in the 125 = buffer switch contact.

123/125

123/125

123/125

123/125

123/125

123/125 1071034.wmf


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11.4

Installation of shaft bundle and trunking (parallel, machinery below)

11.4.1

Installation of the stop switch near the access or trap door (parallel, machinery below) Step 1

Action Pass the stop switch cable and overspeed governor cable (if applicable) through the cable entry between the elevator shaft and pulley room.

Illustration

Fix the cables and connect them.

1058007.wmf

11.4.2

In top of the shaft (parallel, machinery below) Step 1


Note

1070829.wmf


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Step 2

Action Fix the first length of trunking. Place it to the side wall in top of the elevator shaft. NOTE! If there is no car door, place the trunking so that it is possible to install an automatic door later.

Elevator with pulley room

1058008.wmf


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Note WARNING! Ensure that the inspection drive and stop buttons on the car roof operate correctly. Use hearing protection, dust mask, harness, helmet, gloves and goggles. Elevator without pulley room

1058009.wmf

AM-10.65.001 (D) 2013-04-17


11.4.3

Installing shaft bundle (parallel, machinery below) Step 1

Action WARNING! Ensure that the inspection drive and stop buttons on the car roof operate correctly.

Illustration

Use harness and helmet. Place the shaft bundle in the trunking. Place the first branching of shaft wiring approximately to the door lock level.

2

Route the branching of shaft wires in plastic tubes to the door.

3

Fix the tubes to the shaft wall with the delivered fixing clips. Refer to the delivery documents for the devices on each floor.

a10607bz.wmf

NOTE! Connect the wires later. See section 12, Connecting landing doors locks and buttons.

a10607vl.wmf


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11.4.4

Wiring pulley room devices (at the top of the shaft) Step 1 2

11.4.5

Action Connect stop button in the new shaft bundle. Connect the overspeed governor plug in the new shaft bundle and connect the overspeed governor as well.

Illustration

Continue the installation of shaft bundle and trunking to pit (parallel, machinery below) Step 1

Action At the bottom floor, lower the remaining shaft bundle into the pit. Check that the shaft bundle end will not get damaged or stop the car moving.

Illustration

1071036.wmf

2

WARNING! Ensure that the inspection drive and stop buttons on the car roof operate correctly. WARNING! PUSH DOWN THE STOP BUTTON ON THE CAR ROOF. Go to the bottom of the pit: • Check that the shaft bundle will be free to move and will not get damaged when it is passed to machine room. • Place the openable plastic tube (package 209) around the shaft bundle to protect the bundle when it entries the machine room.


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Finalising new elevator shaft lighting (if included) Step 1 2

Action Push the stop button down when entering the pit. Fix the last light of the elevator shaft lighting into vertical position as shown. Use hearing protection, dust mask, gloves and goggles.

Note

max 500 mm

11.5

1015277.wmf

3

Machine room above: Connect the shaft lighting to the pit switch unit.

P112

XH157 4

1070348.wmf

Machine room below: Fix the shaft lighting supply adapter to the shaft wall. Connect the shaft lighting and lighting control button of the pit switch unit to the shaft lighting supply adapter. Connect the pit stop switch to the shaft bundle. 1070350.wmf


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11.6

Finalising the travelling cable installation Step 1

2 3

Action Position the car so that you have access to the pit and reach to the car sling from pit floor and car roof. Remove the old travelling cable from under the car. Install the new travelling cable support under car.

Note WARNING! In case of deep pit, use working stool or scaffolds.

1

2

WARNING! Remember to use safe access procedures.

5

Measure the distance (II) between the car and car buffer(s). Hold the travelling cables in your hand below the hanger. Adjust the travelling cable loops to correct lengths. Ensure that the inner diameter of the travelling cable loop is not less than 400 mm. Adjust the distance between travelling cables to 100 mm. Adjust the distance from the pit floor to the bottom of the cable loop to 150 mm.

=

4

=

1015285.wmf

400mm

100mm 150mm 1010076-1.wmf


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Step 6

Action Raise the cables and fix the travelling cables to the travelling cable hanger under the car.

Note

1027312.wmf

7 8 9 10

11.7

Route the travelling cable under the car. Fasten excess length (if any) to the car floor with cable ties. Lower a pull rope from car roof below the car. Attach the pull rope to the end of the new travelling cable and other cables that may be located below the car, for example load weighing device or safety gear contact cables.

1040852.wmf

Re-connecting travelling cables, if necessary Step 1

2

Action Switch the mains power OFF. Isolate the lighting supply. This may be separate. Verify de-energisation of mains supply and lighting supply (if separate).

Illustration

0V

1070189.wmf


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Step 3 4

Action Lift the travelling cable and other cables up to the car roof using the pull rope. Fix the travelling cable to the car roof edge.

Illustration

1039533.wmf

5 6

Fix the travelling cable inside the box. Connect travelling cable to: • XT1 on KCECCG board • XT3 on KCEREL board. • all unused wires to PE bar to prevent risk of the electric shock • do not connect XT20 (for KRM) at this phase

XT1

PE XT3

In case of 3PH car door or retiring ramp connect the wires to terminal X49 and/ or KCEREL board. Refer to circuit diagrams.

11.8

1067599.wmf

Taking the shaft bundle to the machine room Step 1

2

Action WARNING!Ensure that the inspection drive and stop buttons on the car roof operate correctly.

Note

• Move the car to the top of the elevator shaft and prepare the machine room end of the shaft bundle. • Check that the shaft bundle will 1058004.wmf be free to move and will not get damaged while pulling up. Go to the machine room and pull the shaft bundle up into the machine room.


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11.9

Connecting shaft bundle (safety chain) in to the control panel

XH11 XH1

XH1

PE1

XH157 XH1

1071116.wmf

Step 1

Action Note WARNING! Ensure that the power is switched off at the main switch.

2

Pass the shaft bundle through the machine room trunking. Connect the elevator shaft wiring to the KCE control panel: Safety circuit: Old safety circuit (122) remains • XH1 to extension tool connected and new safety circuit is (remove the jumper from XH1 on connected to XH1. extension tool) • PE1 earthing bar Alarm bell to XH11. Pit socket/shaft lighting to XH157. Do not connect KSS signalization yet. These will be connected to KCECPU, KCEPIO and/or KCEOPT boards after Do not connect parallel signalization connections at the shaft have been yet. done. Do not connect FRD, FID or OSS yet.


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AM-10.65.001 (D) 2013-04-17


12

CONNECTING LANDING DOORS LOCKS AND BUTTONS PHASE: 12 LOCATION: Shaft

1 122

2

3

121 1058219.wmf

WARNING For lock wiring and connection, push the car stop button down to disconnect the safety chain voltage from door lock contacts. Ensure no voltage exists on lock wiring. NOTE! Shaft safety chain voltage is 100 VDC.

Heading 12.1, Positioning of the car 12.2, Connection of landing door lock (serial) 12.3, Wiring of landing call buttons (serial) 12.4, Connection of landing door lock (parallel) 12.5, Wiring of indicators and optional landing devices (parallel) 12.6, Connecting shaft bundle (signalization) in to the control panel


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Page 132 133 135 136 144 154

AM-10.65.001 (D) 2013-04-17


12.1

Positioning of the car Step 1 2

Action Turn the elevator on inspection drive. Place the car so as to have access to the landing.

Note Use harness, helmet and gloves.

WARNING! PUSH THE STOP BUTTON down to disconnect the safety chain voltage from door lock contacts always before any works on the door safety chain. Verify de-energisation of door lock contacts. 0V

1070189.wmf


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AM-10.65.001 (D) 2013-04-17


12.2

Connection of landing door lock (serial) Use harness, helmet and gloves.

12.2.1

Swing door Step 1

Action PUSH THE STOP BUTTON. Verify de-energisation of door lock contacts.

Note

0V

1070189.wmf

2

Disconnect the old door lock (122) and contact (121) wires. Overconnect with the terminals included in the delivery (at new cables).

122

122

121 1058223.wmf

3

4

5

6 7 8

121

1058221.wmf

Door lock circuit 1 = Old elevator shaft wiring • Connect the cable n°122 on the 2 = New elevator shaft wiring contacts 3 = Green / yellow wires (G/Y) • Connect the wire G/Y on the earth Door contact circuit • Connect the cable n°121 on the contacts • Connect the wire G/Y on the earth 1 Check that neither the new wires connected to the lock nor the old 3 122 shunted wires with terminal block, will not interfere with the function of the door 2 121 1058219.wmf or the movement of the car. RELEASE THE STOP BUTTON. Check that opening the landing door stops movement of the car. Repeat for all landing doors. Lift the car up so that you can reach the lowest level landing door lock.


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AM-10.65.001 (D) 2013-04-17


12.2.2

Automatic door Step 1


Note

0V

1070189.wmf

2

Disconnect the old door lock (122) wires. Overconnect with the terminal included in the delivery (at new cable).

122

122 1058224.wmf

1058222.wmf

3

4

Door lock circuit • Connect the cable n°122 on the contacts • Connect the wire G/Y on the earth Check that the new wires connected to the lock and that the old shunted wires, with terminal block, will not interfere with the function of the door, or the movement of the car.

1 = Old elevator shaft wiring 2 = New elevator shaft wiring 3 = Green / yellow wires (G/Y)

1 3 2

122 1058225.wmf

5 6 7

RELEASE THE STOP BUTTON Check that opening the landing door stops movement of the car. Repeat for all landing doors.


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Lift the car up so that you can reach the lowest level landing door lock.

AM-10.65.001 (D) 2013-04-17


12.3

Wiring of landing call buttons (serial) Use harness and helmet.

12.3.1

Delivered button (KCE compatible) In this case new FCB boards, landing call stations and displays are delivered. Step 1

Action PUSH THE STOP BUTTON.

2

In case of PB or DC control: Connect XF1 on shaft bundle (LCEFCB).

3

Note

In case of FC control: Connect XF1 (call buttons) and XF2 (display) on shaft bundle (LCEFCB). RELEASE THE STOP BUTTON For the other levels repeat the operations on this sheet.


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AM-10.65.001 (D) 2013-04-17


12.4

Connection of landing door lock (parallel) Use harness, helmet and gloves.

12.4.1

Swing door Step 1


Note

0V

1070189.wmf

2

Select the correct shaft wires. Refer to the delivery documents for the color codes.

122 bn 121 bn G/Y 1070867.wmf

3

4

5

6

7 8 9

Disconnect the old door lock (122) and contact (121) wires. Overconnect with the terminals included in the delivery. Door lock circuit: • Connect the wires on the 122 contacts • Connect the wire G/Y on the earth Door contact circuit: • Connect the wires on the 121 contacts • Connect the wire G/Y on the earth Check that neither the new wires connected to the lock nor the old shunted wires with terminal block will not interfere with the function of the door nor the movement of the car. RELEASE THE STOP BUTTON. Check that opening the landing door stops the movement of the car. Repeat for all landing doors.


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1 = Old shaft wiring 2 = New shaft wiring 3 = Green / yellow wires (G/Y)

1 122

2

3

121 a10607br.wmf


AM-10.65.001 (D) 2013-04-17


12.4.2

Automatic door Step 1


Note

0V

1070189.wmf

2


122 bn G/Y 1070868.wmf

3

4

5

Disconnect the old door lock (122) wires. Overconnect with the terminal included in the delivery. Door lock circuit • Connect the wires on the 122 contacts • Connect the wire G/Y on the earth Check that neither the new wires connected to the lock nor the old shunted wires with terminal block will not interfere with the function of the door nor the movement of the car.

1 = Old shaft wiring 2 = New shaft wiring 3 = Green / yellow wires (G/Y)

1 3

2

122 a10607bs.wmf

6 7 8

RELEASE THE STOP BUTTON Check that opening the landing door stops the movement of the car. Repeat for all landing doors.


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AM-10.65.001 (D) 2013-04-17


12.4.3

Connection of PB or DC control with micromovement button Step 1


2


Note

bk rd

3

bk = black wire (- 24V indicator lamp, common for calls) rd = red wire (+ 24V indicator lamp) gy = grey wire (direct call for the floor level) Connect the wires to the button and indicator lamp terminals in the landing call button.

gy 1070871.wmf

102

+24 V 102:n

bk rd gy 1070870.wmf


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AM-10.65.001 (D) 2013-04-17


12.4.4

Connection of PB or DC control with mechanical (Arnould) button Step 1


2


Note

bk rd

3


gy 1070871.wmf

bk rd gy


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1070873.wmf

AM-10.65.001 (D) 2013-04-17


12.4.5

Connection of PB or DC control with WMS button Step 1


2


Note

bk rd

3


gy 1070871.wmf

bk rd gr


140 (258)

1070875.wmf

AM-10.65.001 (D) 2013-04-17


12.4.6

Connection of FC control with micromovement button Step 1


2


Note

bk rd

3

bk = black wire (common for calls) gy (103:n) rd = red wire (+ 24V indicator lamp) gy (103:n) = grey wire 103 (direct call gy (104:n) for the floor level) 1070878.wmf gy (104:n) = grey wire 104 (direct call for the floor level) Connect the wires to the button and indicator lamp terminals in the landing call button.

104

103

rd bk gy gy 1070879.wmf


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AM-10.65.001 (D) 2013-04-17


12.4.7

Connection of FC control with mechanical (Arnould) button Step 1


2


Note

bk rd

3

bk = black wire (common for calls) rd = red wire (+ 24V indicator lamp) gy (103:n) = grey wire 103 (direct call for the floor level) gy (104:n) = grey wire 104 (direct call for the floor level) Connect the wires to the button and indicator lamp terminals in the landing call button.

gy (103:n) gy (104:n) 1070878.wmf

* 104

*) Jumper the button pressed information from button to the indicator lamp.

