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KONE ReSolve 200

Installation Instruction

KONE RESOLVE 200,


KONE

AM-10.65.001
All
(D)2009
rights
2013-04-17
ReSolve
KONE
reserved.
Corporation
200

SINGLE / FLEXIBLE MAN INSTALLATION INSTRUCTION

1067629.wmf

2009 KONE Corporation 1 (258) AM-10.65.001


All rights reserved. (D) 2013-04-17
KONE ReSolve 200
Installation Instruction

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.

2009 KONE Corporation 2 (258) AM-10.65.001


All rights reserved. (D) 2013-04-17
KONE ReSolve 200
Installation Instruction

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ride comfort measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1 RECEIPT AND CONTROL OF MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.1 Checking of packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2 Transporting materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3 Unloading materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.1 Safety fences and signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Checking the power sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Checking safety gear operation and overspeed governor. . . . . . . . . . . . . . . . . . . . . 30
2.4 Checking overtravels and safety spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.5 Marking the sling and car position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.6 Measuring travelling cable loop length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7 Checking the car and counterweight balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.8 Preparing the access for the travelling cables and the shaft bundle . . . . . . . . . . . . . 34
2.9 Installation of shaft lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3 INSTALLING TRAVELLING CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1 Installing travelling cable: Machinery below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 Installing travelling cables: Machinery above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.3 Dismantling old car equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2009 KONE Corporation 3 (258) AM-10.65.001


All rights reserved. (D) 2013-04-17
KONE ReSolve 200
Installation Instruction

3.4 Installing car top connection box and inspection drive unit . . . . . . . . . . . . . . . . . . . . 45
3.5 Routing cables to car top connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.6 Connecting the travelling cable in the car top connection box . . . . . . . . . . . . . . . . . 47
3.7 Temporary wiring of car top connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.8 Fixing sensor unit to car roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.9 Installing the wire hanger and limit switch in top of the shaft. . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . 59
6.1 Position the control panel according to the site survey . . . . . . . . . . . . . . . . . . . . . . . 60
6.2 Re-use / installation of trunking for travelling cable and elevator shaft wiring . . . . . . 63
6.3 Routing of wiring between controller panel and machinery . . . . . . . . . . . . . . . . . . . . 64
6.4 Snelis devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.