* 103

rd bk gy (103) gy (104) 1070880.wmf


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AM-10.65.001 (D) 2013-04-17


12.4.8

Connection of FC control with WMS button Step 1


2


Note

bk rd

3

bk = black wire (common for calls) gy (103:n) rd = red wire (+ 24V indicator lamp) gy (103:n) = grey wire 103 (direct call gy (104:n) for the floor level) 1070878.wmf gy (104:n) = grey wire 104 (direct call for the floor level) Connect the wires to the button and indicator lamp terminals in the landing call button. 104

103

rd bk gy (103) gy (104)


1070888.wmf

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AM-10.65.001 (D) 2013-04-17


12.5

Wiring of indicators and optional landing devices (parallel) Use harness and helmet.

Step 1 2

Action PUSH THE STOP BUTTON DOWN. Connect the landing devices on shaft bundle according to detailed instructions below and delivery documents.

3

RELEASE THE STOP BUTTON For the other levels repeat the operations on this sheet


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Note

AM-10.65.001 (D) 2013-04-17


12.5.1

Connection of hall lantern in FC control Step 1


2


3

Note

rd

rd = red wire gy (163) = grey wire gy (164) = grey wire Connect the wires to the landing hall lanterns and gong.

165

164

165

163

gy (163) gy (164) 1070890.wmf

gy (164) gy (163) rd 1070896.wmf


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AM-10.65.001 (D) 2013-04-17


12.5.2

Connection of In use light in DC and FC control Step 1


2


3

Note

rd gy (161)

rd = red wire (common +24V) gy (161) = grey wire (common for indicators) Connect the wires to the In use light.

1070897.wmf

gy (161) rd

12.5.3

1070898.wmf

Connection of HSL with secondary door lock contact Step 1


2


3

Note

rd bk

rd = red wire (+24V) bk = black wire (ground) Connect the wires to the HSL.

1077371.wmf

rd bk 1077369.wmf


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AM-10.65.001 (D) 2013-04-17


12.5.4

Connection of direction arrows with micromovement device Step 1


2


3

Note

rd gy (173) gy (174)

rd = red wire (common) gy (173) = grey wire (common down) gy (174) = grey wire (common up) Connect the wires to the direction arrows.

1070931.wmf

174

X1

173

X1

gy (174) gy (173) rd 1070932.wmf


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AM-10.65.001 (D) 2013-04-17


12.5.5

Connection of car here light Step 1


2


Note

103 & 104

103 & 104 = wires for the landing call buttons rd = red wire (analog floor select signal) gy = grey wire (HSL signal) 3

rd gy

1070935.wmf

Connect the wires to the car here light.

104 rd

162 gy

103 1070936.wmf


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AM-10.65.001 (D) 2013-04-17


12.5.6

Connection of Out of service key switch (OSS) Step 1


Note

2

Select the correct shaft wires. Refer to the delivery documents for the color codes. If there is only one key switch:

gy = grey wire (OSS key output/signal) bk = black wire (ground) If there are more than one key switches:

gy bk

gy bk

1070937.wmf

1070938.wmf

3

Connect the wires to the out of service key switch.

116

gy bk


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1070940.wmf

AM-10.65.001 (D) 2013-04-17


Connection of floor indicators with lamps Step 1


2

Select the correct shaft wires. Refer to the delivery documents for the color codes. Connect the floor indicators.

3

Note

176:1

1

2

11

gy(A) 176:1 gy(B) 176:2 gy(C) 176:3 gy(D) 176:4 gy(E) 176:5 gy(F) 176:6 gy(G) 176:7 gy(A1) 176:8 gy(B1) 176:9 gy(C1) 176:10 gy(D1) 176:11 gy(E1) 176:12

164

176:T

12

163

gy(164) 164 gy(163) 163 rd +24V

12.5.7

1070943.wmf


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AM-10.65.001 (D) 2013-04-17


12.5.8

Connection of floor indicators with 7 segment displays Step 1


2

Select the correct shaft wires. Refer to the delivery documents for the color codes. Connect the wires of the display: Grey (A) to terminal A Grey (B) to terminal B Grey (C) to terminal C Grey (D) to terminal D Grey (E) to terminal E Grey (F) to terminal F Grey (G) to terminal G Grey (A1) to terminal G1 Grey (B1) to terminal B1 Grey (C1) to terminal C1 Grey (D1) to arrow up Grey (E1) to arrow down Red wire to common

3


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Note

AM-10.65.001 (D) 2013-04-17


12.5.9

Connection of floor indicators with DOT matrix or 16 segment displays Step 1


2

Select the correct shaft wires. Refer to the delivery documents for the color codes. Connect wires to the display element:

3

Note

Grey (A) to terminal 1 Grey (B) to terminal 2 Grey (C) to terminal 4 Grey (D) to terminal 8 Red wire to common Black wire to ground


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AM-10.65.001 (D) 2013-04-17


12.5.10 Connection of floor indicators with WMS displays Step 1

Action Note PUSH THE STOP BUTTON Select the correct shaft wires. Refer to the delivery documents for the color codes.

2

Install a terminal strip to the display box or other suitable box beside the display. Route the cables from the display to terminals. There are 3 cables connected in the WMS display. ST1: marked with red point ST2: marked with blue point ST3: marked with green point

3

Connect the wires of WMS display to the terminals: ST1/ yellow to grey 1 ST1/ white to grey 2 ST1/ blue to grey 3 ST1/ red or green to grey 4 ST2/ yellow to grey 5 ST2/ white to gr 6 ST3/ red or green to red wire ST3/ blue or dark to blue wire ST2/ blue or dark to grey 17 ST1 (rd) ST2/ red or green to grey 18 ST2 (bl)

1 2 3 4 5 6

Do not leave any wires unconnected. Connect the free wires to spare terminals.


-

17 18

G Y ye wh

bl rd gn

bl

rd gn

ST3 (gn) ye wh bl rd gn ye wh

The correct alternatives of wire colors are depending on the manufacturing time (before or after 01/1996)

G V

a10607ef.wmf

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AM-10.65.001 (D) 2013-04-17


12.6

Connecting shaft bundle (signalization) in to the control panel

X3 X2 X1 KCEPIO

XS2

X3 X2 X1 X1 X2 X5

KCEOPT X1 X2 X5

1070324.wmf

Step 1

Action Note WARNING! Ensure that the power is switched off at the main switch.

2

Connect the elevator shaft wiring to the KCE control panel: KSS signalization: to XS2 on KCECPU board. Parallel signalization: Refer to elevator circuit diagrams. to X1, X2, X3 on KCEPIO board and to X1, X2, X5 on KCEOPT board. FRD, FID or OSS to KCEOPT board or KCEPIO board.


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AM-10.65.001 (D) 2013-04-17


13

REMOVING THE OLD SHAFT BUNDLE PHASE: 13 LOCATION: Machine room, shaft

Step 1

Action Note Remove the shaft bundle from the machine room: • Switch the power OFF. • Remove the wires from extension tool. • Remove the extension tool and reconnect the shaft bundle to XH1 on KCEMSC board. • Switch the power ON.

XH1

XH1 1071119.wmf

2

3 4

Ensure that the new safety circuit is functioning properly: Open a door and try to run the elevator. The elevator must not move. Remove the old shaft bundle from the elevator shaft. Fix the trunking covers to place.


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AM-10.65.001 (D) 2013-04-17


14

INSTALLATION AND WIRING OF ALL CAR EQUIPMENT PHASE: 14 LOCATION: Car

1015363.wmf

1072269.wmf

NOTE! At end of the Phase 14 turn the inspection drive unit 42:DS to NORMAL. NC = Contact normally closed, NO = Contact normally open NOTE! Route and connect all necessary cables inside the car top connection box before closing it.


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AM-10.65.001 (D) 2013-04-17


Heading 14.1, Dismantling old car equipment 14.2, Installation of door control box 14.3, Installation of parallel I/O box (only with parallel signalization) 14.4, Installation of ACU box 14.5, Wiring of car top connection box 14.6, Wiring of old car light 14.7, Wiring of old car fan 14.8, Wiring of ADV door operator (Isola 96, Athena 96, Renova 96) 14.9, Wiring of retiring ramp 14.10, Wiring of door inverter control 14.11, Wiring of contactor control door operator 14.12, Wiring of Starlift door operator 14.13, Wiring of ADF - ADX door operator 14.14, Wiring of AMD door operator (Drive 1, 1.5 and 2) 14.15, Wiring of DC2000 door control 14.16, Wiring of KOF230V, C-type door control 14.17, Wiring of ADT 3PH 125V door operator 14.18, Wiring of close command door operator 14.19, Wiring of FIAM B/S door operator 14.20, Wiring of Sabiem C door operator 14.21, Wiring of ACC 230V door operator 14.22, Wiring of general 24V electronic control door operator 14.23, Wiring of Selcom 1PH 220V automatic door operator 14.24, Wiring of no car door, EMO N, AT 14.25, Wiring of BOF unit for non-automatic doors 14.26, Wiring of new COP 14.27, Wiring of old COP and display (if any, parallel I/O module) 14.28, Connection of ACU, if applicable 14.29, Connection of KRM, KSS ReVive signalization 14.30, Connection of KRM, parallel signalization 14.31, Wiring of car extension door (CED)


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Page 158 159 160 160 161 163 163 164 168 169 171 173 175 178 182 185 187 189 191 193 195 197 199 201 202 203 204 207 208 208 209

AM-10.65.001 (D) 2013-04-17


14.1

Dismantling old car equipment Step 1 2 3 4

Action Position the car to the bottom floor. Ensure that there is no power on old electrification system. Disconnect and remove the old car wiring. Remove rest of the old equipment that will not be re-used. For information on assessed weights of existing components, see site survey.

Note

1040859.wmf

6

5 4 6

5 4


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AM-10.65.001 (D) 2013-04-17


14.2

Installation of door control box (The door control box is not needed for ADF, ADX, ADV, AMD1, AMD1.5 or AMD2) Step 1

Action Use harness, helmet and gloves.

Select the position and fixing of the door control box: • Vertical in top of the car front (1) • Horizontal on the car roof (2) • On top of the car top connection box (3) NOTE! Fix the door control box close to the existing door operator. NOTE! The door control interface may be located inside the parallel I/O box (if any). Advised positions of door control box:

1 2

3

1080998.wmf


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AM-10.65.001 (D) 2013-04-17


14.3

Installation of parallel I/O box (only with parallel signalization) Step 1

Action

Illustration

Use harness, helmet and gloves. Install the I/O box to the car roof. The position of this box is not critical unless there is a car position indicator far away from the COP. In that case fix the I/O box mid-way between the COP and the indicator. 1 = Position indicator 2 = I/O box 3 = COP

14.4

1 2 3

1015305.wmf

Installation of ACU box Step 1

2

Action Use harness, helmet and gloves. Find place for ACU box on the car roof near the car top connection box and I/O box. 1 = Position indicator,  2 = I/O box,  3 = COP 4 = ACU box 5 = car top connection box Open and fix the ACU box to the car roof.

Note

5 2 3

1

4

1070980.wmf

1072315.wmf


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AM-10.65.001 (D) 2013-04-17


14.5

Wiring of car top connection box XT1 XB18 XO2

XB7 XB11 XB10 XB12

XB6

XB15 XB14 XB8

KCECCG

XB16 XB13 XB9 XB17 XB19

XB3 24VIN XB2

KCEREL

X19 X20 X18 X17 X16 X15 X14 X13 XT3 X42 X41

XS1 XS2 XS3 XS4 XS5 XS6 XS7 XS8 XS9 XS10

X21

XB20

1069992.wmf

Car equipment XO2 LON OPT XB3 24V optional output XB8 Front door operator XB11 Front door 3D sensor XB14 Rear door photocell XB17 LWD

XT1 Travelling cable 24VIN 24V supply input XB2 Battery / test resistor XB6 KCEREL XB7 Alarm bell XB9 Front door zone sensor XB10 Front door photocell XB12 Rear door operator XB13 Rear door zone sensor XB15 Rear door 3D sensor XB16 Absolute positioning XB18 COP sensor XB19 Alarm contact XB20 Inspection drive unit XS1 Final limit switch on car roof (51) XS2 Safety gear contact or buffer contact on car roof (52/58) XS3 Emergency exit contact in car/emergency stop switch on car roof (57/41) XS4 Slack rope contact on car roof or safety sill contact in car (53/54) XS5 Front car door contact or car door gate contact (87/55) XS6 Rear car door contact or rear car door gate contact (B87/B55) XS7 Buffer contact on car roof (58:N) XS8 Buffer contact on car roof (58:U) XS9 Service limit (68:U) XS10 Service limit (68:N)


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AM-10.65.001 (D) 2013-04-17


Step 1

Action Route and connect all cables (for miscellaneous devices) on the car roof.

2

Remove the jumpers from plugs XS1, XS2, XS3, XS4, XS5, XS6, XS7, XS8, XS9 and XS10. Only if following functions will not be taken in use jumper them with the delivered jumpers: • XS1 Final limit switch on car roof (51) • XS3 Emergency exit contact in car / emergency stop switch on car roof (57/41) • XS4 Slack rope contact on car roof or safety sill contact in car (53/54) • XS6 Rear car door contact or rear car door gate contact (B87/B55) • XS7 Buffer contact on car roof (58:N) • XS8 Buffer contact on car roof (58:U) • XS10 Service limit (68:N)

3


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AM-10.65.001 (D) 2013-04-17


14.6

14.7

Wiring of old car light Step 1

Action Route the car lighting power supply cable to the car top connection box.

2

Connect the cable to KCEREL: • X14/1 • X14/2 • PE bar


Wiring of old car fan Step 1

Action Route the car fan power supply cable to the car top connection box.

2

Connect the cable to KCEREL board.


1-speed fan to: • X15/1 • X15/3 • PE bar 2-speed fan to: • X15/1 (high speed) • X15/2 (low speed) • X15/3 • PE bar


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AM-10.65.001 (D) 2013-04-17


14.8

Wiring of ADV door operator (Isola 96, Athena 96, Renova 96) Use harness, helmet and gloves.

14.8.1

Wiring of car top connection box Step 1 2

Action Route the car door cables on the car roof. If there is an existing door operator: • Disconnect the existing wires on the ADV operator connectors. • If door operator type is Isola 96 or Athéna 96, remove the interface board.

Note

1015328.wmf

14.8.2

Connections on ADV board for curtain of light/photo cell Step 1

2

Action Note Curtain of light/photo cell, power supply 24 VDC Connect transmitter: Connect receiver: • the + (grey) to terminal 45 • the + (brown) to terminal 45 • the - (black) to terminal 46 • the - (blue) to terminal 46 • the contact (black) to terminal 41 Curtain of light/photo cell, power supply 230 VAC Connect the contact of curtain of light/ Connect the supply for curtain of light/ photo cell photo cell • Contact between terminal 41 and • Connect to car top connection box 46 X49 L/N or KCEREL X18 Transmitter and receiver are already connected.


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AM-10.65.001 (D) 2013-04-17


14.8.3

Door contact and power supply (two cases)

Step 1

Action P1 X1 X2

D1 D2

B

A

B: Isola, Renova, Athena

A: ADV

D2

Bk Bk Bl Br

D1

D1 D2

Gn/Ye

P1

1.

12. 1039539.wmf

Insert the plugs of the cable from car top connection box in ADV door: • The door contact connector D2 • The power supply connector D1


plug

in

plug

in

165 (258)

Connect the cable from car top box to terminals of connector P1 in Isola, Renova or Athena door: • The door contact in 1 (Bk = Black) and 2 (Bk = Black) • The power supply in 3 (Bl = Blue) and 4 (Br = Brown) • The earth in 12 (GnYe = GreenYellow)

AM-10.65.001 (D) 2013-04-17


14.8.4

Connections on the ADV board

32 2/bn SD 14 7/bu 41 44 45 46

A

X1

S1 ON

1/wh G 4/ye 17 3/gn 16 5/gy 10 30 7/pk 31

X2

1. 2. 3. 4.

X1

X2

1071040.wmf

A = control cable gn = green bn = brown Step 1 2

wh = white gy = grey bu = blue

ye = yellow pk = pink

Action Note Connect the The phoenix plug in X1 and X2. Position of DIP switches: CAUTION!S1/3-->must always be OFF. S1/1--> Speed S1/2--> Speed S1/3--> Reopen S1/4--> Open button


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AM-10.65.001 (D) 2013-04-17


14.8.5

Connections of ADV door cables in the car top connection box Step 1

Action

Note


X17 X16

Connect the front door cables in the car top connection box: • Micro molex plugs XB8 and XB10 on KCECCG board. • Power supply cable in spring clamp terminals X16 on KCEREL board. If there is a rear door, connect: • Micro molex plugs XB12 and XB14 on KCECCG board. • Power supply cable in spring clamp terminals X17 on KCEREL board.

XB10 XB12

XB14 XB8

1070006.wmf

For more information on connectors, see section 14.5, Wiring of car top connection box.


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AM-10.65.001 (D) 2013-04-17


14.9

Wiring of retiring ramp Step 1

Action Route the retiring ramp cable.

2

Connections at the retiring ramp: • Blue wire to the minus of the ramp coil. • Brown wire to the positive of the ramp coil. • Green / yellow to the ramp frame. Connections in the car top connection box: • Brown wire to X20/1 on KCEREL board. • Blue wire to X20/2 on KCEREL board. • Green / yellow to PE bar.

3


X20

PE

1070002.wmf


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AM-10.65.001 (D) 2013-04-17


14.10 Wiring of door inverter control 14.10.1 Preparations Step 1

Action Route from the door inverter box: • Cables with connectors/ markings X16, XB8/XB12 and XB10/XB14 to the car top connection box. • Other cables to the door operator.

Note

1070004.wmf

14.10.2 Connections and settings in the Door operator on LCEDIC board Connections on LCEDIC board: PC7: 85 Door motor/inverter  The maximum inverter output voltage is 230 VAC. If the rated voltage of motor is more use DELTA connection. X18: 82:1 Mechanical safety edge 2 (NC contact) X17: 82 Mechanical safety edge 1 (NC contact) PC8: 67:E Locking of automatic car door (NC or NO contact) PC6: 85:SB Close slow limit (NC or NO contact) PC5: 85:OB Open slow limit (NC or NO contact) PC4: 85:SG Close limit (NC contact) PC3: 85:OG Open limit (NC contact)

NOTE! Connect earthing to the motor earth terminal. LCEDIC S1 X18 X17 X16 X15 PC8 X1-X3 PC7 U

V

W

Settings on the LCEDIC board: Set Jumper A according to 85OB and 85:SB contacts: If 85OB and If 85OB and A A 85:SB are 85:SB are NC contact NO contact X1

X2

X3

X1

X2

1081922.wmf

X3

Set DIP switches S1: (ON = Normal Open and OFF = Normal Closed contacts.) Switch S1/4 = 82:1 (X18) Mechanical safety edge 2 Example: Mechanical Switch S1/3 = 82 (X17) Mechanical safety edge 1 safety edge 82 Switch S1/2 = 88 & 89 (X15 & X16)Photocell is normal open. Switch S1/1 = 67:E (PC8) Locking of car door


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AM-10.65.001 (D) 2013-04-17


14.10.3 Connections in the car top connection box Step 1

Action

Note


X17 X16


XB10 XB12

XB14 XB8

1070006.wmf



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AM-10.65.001 (D) 2013-04-17


14.11 Wiring of contactor control door operator 14.11.1 Preparations Step 1

Action

Note

Use harness, helmet and gloves. Route and connect the car door cables: • Cables with connectors X49, XB8/XB12 and XB10/XB14 to the car connection top box. • Other cables to the door operator.

1070004.wmf

14.11.2 Connect the door operator NOTE! Connect earth wire to motor earth terminal. Connect cables to connectors on the KCEDCC board: 85 Door Motor PC8: 67:E Locking of automatic car door (NC contact) PC4: 85:SG Close limit (NC contact) PC3: 85:OG Open limit (NC contact) X18 82:1 Mechanical safety edge 2 (optional) X17 82 Mechanical safety edge 1 (optional)

PC8 PC4 PC3 X18 X17 PC14

KCEDCC

1083160.wmf


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AM-10.65.001 (D) 2013-04-17


14.11.3 Setting DIP switches on KCEDCC DIP switches S1: (ON = Normal Open and OFF = Normal Closed contacts.) S1 / 1 = S1 / 2 = 88 &89 (X15 & X16) Photocell S1 / 3 = 82 (X17) Mechanical safety edge 1 S1 / 4 = 82:1 (X18) Mechanical safety edge 2 DIP switches S2: (ON = Normal Open and OFF = Normal Closed contacts.) S2 / 1 = S2 / 2 = 85:SG (PC4) Close limit S2 / 3 = 85:OG (PC3) Open limit S2 / 4 = ON If No 67:E (PC8) Locking of car door

S2 S1

1081918.wmf

Example: Mechanical safety edge 2. (82:1) has Normal open contact => S1/4 to ON.

14.11.4 Connect car connection box Step 1

Action

Note

Use harness, helmet and gloves. Connect the front door cables in the car top connection box: • Micro molex plugs XB8 and XB10 on KCECCG board. If there is a rear door, connect: • Micro molex plugs XB12 and XB14 on KCECCG board.

2

For more information on connectors, see section 14.5, Wiring of car top connection box. Connect the module supply cable to the car top connection box spring clamp terminals X49/1-3 and PE bar.


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X49 XB10 XB12

XB14 XB8

1070011.wmf

AM-10.65.001 (D) 2013-04-17


14.12 Wiring of Starlift door operator 14.12.1 Preparations Step 1

Action

Note


1070004.wmf

14.12.2 Connect the door operator NOTE! Connect earth wire to motor earth terminal. Connect cables to connectors on the KCEDCC board: 85 Door Motor PC14: Belt slip PC8: 67:E Locking of automatic car door (NC contact) PC4: 85:SG Close limit (NC contact) PC3: 85:OG Open limit (NC contact) X18 82:1 Mechanical safety edge 2 (optional) X17 82 Mechanical safety edge 1 (optional)


PC8 PC4 PC3 X18 X17 PC14

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KCEDCC

1082038.wmf

AM-10.65.001 (D) 2013-04-17


14.12.3 Setting DIP switches on KCEDCC DIP switches S1: (ON = Normal Open and OFF = Normal Closed contacts.) S1 / 1 = S1 / 2 = 88 &89 (X15 & X16) Photocell S1 / 3 = 82 (X17) Mechanical safety edge 1 S1 / 4 = 82:1 (X18) Mechanical safety edge 2 DIP switches S2: (ON = Normal Open and OFF = Normal Closed contacts.) S2 / 1 = S2 / 2 = 85:SG (PC4) Close limit S2 / 3 = 85:OG (PC3) Open limit S2 / 4 = ON If No 67:E (PC8) Locking of car door

S2 S1

1081918.wmf



Action

Note


2



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X49 XB10 XB12

XB14 XB8

1070011.wmf

AM-10.65.001 (D) 2013-04-17


14.13 Wiring of ADF - ADX door operator 14.13.1 Wiring of car top connection box Step 1

Action Route and connect the car door cables. WARNING! Ensure that the power is off.

2


If door operator exists: • Disconnect the existing wires on the ADF - ADX operator connectors. • If Expanded I/O board (interface board) exists, remove it. Expanded I / O board + SD 12 28 11 14 17 16 -

X1

X2 CONTROL INPUTS

CONTROL OUTPUTS RE5

SAFETY EDGE DET.

H12

SERVICE MODE

H7

PHOTO CELL DET.

RE4

ENABLE SELF REOPENING

H6 LOW AKTIV HIGH

S2

RE3

H10

H5

S1

NUDING

D ESR LS

H11 REOPEN REQUEST

LOW SPEED

N OB C O

RE2

CLOSE END

H9

H4 OPEN BUTTON

H3

S3

OPEN END

RE1

H8

BUZZER ON

H2 CLOSE

10 11 14 30 16 17 36 41 +

H1

COMMAND CONTINUES

OPEN

9 13 28 12 SM

D1

D2 D3

1039558.wmf


175 (258)

D4

AM-10.65.001 (D) 2013-04-17


14.13.2 Connections to make on ADF - ADX board with safety ray Step 1

2

Action Safety ray power supply 24 VDC: Connect transmitter: • the + (grey) to terminal 49 • the - (black) to terminal 48

Note Connect receiver: • the + (brown) to terminal 45 • the - (blue) to terminal 46 • the contact (black) to terminal 44

Safety ray power supply 230 VAC: Connect the contact of safety ray Contact between terminal 44 and 46.

Connect the supply for safety ray to car top connection box X18 or X49/L-N if present. Transmitter and receiver are already connected. 14.13.3 Connect door contact and power supply Step 1

Action Connect the cables: • The door contact in D2 • The power supply in D1

Note

D2

D1

1039559.wmf

14.13.4 Connect ADF - ADX board and Dip-switch positions Step 1

Action

Note

Connect:

X 2 X 4

X 3 X 5

• The phoenix plug in X2 and X4

1039560.wmf

2

Position of DIP switches: S1/4 = OFF = safety ray (1) is connected S2/2 = OFF = mechanical edge is connected S2/3 = OFF if electronic edge is connected S2/4 = OFF if safety ray (2) is connected

S1

S2

OFF

1 2 3 4 1 2 3 4 1 2 3 4 J1


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S3

ON

1039561.wmf

AM-10.65.001 (D) 2013-04-17



Action Connect the front door cables in the car top connection box: • Micro molex plugs XB8 and XB10 on KCECCG board. • Power supply cable in spring clamp terminals X16 on KCEREL board. If there is a rear door, connect: • Micro molex plugs XB12 and XB14 on KCECCG board. • Power supply cable in spring clamp terminals X17 on KCEREL board. For more information on connectors, see section 14.5, Wiring of car top connection box.

Note

X17 X16

XB10 XB12

XB14 XB8

1070006.wmf


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AM-10.65.001 (D) 2013-04-17


14.14 Wiring of AMD door operator (Drive 1, 1.5 and 2) WARNING Ensure that the power is off. Use harness, helmet and gloves.

14.14.1 Route and connect the AMD cables Step 1

2

3

Action Route and connect the car door cables.

Note For more information on connectors, see section 14.5, Wiring of car top connection box. If there is an existing AMD door operator that remains: disconnect the existing wires between the old car top connection box and the AMD operator connectors. 24 VDC Safety ray cables on the AMD board Connect the transmitter cables: Connect the receiver cables: • the + (grey) to terminal 49 (X16) • the + (brown) to terminal 45 (X15) • the - (black) to terminal 48 (X16) • the - (blue) to terminal 46 (X15) • the contact (black) to terminal 44 (X15) 230 VAC Safety ray cables on the AMD board (Transmitter and receiver are pre connected.) Connect the contact cable: Connect the supply cable: • between terminal 44 and 46 • to the terminal X18 or X49/L-N if (X15). present in the car top connection box.


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AM-10.65.001 (D) 2013-04-17


14.14.2 Connect the cable into AMD door operator Step 1

Action Plug the door contact cable in D2 and power supply cable in D1.

2

Connect the door control cables onto the AMD board. Drive 1 or drive 1.5: Connect the phoenix plug in X1.

X1

Note

D1 D2

X1 1071362.wmf

Drive 2: Connect the phoenix plug in X1 and X2.


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14.14.3 Parameters of AMD (Dip-switch) DRIVE 1

S1/1

ON OFF Speed selection

DRIVE 2 S1 S1/1

S1/2

S1/2

S1/3

Open force limit active

S1/4

Switching causes sw reset

No open force limit

S1/3

S1/4

S1/5 DRIVE 1.5

S1/1 S1/2 S1/3

S1/4

S2/1 S2/2

ON OFF Speed selection

Open force limit active

No open force limit

Railing 1 is existing on operator or in any of the landing doors

All railings are of railing 2 type (car and landings)

ON

OFF 30 potential free N/C contact to GND

30 grounded N/C contact to +24V


S1/6 S1/7 S1 S1/8

S2 S2/1 S2/2

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ON Photocell 1 disabled Photocell 2 disabled Safety edge 1 disabled Safety edge 2 disabled Speed selection

OFF Photocell 1 enabled Photocell 2 enabled Safety edge 1 enabled Safety edge 2 enabled

Open force limit active For railing 1 (ADV)

No open force limit For railing 2

ON

OFF 30 potential free N/C contact to GND

30 grounded N/C contact to +24V

S1

S2

AM-10.65.001 (D) 2013-04-17


14.14.4 Connect the AMD door cables in the car top connection box Step 1

Action Connect the front door cables in the car top connection box: • Micro molex plugs XB8 and XB10 on KCECCG board. • Power supply cable in spring clamp terminals X16 on KCEREL board. If there is a rear door, connect: • Micro molex plugs XB12 and XB14 on KCECCG board. • Power supply cable in spring clamp terminals X17 on KCEREL board. For more information on connectors, see section 14.5, Wiring of car top connection box.

Note

X17 X16

XB10 XB12

XB14 XB8

1070006.wmf


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14.15 Wiring of DC2000 door control 14.15.1 Preparations Step 1

Action

Note

Use harness, helmet and gloves. Route from the door inverter box: • Cables with connectors/ markings X16, X17, XB8/XB12 and XB10/XB14 to the car top connection box. • Other cables to door operator.


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1070004.wmf

AM-10.65.001 (D) 2013-04-17


A2 A1 F1 F2 NEU HOT 120VAC

OPEN

C SS OL OM CL CM

CLOSE

- + - + - +

COMMON

CLOSE END

FORCE LIMIT

0/24V

1 2

3

4

1

XD2

2

XD1

3

OPEN END

4

COMMON

XB8/XB12

5

NUDGING

+24VDC

0/24VDC

6

CLOSE

1

OPEN

2

SERVICE

XP1

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NUDGE

0


120

Signal Colour Armature Brown Armature Blue Field Black Field Grey Common White Soft Start Brown Open Low Green Open Medium Yellow Close Low Grey Close Medium Pink Signal Colour Common n°3 Open End n°1 Close End n°2 85:SG = Close limit (NC contact) 85:OG = Open limit (NC contact) SS = Soft Start (NO contact) OL = Open Low (NO contact) OM = Open Medium (NO contact) CL = Close Low (NO contact) CM = Close Medium (NO contact)

230

DC 2000 Terminal A1 A2 F1 F2 C SS OL OM CL CM CCBS Terminal XB28/6 XB28/7 XB28/5 Legend: M = motor BU = blue BN = brown BK = black G/Y = green/yellow CS = cam switch

SPEED

14.15.2 Connecting the DC door operator

1081930.wmf

AM-10.65.001 (D) 2013-04-17


14.15.3 Door operator without cam switch Step 1

Action If there is no cam switch for soft start or/ and open medium or/and close medium: remove the wire from the speed connector. If the wire is not disconnected, there is hazard of electric shock while setting the adjustments on the board.

Note Wire n°5 Terminal SS for Soft Start Wire N°3 Terminal OM for Open Medium Wire N°1 Terminal OM for Close

14.15.4 Connecting the DC door cables to car top connection box Step 1

Action Use harness, helmet and gloves. Connect the front door cables in the car top connection box: • Micro molex plugs XB8 and XB10 on KCECCG board. • Power supply cable in spring clamp terminals X16 on KCEREL board. If there is a rear door, connect: • Micro molex plugs XB12 and XB14 on KCECCG board. • Power supply cable in spring clamp terminals X17 on KCEREL board. For more information on connectors, see section 14.5, Wiring of car top connection box.


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Note

X17 X16

XB10 XB12

XB14 XB8

1070006.wmf

AM-10.65.001 (D) 2013-04-17


14.16 Wiring of KOF230V, C-type door control 14.16.1 Preparations Step 1

Action

Note

Use harness, helmet and gloves. Route from the door inverter box: • Cables with connectors/ markings X16, X17, XB8/XB12 and XB10/XB14 to the car top connection box. • Other cables to door operator.

1070004.wmf

14.16.2 Connecting door operator


F2 0

KCEDCC

F1 0

1 0

Signal cable SRC cable Limit switch cable Limit switch cable

X1,X2 X1.5 X1.4 X2.10 X2.9 X2.8 X2.6 X2.5 X2.4 X2.3 X2.2 X2.1 X2.7

Supply cable

211:0

Limit switch cable

C1

1 0

Limit switch cable

Core 1 Core 2 Core 3 Core 4 Core 5 Core 6 GN / YE Black Blue Black Blue Black Blue

211:S

Door motor cable

X1.2 X1.1 X1.3

X2/1 X2/2 X2/3 X2/4 X2/5 X2/6 X2/7, Earth X2/8 X2/10 X2/9 X2/10 X1/1 X1/2 KCEDCC / PC1 KCEDCC / PC2 KCEDCC / PC3 KCEDCC / PC4

R3

1082023.wmf

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AM-10.65.001 (D) 2013-04-17


14.16.3 Connecting the DC door cables to car top connection box Step 1

Action Use harness, helmet and gloves. Connect the front door cables in the car top connection box: • Micro molex plugs XB8 and XB10 on KCECCG board. • Power supply cable in spring clamp terminals X16 on KCEREL board. If there is a rear door, connect: • Micro molex plugs XB12 and XB14 on KCECCG board. • Power supply cable in spring clamp terminals X17 on KCEREL board. For more information on connectors, see section 14.5, Wiring of car top connection box.


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Note

X17 X16

XB10 XB12

XB14 XB8

1070006.wmf

AM-10.65.001 (D) 2013-04-17


14.17 Wiring of ADT 3PH 125V door operator 14.17.1 Preparations Step 1

Action

Note


1070004.wmf

14.17.2 Connect the door operator NOTE! Connect earth wire to motor earth terminal. Connect cables to connectors on the KCEDCC board: 85: Door Motor PC8: 67:E Locking of automatic car door (NC contact) PC4: 85:SG Close limit (NC contact) PC3: 85:OG Open limit (NC contact) X18: 82:1 Mechanical safety edge 2 (optional) X17: 82 Mechanical safety edge 1 (optional) XR1: Door braking module

PC8 PC4 PC3 X18 X17

KCEDCC

XR1 PE

1082060.wmf


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AM-10.65.001 (D) 2013-04-17


14.17.3 Setting DIP switches on KCEDCC DIP switches S1: (ON = Normal Open and OFF = Normal Closed contacts.) S1/1 = S1 / 2 = 88 &89 (X15 & X16) Photocell S1 / 3 = 82 (X17) Mechanical safety edge 1 S1 / 4 = 82:1 (X18) Mechanical safety edge 2 DIP switches S2: (ON = Normal Open and OFF = Normal Closed contacts.) S2/1 = S2 / 2 = 85:SG (PC4) Close limit S2 / 3 = 85:OG (PC3) Open limit S2 / 4 = ON If No 67:E (PC8) Locking of car door

S2 S1

1081918.wmf



Action

Note


2



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X49 XB10 XB12

XB14 XB8

1070011.wmf

AM-10.65.001 (D) 2013-04-17


14.18 Wiring of close command door operator Preparations Step 1

Action

Note

Use harness, helmet and gloves. Route and connect the car door cables: • Cables with connectors XB8/ XB12 to the car top connection box. • Other cables to the door operator. • Separate photocell cable (if any) with connectors XB10/XB14 directly from the door operator to the car top connection box.

1071369.wmf

14.18.1 Connect the door operator Step 1

2

Action Connect the door supply and door control cables from door control box to door controller. Connect the separate photocell cable to photocell device (if any).

Note

1081921.wmf


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AM-10.65.001 (D) 2013-04-17



Action

Note


X17 X16


XB10 XB12

XB14 XB8

1070006.wmf



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AM-10.65.001 (D) 2013-04-17


14.19 Wiring of FIAM B/S door operator 14.19.1 Preparations Step 1

Action

Note


1070004.wmf

14.19.2 Connect the door operator NOTE! Connect earth wire to motor earth terminal. Connect cables from door module (KCEDCC board) to door operator: 85: Door Motor PC8: 67:E Locking of automatic car door (NC contact) PC4: 85:SG Close limit (NC contact) PC3: 85:OG Open limit (NC contact) X18: 82:1 Mechanical safety edge 2 (optional) X17: 82 Mechanical safety edge 1 (optional) XR1: Door braking module (1x30R)

PC8 PC4 PC3 X18 X17

KCEDCC

XR1 PE

1071371.wmf


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AM-10.65.001 (D) 2013-04-17



S2 S1

1081918.wmf



Action Use helmet harness, and gloves. Connect the front door cables in the car top connection box: • Micro molex plugs XB8 and XB10 on KCECCG board. If there is a rear door, connect: • Micro molex plugs XB12 and XB14 on KCECCG board.

2


Note

X49 XB10 XB12

XB14 XB8

1070011.wmf

14.19.5 Adjusting resistor All adjustments need to be made power OFF. Adjust resistor close to it's maximum value. Test door deceleration to open and close positions. Adjust door braking resistor value smaller, if deceleration is too fast.


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AM-10.65.001 (D) 2013-04-17


14.20 Wiring of Sabiem C door operator 14.20.1 Preparations Step 1

Action

Note


1070004.wmf

14.20.2 Connect the door operator NOTE! Connect earth wire to motor earth terminal. Connect cables from door module (KCEDCC board) to door operator: 85 Door Motor PC8: 67:E Locking of automatic car door (NC contact) PC4: 85:SG Close limit (NC contact) PC3: 85:OG Open limit (NC contact) X18: 82:1 Mechanical safety edge 2 (optional) X17: 82 Mechanical safety edge 1 (optional) XR1: Door braking module (2x95R)

PC8 PC4 PC3 X18 X17

KCEDCC

XR1 PE

1081919.wmf


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AM-10.65.001 (D) 2013-04-17



S2 S1

1081918.wmf



Action Use harness, helmet and gloves. Connect the front door cables in the car top connection box: • Micro molex plugs XB8 and XB10 on KCECCG board. If there is a rear door, connect: • Micro molex plugs XB12 and XB14 on KCECCG board.

2


Note

X49 XB10 XB12

XB14 XB8

1070011.wmf



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AM-10.65.001 (D) 2013-04-17


14.21 Wiring of ACC 230V door operator 14.21.1 Preparations Step 1

Action

Note


1070004.wmf

14.21.2 Connect the door operator NOTE! Connect earth wire to motor earth terminal. Connect cables from door module (KCEDCC board) to door operator: 85 Door Motor PC8: 67:E Locking of automatic car door (NC contact) PC4: 85:SG Close limit (NC contact) PC3: 85:OG Open limit (NC contact) X18 82:1 Mechanical safety edge 2 (optional) X17 82 Mechanical safety edge 1 (optional) XR1: Door braking module (ACC 230V)

PC8 PC4 PC3 X18 X17

KCEDCC

PE XR1

1081937.wmf


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S2 S1

1081918.wmf



Action Use harness, helmet and gloves. Connect the front door cables in the car top connection box: • Micro molex plugs XB8 and XB10 on KCECCG board. If there is a rear door, connect: • Micro molex plugs XB12 and XB14 on KCECCG board.

2


Note

X49 XB10 XB12

XB14 XB8

1070011.wmf



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AM-10.65.001 (D) 2013-04-17


14.22 Wiring of general 24V electronic control door operator Preparations Step 1

Action

Note

Use harness, helmet and gloves. Route and connect the car door cables: • Cables with connectors XB8/ XB12 to the car top connection box. • Other cables to the door operator. • Separate photocell cable (if any) with connectors XB10/XB14 directly from the door operator to the car top connection box.

1071369.wmf

14.22.1 Connect the door operator Step 1

2

Action Connect the door supply and door control cables from KCEDRB board to door controller.

Note

NOTE: KCEDRB board is located under the KCECCG board, on the lower DIN rail. Connect the separate photocell cable to photocell device (if any).

1071384.wmf


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AM-10.65.001 (D) 2013-04-17



Action

Note


X17 X16


XB10 XB12

XB14 XB8

1070006.wmf



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AM-10.65.001 (D) 2013-04-17


14.23 Wiring of Selcom 1PH 220V automatic door operator 14.23.1 Preparations Step 1

Action

Note


1070004.wmf

14.23.2 Connect the door operator NOTE! Connect earth wire to motor earth terminal. Connect cables to connectors on the KCEDCC board: 85 Door Motor PC8: 67:E Locking of automatic car door (NC contact) PC4: 85:SG Close limit (NC contact) PC3: 85:OG Open limit (NC contact) X18 82:1 Mechanical safety edge 2 (optional) X17 82 Mechanical safety edge 1 (optional)

PC8 PC4 PC3 X18 X17

KCEDCC

1082059.wmf


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AM-10.65.001 (D) 2013-04-17



S2 S1

1081918.wmf



Action

Note


2



200 (258)

X49 XB10 XB12

XB14 XB8

1070011.wmf

AM-10.65.001 (D) 2013-04-17


14.24 Wiring of no car door, EMO N, AT Step 1

Action Use harness, helmet and gloves.

2

Route and connect the cables from curtain of light to car top connection box: • 230 V power supply to connector X16 on KCEREL board and PE • 24 V power supply to connector XB10 on KCECCG board • contact to connector XS5 on KCECCG board

Note

1072302.wmf


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AM-10.65.001 (D) 2013-04-17


14.25 Wiring of BOF unit for non-automatic doors Step 1 2

Action Fix the BOF unit close to the car door operator. Connect the BOF unit between connector XB8 and KCECCG board at the car top connection box.

Note BOF = Buttons to operate (open / close) car doors for service purposes XB12 for rear door.

XB8

XB8

KCECCG

1071375.wmf


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AM-10.65.001 (D) 2013-04-17


14.26 Wiring of new COP Step 1

Action Connect the stop button cable (if any) to the connector XS3 or XS4 on KCECCG board.

2

Connect the cable wires to stop button pins (normal closed, NC).

Note

Verify the correct pins using multimeter.

1041442.wmf

3

Route and connect the COP cable to one of the following: • XS2 on KRMRIF board • XS2 on ACU board • XB18 on KCECCG board


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AM-10.65.001 (D) 2013-04-17


14.27 Wiring of old COP and display (if any, parallel I/O module) WARNING Ensure that the power is off. Use harness, helmet and gloves.

14.27.1 Preparation of parallel I/O module Step 1

Action Install the KCEPIO board behind the existing COP.

Note

Check the assembly location so that when the elevator runs, boards do not hit any structures in the elevator shaft.

1082103.wmf

2 3

Pass cable with plug X02 from I/O module to car top connection box. Route existing COP cables to I/O module.

If there is a stop button in car route cable with plug XS3 or XS4 from old COP to KCECCG board.

Mark wires and remove connectors (if any). Connect the cables to KCEPIO boards in I/O module. Refer to circuit diagrams.

XS3/XS4

2

1 XO

3

2 1070839.wmf

1 = COP 2 = KCECCG board in car top box 3 = I/O module


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AM-10.65.001 (D) 2013-04-17


14.27.2 Connect the old COP Connection First case:  Without common wire between lamp and button.

- 31

- 31 +

31

Note For connection points and DIP switch settings on KCEPIO board refer to wiring diagrams.

31

XXX KG XX PERSONS

1058129.wmf

Second case:  With common wire between lamp and button.

- 31 +

31

1 = Positive lamp 2 = Call lamp 3 = Common call 4 = Call button

31

KCEPIO

STOP

OVER LOAD

11 9

12 10

7

8

5

6

3 1

4 2

- 31 31 1058131.wmf

31 31 31

1 2 3 4

1080995.wmf


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AM-10.65.001 (D) 2013-04-17


14.27.3 Connect the existing car position indicator Step 1

Action 7 Segments or Binary display. Use the mark on wire: • + COM • A / BC1 • B / BC2 • C / BC4 • D / BC8 • E / BC16 • F / BC32 • G • D.P. • 0V A

F

Note For connection points on KCEPIO board refer to wiring diagrams.

KCEPIO

1072156.wmf

B G

E

C D

2

1019625.wmf

Analog display. Use the mark on wire: • + COM • 1 • 2 • 3 • 4 • 5 • 6 • 7 • 8 • 0V

For connection points on KCEPIO board refer to wiring diagrams.

KCEPIO

1072159.wmf


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AM-10.65.001 (D) 2013-04-17


14.27.4 Connect on the car connection box Step 1

Action Connect on the KCECCG board: • mini molex plug in XB18 • LON cable in XO2 NOTE! If there is a stop button in old COP (no car door).

Note

KCECCG

• connect to XS3 or XS4

XS3 XS4

If ACU is used, see section 14.4, Installation of ACU box.

1072683.wmf

14.28 Connection of ACU, if applicable Step 1

Action WARNING! Ensure that the power is off.

Note

XB18


2 3

Route and connect the cable between KCECCG board connector XB18 and ACU board XS1. Route and connect the cable between COP and ACU board XS2. Fix the speaker in a suitable place in the COP or on the car roof. Route the cable between the speaker and SPEAKER plug on the ACU board.

STOP

OVER LOAD

15

16

13

14

11

12

9

10

7

8

5

6

3

4

1

2

SPEAKER VOLUME

XS2

XS1

1070847.wmf


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14.29 Connection of KRM, KSS ReVive signalization Step 1

Action WARNING! Ensure that power is off.

Note


XT20 XS12

2

3

Route and connect cables between KRMRIF module and car top connection box. Route and connect the cable between COP and KRMRIF module.

KCECCG XB18 XB19

X7 XS1 XC9B

F2KMUL/COPMUL J2

1072289.wmf

14.30 Connection of KRM, parallel signalization Step 1


Note


XT20 XS12

2

3

Route and connect cables between KRMRIF module and car top connection box. Route and connect cables between KRMSIG and KRMRIF module.

KCECCG XB18 XB19

X7 XS1 XC9B

KRMSIG XS12

NOTE! KRM modernization package is used with parallel signalization. 1072684.wmf


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14.31 Wiring of car extension door (CED) Step 1


Note

X72

72


XS4 2

X35

Route and connect cables between CED (72), PRC on COP (35) and car top connection box.

35


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1077367.wmf

AM-10.65.001 (D) 2013-04-17


FULL SPEED ADJUSTMENT / COMMISSIONING / SAFETY INSPECTIONS

PHASE: 15 LOCATION: Machine room, shaft

SPEED m/s

TESTS

STOP

0.6 0.3 0.02

RUN OFF

263

INSPECTION UP

NORM

SB-1 SB-2

TEST

STOP

SB-COMM DZI

0.02 0.3 0.6

261

Unlocking zone

15

CALLS

TESTS

TOP CALL

SETUP

SB-3 SB-4

BOOST

RUN INSP

DOWN

TERMINAL STOP BYPASS

BOTTOM CALL

OSG

FAULTS Self check

ETS Bypass NTS Bypass Normal Decel Bypass

Overspeed SELECT

RESET

Unintended movement Run time limiter

SB-1 = Car Doors ( C5, C6 ) SB-2 = Car ( C1-C4, C7-C10, S1, S2 ) SB-3 = Landing Doors ( H3, H4 ) SB-4 = Pit, OSG ( H1, H2, H5, H6 )

PENDANT SERVICE REMOTE

Safety chain open

Use jumpers SB-1 to SB-4 for safety chain bypass

TESTS 261 = inhibit landing calls 263 = enable tests, inhibit door opening

1069928.wmf

CAUTION If the old shaft bundle and/or landing call buttons remain (phases 11 or 12 are not included), change the lamps in the landing call buttons (24 V, 1.2 W). NOTE! If any problems during the commissioning, for more information on fault finding and diagnostics, see AS-10.65.006 Diagnostic guide for KONE ReSolve 200 commissioning and AS-10.65.007 Fault finding instruction for KONE ReSolve 200. NOTE! If electrostatic-discharge-sensitive devices, for example PC board, IGBT transistor, MOSFET, EPROM or CMOS 256K DRAM, are handled on site, see AS-12.02.001, Instruction for handling electrostatic-discharge-sensitive-devices on site. Heading 15.1, Balancing 15.2, Selecting roll call type 15.3, Selecting LWD type 15.4, Shaft setup 15.7, Checking creeping time 15.8, Motor slip compensation 15.9, Floor level adjustment 15.10, Final steps 15.11, External options 15.12, Commissioning of the car door 15.13, Check the parameters for door inverter


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Page 211 212 212 213 215 216 217 219 219 221 223

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Heading 15.14, Checking KCE board versions 15.15, Testing landing door locks 15.16, Testing safety contacts 15.17, Measuring insulation resistance 15.18, Measuring earth continuity 15.19, 24 VDC ground fault test 15.20, Testing operation of RCD 15.21, Speed measurement 15.22, Current measurement 15.23, Testing the final limit switches 15.24, Drive time supervision (DTS) test 15.25, Buffer tests 15.26, Overspeed governor test 15.27, Safety gear test 15.28, Ride comfort /Special V3F10 Adjustments 15.29, Setting the elevator to normal use 15.30, Troubleshooting

Page 224 225 225 225 226 230 231 231 232 232 233 234 236 237 237 240 240

The basic commissioning for nominal speed includes 4 steps: • • • •

15.1

Shaft setup Deceleration distance learning Positioning synchronization magnets Floor level adjustments

Balancing Step 1

2

Action Check and adjust balancing of car and counterweight. Check from the layout drawings which weight the elevator is balanced to. Most of the elevators are balanced to 50 %. Ensure that the LWD is connected and the switch is working properly.


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Note The counterweight to be balanced to empty car weight + 50 % of the rated load. In some old elevator installations this figure may vary.

AM-10.65.001 (D) 2013-04-17


15.2

Selecting roll call type Step 1

15.3

Action If landing call buttons and displays are connected to FCB board, set the value of parameter ID 280 to 1.

Note Roll Call Direction parameter (ID 280) can be found under Lift Structure / Building categories.

If landing call buttons and displays are connected to KCEPIO board, set the value of parameter ID 280 to 0.

0 = roll call for car and machine room networks only 1 = roll call for shaft from top to bottom 2 = roll call for shaft from bottom to top

Selecting LWD type Step 1

Action Set the value of parameter ID 1082 according to the load weighing device type.

2

If there is no load weighing device: Set the value of parameters ID 1161 and ID 1162 to 1.

Note 0 = analog LWD device, load info through CCG analog input 1 = digital LWD device, load info through CCG digital & analog inputs Over load polarity (ID 1161) Full load polarity (ID 1162) 0 = input polarity not inverted, NC contact 1 = input polarity inverted, NO contact


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15.4

Shaft setup WARNING No people are allowed to be on the car roof during the setup.

15.4.1

Prerequisites All installation is completed and elevator is ready for normal drive. NOTE! The elevator must not be located either at the topmost or at the bottom floor at the beginning of the setup.

15.4.2

Setup drive NOTE! If elevator drives to buffer during the setup, check that the final limit magnets and switches are in correct position. Compare delivery documents and set up table of the KONE Mini Console or check the positions manually from the car roof. Step 1 2

Action Ensure that the elevator is on RDF. Set test switch to position 263. The test LED turns ON.

Note TESTS

OFF 261 263 TEST

3

1069941.wmf

Push setup button. 1069629.wmf


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Step 4

Action Turn the elevator to normal drive (RDF switch to normal). The setup drive begins.

Note

NOTE! RDF switch must be switched to normal within 10 seconds after setup button has been pushed.

5

6

1069628.wmf Do not interrupt the setup drive. The setup drive consists of four phases: 1. Elevator drives to final limit (bottom) on inspection speed. The setup LED repeats sequences of one blink. 2. Elevator drives to final limit (top) on inspection speed. The setup LED repeats sequences of two blinks. 3. Elevator drives to bottom floor on full speed. The setup LED repeats sequences of three blinks. KCE resets itself automatically (KMC shuts down for few seconds). 4. Roll call is executing. The setup LED repeats sequences of four blinks. This may take up to 5 minutes, do not interrupt. 5. Setup is completed when the setup LED stops blinking and turns OFF. The setup drive will be aborted (setup LED is lit) if: • elevator does not begin the setup drive within 30 seconds • elevator does not reach the final limit during phase 1 or 2 Turn test switch to OFF position after setup is completed.

If the elevator does not run after setup, check the door parameter values (515, 520, 529, 530, 547, 548). If there is no door pressure contact on the car door operator, make an overconnection on the interface box.


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For door parameter values, see section 15.12, Commissioning of the car door.

AM-10.65.001 (D) 2013-04-17


15.5

Connecting FRD / FID (optional) Step 1 2 3

15.6

Note For more information, see wiring diagrams.

Adjusting motor no load current Step 1 2

3

15.7

Action Check and identify the over connecting plugs at the option board. Remove the plugs and connect the FRD / FID devices. Check the FRD / FID device functionality.

Action Give a car call to the topmost floor. Record the value of Output current parameter U1-03 when the car is passing the middle floor. Set the Motor no-load current parameter E2-03 to calculated value.

Note The car must be empty.

Value = Measured current / Nominal current (E2-01) x 100.

Checking creeping time Step 1 2

3

Action Note Drive the empty car to the middle floor level from both directions. Observe the speed after deceleration There should be a short (approximately point. Ensure that the elevator runs at 0.8 s) creeping time in both directions. creeping speed before stopping. If the creeping time is too short: • decrease deceleration time by Yascawa parameter C1-02 OR • move deceleration magnet further away off the floor level.


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15.8

Motor slip compensation

15.8.1

Checking the need for adjusting motor slip compensation Step 1 2

Action Drive the empty car from the bottom floor to the middle floor. Check the stopping distance from KONE Mini Console. Check that the car door sill and the landing door sill are at the same level with each other.

3

4

Note Use the same “middle floor“ in each phase of the adjustment procedures. Correct the magnet position in the shaft if necessary. Example: Mini Console shows +5 mm and the car sill is 20 mm above, move the floor magnet 15 downwards. NOTE! If position magnet is moved, the deceleration magnets must be moved accordingly.

Drive the empty car to the middle floor level from both directions. Check the stopping distance from KONE Mini Console. Do not adjust the motor slip parameter if the stopping distance is equal to both directions: • the car stops before the landing (same distance) to both directions • the car passes the landing (same distance) to both directions Adjust the motor slip parameter if the stopping distance is unequal to both directions (for example the car passes the floor by 10 mm to up direction and 20 mm to down direction).

15.8.2

Adjusting motor slip compensation Step 1

2 3

Action Adjust Motor rated slip parameter E2-02 value in small steps.

Note If the value is too high, it may cause vibration during nominal speed run.

If creeping speed running time is shorter when driving to light direction, increase the value. Make test run in both directions. Repeat as many times as necessary.


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15.9

Floor level adjustment Step 1

2

3

4

Action Drive the car from the bottom floor to the middle floor. Check the stopping accuracy from KONE Mini Console. Adjust the value of parameter 1207 (Final stopping point) according to the values to improve the stopping accuracy.  Switch the power OFF and ON after adjusting the parameter value. Check the stopping accuracy by measuring distance between car and landing sills at each landing. Correct the magnet position in the shaft if the gap between sills is more than 10 mm.

Note

Example: If car stops 20 mm before the landing when driving to up direction, reduce the value of parameter 1207 by 20. Parameter 1207 can be found under parameter category Drive interface / Limits. Write down the values to the table below.

When adjusting the magnet position, move magnet and the plate. Do not move the magnet position on the plate, this may cause errors in positioning.

5 6

NOTE! If position magnets are moved, the deceleration magnets must be moved accordingly. If magnets were moved, perform the shaft setup again. Make a new test run and ensure that the stopping accuracy is acceptable at each landing.


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1070401.wmf

AM-10.65.001 (D) 2013-04-17


LEVELS 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1


DESCRIPTION

MEASURED FROM CAR Up Down X

X

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15.10 Final steps Step 1

2 3

Action Connect the emergency lighting battery plug “227 Battery” in the car roof electrification unit. Do not connect the battery before commissioning is complete (to prevent unnecessary discharging). Make the settings for the KRM according to AM-13.25.008. Check the Emergency battery drive if any by switching the power off, when the elevator drives in normal drive. The elevator should drive to the defined floor level and open doors.

15.11 External options 15.11.1 External inputs Input External OSS L Out of service switch

FID Fire detection External FRD fireman drive

Connector KSS signalization: XF3 on LCEFCB board

Note Only for potential free.

Parallel signalization: KCEPIO board, refer to circuit diagrams Refer to circuit diagrams.

15.11.2 External outputs Input OSI A Out of service indication

DAL-GP Disturbance alarm FRD Fireman drive return FRD Fireman drive service


Connector KSS signalization: XF4 on LCEFCB board Parallel signalization: KCEPIO board, refer to circuit diagrams KCEOPT board, refer to circuit diagrams Refer to circuit diagrams.

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Note

AM-10.65.001 (D) 2013-04-17


15.11.3 Connections of the remote alarm Step 1

2

Action Connect the remote alarm output cable and alarm reset cable (if any) to the connector XM30 on the LCERAL board. Check the required alarm method.

3

Test and reset the remote alarms.


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Note Refer to the circuit diagrams.

Set the required alarm transfer delay using rotary switch S2 on the LCERAL board. If required, inhibit the remote alarm by setting the Alarm switch in OFF position.

AM-10.65.001 (D) 2013-04-17


15.12 Commissioning of the car door Set the door parameters according to the door type. See parameter values in table below. For more information on parameters and values, see table on next page.

Door type AMD, drive 1 AMD, drive 1.5 AMD, drive 2 ADT ADV ADX / ADF Close command 24V, 230V Close command 48V Close command 110V Contactor control, 3 phase Fermator C2T Fermator C4T Fermator VVVF FIAM B FIAM S Inverter control No car door Sabiem C Selcom, 1 phase Selcom/Wittur ECO Auto Selcom/Wittur MIDI Auto Selcom/Wittur MSUPRA Auto 24V Electronic


515 1 1 1

520 1 1 1

529 1 1 1

Parameter ID 530 531 536 1 1 0 1 1 0 1 1 0

1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 0 0 0 0 0 0 1 0 0 0 1 0 0 1 1 1 1

1 0 0 1 1 0 0 0 1 0 0 0 1 0 0 1 1 1 1

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1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0

546 20 20 20

547 0 0 0

548 0 0 0

549 1 1 1

20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20

0 0 0 0 0 1 0 0 0 1 1 0 0 1 1 0 0 0 0

0 0 0 0 0 1 0 0 0 1 1 0 0 1 1 0 0 0 0

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

AM-10.65.001 (D) 2013-04-17


Parameter ID name 515 Door type

Default Min Max Comment value value value 1 0 6 0 = no door 1 = automatic door, parallel interface 2 = automatic door, serial interface 3 = swing door at landing, manual car gate 4 = swing door at landing, safety ray in car 5 = swing door at landing, automatic door in car, parallel interface 6 = swing door at landing, automatic door in car, serial interface 520 Door reopen 0 0 1 Door reopen allowed by photocell allowed by 0 = photocell input disabled 1 = photocell input enabled SRC 529 Door open 1 0 1 Door open limit in use 0 = open limit doesn’t exist limit present 1 = open limit exists 530 Door close 1 0 1 Door close limit in use limit present 0 = close limit doesn’t exist 1 = close limit exists 531 Door nudging 0 0 4 Nudging service: 0 = not in use type 1 = in use, DOB inoperative 2 = in use, DOB remains operative 3 = in use, DOB inoperative, load detection 4 = in use, DOB remains operative, load detection 536 Door closed 0 0 1 0 = door close torque released when door closed torque 1 = door close torque not released when door closed 2 = door close torque released even door locked 546 Door retiring 20 0 200 Retiring ramp magnet control full voltage time Defines time to keep full voltage in RR circuitry when RR ramp full energized in 0.1 s (*) voltage time 547 Door close 0 0 1 Defines the polarity of door close limit input 0 = not inverted, NO-contact limit polarity 1 = inverted, NC-contact 548 Door open 0 0 1 Defines the polarity of door open limit input limit polarity 0 = not inverted, NO-contact 1 = inverted, NC-contact 549 Door opened 1 0 1 Door torque control when door is open 0 = door open torque released when door fully opened torque 1 = door open torque not released when door fully opened *) Parameter ID 546 shows the value in 0.1 s. For example parameter value 20 corresponds 2 seconds.


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Cate gory   Doors /  Miscella neous

   Doors / Limits

   Doors / Miscella neous

Doors / Times    Doors / Miscella neous

AM-10.65.001 (D) 2013-04-17


15.13 Check the parameters for door inverter If you want more explanation on Yascawa door inverter, the commissioning procedure is described in separate instruction (773556).

15.13.1 Control logic parameters Parameter

b1-02 b1-01 H1-05 H1-04 H1-03 L2-01

Function

Yaskawa initial

Run command selection Frequency reference selection Multi-function input selection 5 Multi-function input selection 4 Multi-function input selection 3 Momentary power loss ride through method

1 1 3 14 24 0

Door operator setting 1 1 8 7 6 2

15.13.2 Motors parameters (depend on used door motor)

CAUTION If you do not know the door open or close speeds with rated frequency use first reduced speeds. Increase frequencies incrementally after testing the drive. Over speed could cause mechanical damages!

Parameter

Function

Yaskawa initial

E1-04

Max. output frequency

60

E1-05

Max. voltage

200*

E1-06

Max. voltage output frequency (base freq.)

60

E1-07 E1-08 E1-09 E1-10 E2-01

Mid. output frequency Mid. output frequency voltage Min. output frequency Min. output frequency voltage Motor rated current

3.0 16* 1.5 12*


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Door operator setting From name plate From name plate Same than n09 3.3 20 3.3 20 From name plate

Hz V Hz Hz V Hz V A

AM-10.65.001 (D) 2013-04-17


15.13.3 Open and close curve parameters Parameter

C1-01 C1-02 d1-01 d1-02 d1-03 d1-04 d1-05 d1-06 d1-07 d1-08

Function

Acceleration time 1 Deceleration time 1 Open braking frequency Close braking frequency Nudging frequency Nudging frequency Open frequency Close frequency Nudging frequency Nudging frequency

Yaskawa initial 10 10 0 0 0 0 0 0 0 0

Door operator setting 0.0...1.0 0.0...0.2 4...20 4...20 4...20 Same as n23 15...50/60 15...50/60 Same as n23 Same as n23

V3F initial setting 1.0 50 1.00 0.0 2000

Door operator setting 0...100 0.0...2.0 0.0...2.5 0.0...20 50...80 0.0...2.5 0.0...25.5

s s Hz Hz Hz Hz Hz Hz Hz Hz

15.13.4 Fine adjusting parameters Parameter

d3-04 b2-02 C4-01 E2-02 E2-03 C3-01 C3-02

Function

DC injection braking current DC injection braking time at stop Torque compensation gain Motor rated slip Motor no-load current Slip compensation gain Slip compensation time constant

% s Hz % s

15.14 Checking KCE board versions Step 1

Action Check the board versions on bar code labels of KCEMSC, KCEFUI and KCECCG boards are same as stated in delivery documents.

Note

1079581.wmf


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AM-10.65.001 (D) 2013-04-17


15.15 Testing landing door locks Step 1 2

Action Open the landing door lock contact and try to drive the elevator. Repeat for each landing door lock.

Note The elevator must not run.

15.16 Testing safety contacts Step 1

Action Activate each safety contact one at the time. Try to drive the elevator by inspection drive from the car roof.

Note The elevator must not run.

15.17 Measuring insulation resistance Step 1

Action Ensure that the power is off.

2

Ensure that all the other switches and circuit breakers are turned on. Measure insulation resistance between PE and main switch (L1, L2, L3, (N)) load side. Measure insulation resistance between PE and lighting switch (L, N) load side. Measure insulation resistance between PE and machine terminals (U, V, W).

3

4 5


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Note Both main switch and lighting switch must be turned off.

Use 500V (d.c.) test voltage. Insulation resistance must be minimum 1.0 M (Mohm).

AM-10.65.001 (D) 2013-04-17


15.18 Measuring earth continuity Earth continuity meter is needed. Always refer to the circuit diagrams. All conductive metal surfaces that can be touched by a user / fitter / service technician, and which may accidentally become live, must be connected to protective earth and must be measured. Step 1

2 3 4 5

6

Action Switch the power ON: • Shaft light • Main switch (220) Switch the RDF ON. Drive the car roof to the topmost landing level. Open the landing door. Block the landing door in open position. Check that the red CHARGE LED of the drive module is on.

Note

Switch off the main switch (Q220). Switch off the lighting switch (Q262). WARNING! Ensure that ALL electrical energy sources are identified and disconnected including main switch, lighting switches, auxiliary supplies, emergency batteries and emergency generators.

1078874.pdf

7

Wait 5 minutes and check that the red CHARGE LED turns off.


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AM-10.65.001 (D) 2013-04-17


Step 8

9

Action Check that the main power supply is safely disconnected by measuring voltage between the main switch terminals (Q220: L1-PE, L2-PE, and L3-PE). Check that the lighting power supply is safely disconnected by measuring between the lighting switch terminals (Q262:2-PE and 4-PE).

Note These markings match only if the mains switch is in control panel. If old mains switch unit is used, the correct measuring points must be defined on site.

L1

L1

10

Measure the resistance of the test leads if it is not possible to reset the continuity meter (compensate the test lead resistance).

11

Connect the earth continuity meter: • (-) to earth bar or PE terminal • (+) to test point Measure the earth continuity (a resistance of the earth connection). If required calculate the resistance: Result of measurement - resistance of test leads.

L2

L2

L3

L3

1080520.wmf

Calibrate the meter to exclude the measuring lead resistance. If not possible, measure and record the measuring lead resistance. Subtract the resistance value from the measurement results. WARNING! When measuring the landing doors: • Close the car top box and keep the (-) lead connected to car top box PE terminal. • Press the car roof stop button down before making any measurements. 

Pressing the car roof stop button switches the power of the landing door safety chain OFF.


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AM-10.65.001 (D) 2013-04-17


Test points in the machine room: 1. Drive - Machine 2. Drive - Car top box 3. Controller - Car top box

1 R

2 R

3 R

1080374.wmf

R = Earth continuity meter Test point 2, Drive - Car top box, the resistance must be less than 2.0 . Other test points, the resistance must be less than 0.5 .


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Test points in the elevator shaft:

1. 2. 3. 4. 5. 6. 7. 8. 9.

Car top box - Car door operator Car top box - Car shell Car top box - Car fan Car top box - Car light Car top box - Any optional device Car top box - Landing door top track Car top box - Landing door frame Car top box - Shaft network module, if any Controller - Car top box

R

6

7 R

9 R

1 R

R

R = Earth continuity meter

8 R

2

R

3, 4, 5

1080375.wmf

WARNING WARNING: Press the car roof stop button down before making any measurements of the landing doors.

Test points 6, 7 and 8 Car top box - Landing door test points / shaft network module, the resistance must be less than 5.0 . Other test points, the resistance must be less than 0.5 .


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15.19 24 VDC ground fault test Step 1

7 8 9

Action Check that the 24V OK LED on the KCEMSC board is lit. Switch the main power OFF. Disconnect the travelling cable (XC1) from KCECPU board. Connect a short circuit wire (KM796185G10100) between a free XTTS connector on KCEMSC and PE bar on the control panel. Switch the power ON. A multifuse on KCECPU board disconnects power to KCEMSC board. Check that the 24V OK LED on the KCEMSC board is not lit. If the 24V OK LED is lit, check the PE connection* on KCECPU and repeat the test. Switch the power OFF. Remove the short circuit wire. Connect the travelling cable XC1.

10

Switch the power ON.

2 3 4

5

6


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Note

KCEMSC 24V OK XTTS KCECPU PE XC1

*

PE 1079583.wmf

A multifuse resets itself automatically. The emergency battery on the car roof energizes the KCEMSC board. 24V OK LED turns on.

AM-10.65.001 (D) 2013-04-17


15.20 Testing operation of RCD Step 1

Action Press the test button on the residual current device (RCD).

Note

F286

Check that the device tripped. If the RCD does not trip, check the connections or change the device.

F290 1080365.wmf

2

Switch the RCD back to ON position.

15.21 Speed measurement Step 1 2

Action Drive the car to both up and down directions at nominal speed. Measure the elevator speed from machine traction sheave using a manual tachometer.


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Note

AM-10.65.001 (D) 2013-04-17


15.22 Current measurement Step 1

Action Select the Monitor display menu on drive unit. Mon appears on display.

Note

1071113.wmf

2 3

4

Activate parameter U1-03. Read the parameter value while driving the car to both up and down directions at nominal speed. Press the key until F 0.00 ESC  appears on display.

0.00A appears on display.

15.23 Testing the final limit switches Step 1 2 3

Action Call the car to the top floor. Set test switch to position 263. The test LED turns ON. Switch the elevator to RDF (INSPECTION switch to low position).

Note Check that there is no one in the car. STOP

TESTS

RUN OFF 261 263 TEST

STOP INSPECTION NORM

CALLS UP

TOP CALL

RUN INSP

4

5

6

7 8 9

1074498.wmf

Drive the car upwards with RDF until Elevator drives in inspection low speed the car stops (car stops automatically when available. when the final limit is reached). Switch the elevator to NORMAL KONE Mini Console (DOORS menu) is (INSPECTION switch to up position). showing Car on final limit. Check that the Safety circuit open LED on KMI is lit. Switch the elevator to RDF (INSPECTION switch to low position). Open the landing door at top landing. Confirm that the deviation is according to Measure the deviation of car and the local regulations. landing sills. Drive the car away from the final limit switch with RDF. Switch the elevator to NORMAL (INSPECTION switch to up position). Repeat the same at bottom landing for the lower limit switch.


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15.24 Drive time supervision (DTS) test Step 1 2

Action Drive the elevator to the bottom landing. At the beginning bb is blinking on the drive unit display.

Display

1069865.wmf

3

4

Press the key at the drive unit  user interface until PAr appears on display. Make a car call by pushing top call button on KMI.

1069864.wmf

The main contactor energises but the elevator does not run.

1069628.wmf

5

DTS supervision operates after DTS time: • fault code 1040 appears • the main contactor de-energises • run time limitter LED turns ON at KMI To reset the fault: Set test switch to position 263. Push the Reset button at KMI. The run time limitter LED turns OFF.

TESTS

OFF 261 263 TEST

6

1069941.wmf

1069633.wmf

Press the key at the drive unit ESC user interface until F 0.00 appears on display. Turn test switch to OFF position.

1069625.wmf


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15.25

Buffer tests

15.25.1 Car buffer test with rated load Step 1 2

Action Drive the elevator to the top floor. Set test switch to position 263. The test LED turns ON.

Note TESTS

OFF 261 263 TEST

3

1069941.wmf

Push the terminal stop bypass SELECT button once. The normal decel bypass LED turns ON.

1069632.wmf

4

Make a call to the bottom floor. The car drives to the buffer. NOTE! The call must be made within 10 seconds after terminal stop bypass button has been pushed. 1069628.wmf

5 6

Drive the car to the bottom floor level with RDF. Turn test switch to OFF position.

1069625.wmf


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15.25.2 Counterweight buffer test with empty car Step 1 2

Action Drive the elevator to the bottom floor. Set test switch to position 263. The test LED turns ON.

Note TESTS

OFF 261 263 TEST

3

1069941.wmf

Push the terminal stop bypass SELECT button once. The normal decel bypass LED turns ON.

1069632.wmf

4

Make a call to the top floor. The counterweight drives to the buffer. NOTE! The call must be made within 10 seconds after terminal stop bypass button has been pushed. 1069628.wmf

5 6

Drive the car to the topmost floor level with RDF. Turn test switch to OFF position.

1069625.wmf


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15.26 Overspeed governor test Step 1 2

Action Push the controller stop button down. Go to the overspeed governor. Lift the rope out of the groove.

Note

1015446.wmf

3

4

5

Measure the overspeed governor speed using a manual tachometer. Accelerate the overspeed governor manually until the electrical contact (pos. 22) operates. Read the operation speed. Measure the overspeed governor speed using a manual tachometer. Accelerate the overspeed governor manually until it trips. Rotate the overspeed governor to the tripping direction. Read the tripping speed. Place the rope back to the groove.

Nominal speed 0.6 m/s 1.0 m/s 1,2 m/s 1.4 m/s 1.6 m/s 1.78 m/s


Check the correct electrical contact operation speed from the type label.

Refer to the table below for correct tripping area.

Correct tripping area: Tripping range Vn x 1.15 Vn x 1.25 + (0.25/Vn) > 0.70 m/s < 1.17 m/s > 1.15 m/s < 1.50 m/s > 1.38 m/s < 1.71 m/s > 1.61 m/s < 1.93 m/s > 1.84 m/s < 2.16 m/s > 2.04 m/s < 2.37 m/s

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15.27 Safety gear test Step 1

Action Perform the safety gear test according to the safety gear instructions.

Note

15.28 Ride comfort /Special V3F10 Adjustments 15.28.1 Motor slip compensation NOTE! This tuning is required if the difference in creeping speed running time to heavy and light directions is big. Step 1

2 3

Action Adjust Motor rated slip parameter E2-02 value in small steps.

Note If the value is too high, it may cause vibration during nominal speed run.

If creeping speed running time is shorter when driving to light direction, increase the value. Make test run in both directions. Repeat as many times as necessary.

15.28.2 No load current NOTE! This tuning is required only if there are problems in the drive performance. Optimal drive performance requires correct setting of no load current (motor magnetisation current). This value is typically not labelled in the motor nameplate. If better performance is required but autotuning is not possible, alternatives to set these parameters are: • Leave it to original default for the module size. This value is typically 20-30% of inverter nominal current for the module size. • Elevator motors typically have higher no load current. Estimate 50 – 60% of motor nominal current. • Estimate based on power factor of the motor • No load current = ((1/cosfii ) – cosfii) x Motor nominal current. • Have a balance load (50% load) in the car and observe current from Monitor Constant U103 (output current)


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15.28.3 Fine tuning parameters for K1000 drive When performance with KONE default settings is not adequate, adjust the following K1000 tuning parameters. Refer also to finetuning hints on following pages. Parameter name

Number

Acceleration time 1 (Accel Time 1)

C1-01

Deceleration time 1 (Decel Time 1)

C1-02

S-curve characteristic time at acceleration start  (SCrv Acc @ Start) S-curve characteristic time at acceleration end  (SCrv Acc @ End) S-curve characteristic time at deceleration start (SCrv Dec @ Start) S curve at deceleration end

C2-01

Brake open delay

Brake closing delay

Related performance Time to accelerate from zero to maximum frequency Time to decelerate from maximum frequency to zero Rounding time at start of acceleration

Def

Range

2.0

0-10 s

2.0

0-10 s

1.0

0.50 - 2.50 s

Adjustment

C2-02

Rounding time at end of acceleration

0.5

0.50 - 2.50 s

C2-03

Rounding time at start of deceleration

0.5

0.50 - 2.50 s

(recommended) (possible)

C2-04

Overshoot at deceleration end

0.8

0.50 - 2.50 s

S1-06

Speed reference is held at zero during this time to let brake open

0.2

0.0-10.0 s

Overshoot at deceleration end -> increase setting elevator runs against the brake at start: -> increase setting

0 - 10.0 s.

Extensive roll back at start: ->reduce setting Try to find good compromise to get good levelling.

S1-07


Defines the time to wait after zero speed has reached before brake is closed.

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0.1 s

AM-10.65.001 (D) 2013-04-17


15.28.4 Fine tuning hints for V3F10 Find the problematic drive section in the curve below.  Read some helping hints in table on the next page.  Up or Down command from KCE to V3F10

 Levelling speed command from KCE to V3F10

Nominal speed command to V3F10

4

V

5

3

1

6

7

2

8 9

T

1072308.wmf

1 2 3 and 4 Brake Brake Brake open closed open delay


5, 6 and 7 Brake command from V3F10

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8 Brake close delay

9 Brake closed

AM-10.65.001 (D) 2013-04-17


Fine tuning hints: Section of drive curve 1 DC injection/Start 2 Brake open delay S-curve/ start 3

Acceleration time

4

Deceleration time

5

DC-injection/Stop

Operation

Correction

Extensive roll back Start against brake Rough and jerky start Too slow acceleration Too fast acceleration Too slow deceleration Too fast deceleration

Note

S1-02 Increase S1-20 Increase S1-06 Increase C2-01 Reduce C1-01 Increase C1-01 Reduce C1-02 Increase C1-02 S1-03

15.29 Setting the elevator to normal use Step 1 2

Action Set the elevator to normal drive and return it to the group, if any. Close the panels and other covers. Lock the machine room.

Note

15.30 Troubleshooting For more information, see AS-11.65.004 and 878327, V3F10 fault code listings.


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16

HANDLING WASTE For more information on handling waste material, see AM-01.01.190 Environmental excellence - installation.


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17

HANDOVER TO MAINTENANCE

17.1

Prerequisites Before the handover procedure can take place, the safety inspection must have been completed and passed. The safety inspection also covers issues described in EN81 Annex D, which gives mandatory actions from a code point of view, where EN regulations apply. It is also important to verify that some of the issues in the handover form have already been checked during the safety inspection.

17.2

Handover form In the handover form there is a list of items that are assessed during the handover procedure. Local practices determine whether it is necessary to specifically examine all the different points on the list. However, both the installation and maintenance representatives must be positive that the items listed are in an acceptable condition. The purpose of the form is that its subscribers know that the installation meets KONE quality standards.


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Handover, Installation / Maintenance General data Date: Elevator Number:

Elevator Address:

Installation Representative:

Maintenance Representative:

Handover Checks Accepted Yes No

Why not?

Ride quality Levelling Car & Signalization Control panel Brake Machine Traction sheave and ropes Guide rails Shaft Doors: Landing door mechanical Landing door locks and contacts Car door mechanical Car door electrical

OSG and Safety gear Pit Installation accepted to maintenance

Yes

No

If rejected, person responsible for corrective actions

Agreed deadline for completion of the work

Installation Representative


Maintenance Representative

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17.3

Autocontrol form Ensure that the country-specific autocontrol form is filled out.

17.4

Ride comfort Ride comfort is tested before and after the installation. Measure and register ride comfort now. Compare the results. Start corrective actions when required. More information on ride comfort refer to section “Required checkings and measurements”.

17.5

Installation quality checks The following pages of this document contain a list which describes the required condition of the installation in detail. Refer to it whenever you are unsure whether a component is in an acceptable condition or not. Ride quality • There should be no vibration during the acceleration or deceleration. • There should be no sudden movements or unexpected noises during the drive. Levelling • Maximum levelling deviation in either direction is ± 5 mm. Car and signalization • • • • •

Push buttons and signalization should work as expected in the car and on the landings. Car lighting should operate correctly. Car emergency light should operate correctly. Decoration should be clean and free from scratches and dents. There must not be any unnecessary installation time protections, such as plastic coatings left. • Remote monitoring and alarm buttons (3 pcs) must function correctly. • Car labels must be in place. • Car fan should operate correctly.


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Controller • • • • • • •

All covers and protections must be correctly positioned. All unusual registered faults should be solved and unit reset. Controller door must be locked and closed properly. There should be no abnormal noises coming from the contactors, etc. Elevator shaft emergency light and alarm bell must work when power is off. Rescue drive should work in both directions. Brake must engage fully when handle is released. There must be no kinks or other deformations in the brake release cable. • The brake must stop the car in an up direction emergency stop. There must be no excessive slide. • All earth wires on the whole installation must be correctly connected to the earth terminal. • ANY ELECTRICAL OVER CONNECTIONS MUST BE REMOVED Machine • All internal and external fastenings should be tight. • The braking surface on the machine should be clean and free from rust and other contaminants. • There must be no mechanical contact with machine body and fixings. Ropes • Ropes must be free from rust. • Should not be dry or dirty, and there should be no broken strands, kinks or twists. • Rope labels must be attached to the rope suspensions. Traction sheave, rope terminations and springs • • • • •

Maximum deviation in spring length must be 3 mm. Rope anchorages must be correctly secured with two nuts and a split pin. Ropes should be secured with rope grips. There should be no twisting of rope termination. There should not be any mechanical contact between rope grips.

Elevator shaft • Pulleys should rotate silently. • All elevator shaft lighting should work. • Final limit switches must operate, the roller must rotate and the switch must meet the ramp both top and bottom. Ramps must be correctly vertically aligned. • Top and bottom safety spaces must be according to the layout drawing. • The travelling cable loop should be a minimum of 150 mm from the pit bottom when the car is on the bottom floor. The loop inner diameter should be a minimum of 400 mm. Guide shoes • Guide shoes should be correctly adjusted with a total gap in distance between the guide rails of max. 2 mm. • Oil cups should be full.


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Travelling cable • Should hang correctly. • Should be in good condition with no cracks, marks etc. on external insulation. • The text side should be outside the loop. Car roof • Should be clean, tidy and free from oil or grease. Car top connection box • All electrical devices and switches must work correctly. Safety devices • All safety switches must operate correctly. Counterweight • • • •

Free movement of shoes between rails should be between 2 and 3 mm. Oil cups must be full. Rope guards must be in place. Filler blocks must be in place and securely fixed down.

Landing door mechanical (automatic doors) • If no longer required, surface protections should be removed. • Must be adjusted so that panels do not touch each other. Maximum gap between frame, sill or another panel is max. 6 mm (nom. 5 mm). For glass panels maximum gap between frame and panel is 3 mm. • Max. door gap in closed position, with 15 kg hand force is 30 mm (measured at the bottom of the panels). • Synchronization rope should touch the steel back plate when pressing it with thumb at distance of 10 cm from the synchronisation roller. • Rollers should run smooth, aligned with the guide rail. • Anti-tip rollers must slightly touch the rail. • Closing weight wire guard on diverting pulley should be in horizontal position, not touching the wire. • Sills should be clean and securely fixed • Distance between car sill and landing sill should be 30 ± 1.


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Landing door locks and contacts • • • • • • • • • • •

Contacts should be clean. Lock hook and beak overlap when contact operates must be min. 7 mm. Contact bridge should push the contact surface down min. 3 mm. Contact bridge should be aligned to the middle of contactor holes, not touching the hole edges. Electrical terminations should be tight and secured. Must move freely and close by itself. Must be securely fixed. If the door opens, safety circuit must be interrupted. Lock buffers should be in place. Landing lock rollers should rotate. Emergency opening device must operate and the lock must return automatically to locked position.

Car door mechanical • • • • • • • • • • • • • • • • •

Door shoes must be securely fastened. Shoes should not allow the door to rattle on normal operation. Distance between door bottom and sill should be max. 6 mm (nominal 5 mm). Synchronization rope should touch the steel back plate when pressing it with thumb at distance of 10 cm from the synchronisation roller. The drive belt sides should touch each other when pressed with thumb in the centre of the belt. Coupler rollers should be in the middle of operator vanes, running clearance min. 5 mm, nom. 10 mm. Couplers should engage properly, engagement with rollers 10 mm ± 1 mm. If the door is opened, safety circuit must be interrupted. Must be adjusted so that panels do not touch each other and any gap between frame, sill or another panel is max. 6 mm, nom. 5 mm. Should not rattle during drive. Should operate smoothly, also when looking from the landing side. Should be correctly aligned with the slam post. Door operates correctly (check by operating manually from car roof). All rollers should run smoothly and be aligned with the guide rail. Panels should run smoothly and be aligned with the guide rail. Rollers and diverters should be firmly fixed, not causing noise. Anti-tip rollers must prevent the door from leaving the track.

Car door electrical • • • •

Should be free from dust Contact bridge should push the contact surface down min. 3 mm. Door operator buttons must operate correctly. Door protective devices must reopen the door action when operated.


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Overspeed governor and rope • • • • • •

Should run quietly. Must be tested by hand. Must operate freely when activated. Electrical contact must work. Seal should be intact. Rope should not be dirty and there should be no broken strands, kinks or twists.

Safety gear • • • • •

Must be correctly aligned, the rollers must meet both guide rails evenly. All bolts and nuts must be in place and properly fixed. Both sides must operate synchronously, gripping at the same time. Must be fully disengaged during normal operation. Must move freely and engage fully, when operated by pulling the overspeed governor rope.

Overspeed governor tension weight • Must fully tension the governor rope. • Safety switch trigger should be in the middle of the opening. • Should move easily. Pit • There should be no oil, rubbish or water in the pit. • Oil collectors should be in place. • Buffers must be securely fixed.


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18

APPROVALS AND VERSION HISTORY Compiled by:

Information Product Author / Tiina Halonen

Checked by:

Global Installation Support / François Le Maut

Approved by:

Global Installation Support / Håkan Bärneman

Issue Date Description of Change Ref CR 2011-02-14 First issue for piloting. A 2012-03-27 Second issue for piloting. Updated positioning system. Other changes, see change bars. B 2012-09-17 Additions and improvements, see change bars. C 2012-11-22 Additions and improvements, see change bars. D 2013-04-17 Added new options, see change bars.


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Approved by Håkan Bärneman Håkan Bärneman

Håkan Bärneman Håkan Bärneman Håkan Bärneman

AM-10.65.001 (D) 2013-04-17


APPENDIX A. Changing the characteristics / V3F10 K1000 LED user interface

A.1

User Interface For more information, see AS-11.65.004.

12 1

13

11 5 9

2

15 3 14

STOP

10

7 4

8

6

1064941.pdf

Figure A1.

Digital LED operator


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Table A1. Keys and displays on the LED operator No 1 2 3

Name Data display area ESC key RESET key

4 5 6 7

RUN key Up Arrow key Down Arrow key STOP key

8

ENTER key

9

LO/RE selection key

10 11 12 13 14

RUN light LO/RE light ALM LED light REV LED light DRV LED light

15

FOUT LED light


Function Displays the frequency reference, parameter number, etc. Returns to the previous menu. Moves the cursor to the right. Resets the drive to clear a fault situation. Starts the drive. Scrolls up to select parameter numbers, setting values, etc. Scrolls down to select parameter numbers, setting values, etc. Stops the drive. NOTE! Stop priority circuit. A fast-stop is available by pressing the STOP key when the drive detects a danger even if the drive is running by a signal from the multi-function contact input terminal (REMOTE is set). To avoid stoppage by using the STOP key, set o2-02 (STOP Key Function Selection) to 0 (Disabled). Selects all modes, parameters, settings, etc. Selects a menu item to move from one display screen to the next. Switches drive control between the operator (LOCAL) and the control circuit terminals (REMOTE). NOTE! LOCAL/REMOTE key effective during stop in drive mode. If the digital operator could change from REMOTE to LOCAL by incorrect operation, set o2-01 (LOCAL/REMOTE Key Function Selection) to “0” (disabled) to disable LOCAL/ REMOTE key. Lit while the drive is operating the motor. Lit while the operator (LOCAL) is selected to run the drive. Lit when drive detects an alarm or error Lit when motor is rotating in reverse Lit when in drive mode. Drive mode allows motor operation and parameter monitoring. Parameter settings cannot be changed in drive mode (Æ programming mode). Output frequency is displayed

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A.2

Parameters

A.2.1

Drive parameters See the document AS-11.65.004, the sections “V3F10 (K1000) parameters” and “V3F10 (K1000) parameters (password required)”.

A.2.2

Menu structure

Description of Key Operations

:

DRV light is on. *Pressing RUN will start the motor.

Turn the power on

* Forward Selection

:

Reverse Selection

: :

Output Frequency

Output Current

Output Voltage

Note: “XX” characters are shown in this manual. The drive will display the actual setting values.

XX Monitor Display

XX XX XX

XX

XX XX

XX

DRV light is off. *Drive cannot operate the motor.

Verify Menu

XX Set Up Mode

XX XX

XX XX

Parameter Setting Mode

XX

Auto-Tuning

XX

1064942.pdf

Figure A2.

Digital LED operator menu structure


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A.2.3

U-parameters

U1

Status monitor constants KONE LIFT ACCESS

U2-01

Current Fault

U3-01

U1-01

Frequency Reference

U2-02

Last Fault

U3-02

2nd last fault

U1-02

Output Frequency

U2-03

Reference Frequency at fault

U3-03

3rd last fault

U2

Fault Trace

U3

Fault History Last Fault

U1-03

Output Current

U2-04

Output frequency at fault

U3-04

4th last fault

U1-04

Control Method

U2-05

Output current at fault

U3-05

Cumulative operation time at fault

U1-05

Motor Speed

U2-06

Motor Speed at fault

U3-06

Acumulative operation time of 2nd fault

U1-06

Output Voltage

U2-07

Output voltage reference at fault

U3-07

Acumulative operation time of 3rd fault

U1-07

DC Bus Voltage

U2-08

DC bus voltage at fault

U3-08

Acumulative operation time of 4th fault

U1-08

Output Power

U2-09

Output power at fault

U3-09

U1-09

Torque Reference

U2-10

Torque reference at fault

U3-14

U1-10

Input Terminal Status

U2-11

Input terminal at fault

U3-15

U1-11

Output Terminal Status

U2-12

Output terminal status at fault

U3-20

U1-12

Operation Status

U2-13

Operation status at fault

U1-13

Cumulative Operation Time

U2-14

Cumulative Operation Time at fault

U1-14

Flash Memory ID 21010 KONE ADVANCED LEVEL (1410)

U1-18

Motor Secondary Current

U1-19

Motor Excitation Current

U1-20

Output frequency after Softe Starter

U1-26

Voltage Reference

U1-28

CPU SW number ID 20010

U1-32

ACR output of q-axis

U1-33

ACR output of d-axis

U1-34

OPE fault Code

U1-40

Cooling fan operating time

U1-50

Speed Comp Value

Figure A3.

5th last to 10th last fault Acumulatived time of 5th to 10th fault

1027720.pdf

U-parameters


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APPENDIX B. Control panel introduction The control panel is pre-tested at the factory and the basic adjustments are already set.

B.1

Control panel with drive

1. LCERAL board (optional) 2. Alarm and intercom interface (optional) 3. KCEFUI board 4. KCEPIO board (optional) 5. KCECPU board (optional) 6. Travelling cable optional terminals 7. PE1 earthing bar 8. KCEOPT board 9. 24 VDC power supply 10.Power supply and THD-filter terminals 11.KCEMSC board 12.Drive unit 13.Braking resistor module 14.EMI suppression ferrite 15.Contactor module 16.RFI filter 17.Control power module 18.Brake and ramp voltage transformer (optional) 19.Lighting module 20.Hoisting motor interface terminals 21.Door transformer (optional) / THD filter 22.EMC clamp for motor cable 23.FRD FR amplifier

1

11

2

12 13

3 4 5

14

6 7

15 16 17 18

8

19 9 20

23

21

10

22 21

1067571.wmf


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B.2

Switches and fuses

Pos.No Q220 Q262 F281 F290 F290:1 F290:2 F286 F286:1 F286:2 F286:3 F288:1, F288:2 F207 F283

Switch / Fuse Main switch in control cabinet Main switch for lighting Main fuse in control cabinet Residual current circuit breaker for lighting circuits Car lighting fuse Shaft lighting fuse Residual current circuit breaker for control circuits Car door circuit breaker Control system circuit breaker Circuit breaker of safety circuit and start permit chain Autotransformer primary circuit breaker (optional) Autotransformer secondary circuit breaker (optional) brake power supply Retiring ramp and DC breaking fuse (optional) Fuse for 3-phase door operator (optional)


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APPENDIX C. Locking and unlocking Yaskawa parameter menus Parameter menu is unlocked as default when control panel is delivered to site.

C.1

Unlocking parameter menu Step 1


Note

1069865.wmf

2

Select the PAr menu. 1069864.wmf

3 4 5

C.2

Set the parameter A1-04 value to 1410. Set the parameter A1-01 value to 1410. Press the key until bb is ESC  blinking on the display. Otherwise the elevator will not run.

1069865.wmf

Locking parameter menu Step 1


Note

1069865.wmf

2

Select the PAr menu. 1069864.wmf

3 4 5

Set the parameter A1-04 value to 1410. Set the parameter A1-01 value to 0000. Press the key until bb is ESC  blinking on the display. Otherwise the elevator will not run.


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1069865.wmf

AM-10.65.001 (D) 2013-04-17


APPENDIX D. Estimating the mass of the counterweight Step 1

Action Calculate CWT volume.

H  C  D  cm  ------------------------------------1000 2 3 4

Draw a line from CWT volume value to concrete or steel/cast iron line. Draw a line left to CWT weight value. Use this value as estimation of CWT weight.

8000

3.

7000 6000 5000

4. 4000

2.

3000 2000 1017856.wmf

1000 0 100

200

300

400

500

600

1. 1. 2. 3. 4.


700

800

900

1000

1017855.wmf

CWT volume (H x C x D /1000) Concrete Steel / cast iron CWT weight (kg)

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m/s

f

m/s

0,4 f

m/s

0,5 f

m/s

0,63 f

m/s

0,7

Nominal speed, m/s

f

m/s

0,8 f

m/s

0,9 f

m/s

1,0

© 2009 KONE Corporation All rights reserved. 13,3 0,08 10,0 0,08 8,0 0,08 6,3 0,08 5,7 0,08 5,0 0,08 4,4 0,08 4,0 0,08

d1-17

Levelling

Levelling speed

33,3 0,2 25,0 0,2 20,0 0,2 15,9 0,2 14,3 0,2 12,5 0,2 11,1 0,2 10,0 0,2

Correction drive, Correction drive speed d1-04 10 inspection drive slow speed, recall drive, setup drive

50,0 0,5 39,7 0,5 35,7 0,5 31,3 0,5 27,8 0,5 25,0 0,5

50,0 0,3 37,5 0,3 30,0 0,3 23,8 0,3 21,4 0,3 18,8 0,3 16,7 0,3 15,0 0,3

f

0,3

Inspection drive, high speed Inspection drive speed d1-02 15

Default value 50,0 0,3 50,0 0,4 50,0 0,5 50,0 0,6 50,0 0,7 50,0 0,8 50,0 0,9 50,0 1,0

High speed

Normal run

Par

d1-01 50

Speed level

KCE control, d1-18=11

Lift drive function

KONE ReSolve 200

Installation Instruction

APPENDIX E. Speed parameters For more information on correct parameter values, see also delivery documents (wiring diagrams).

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AM-01.01.300_main_en.A.1

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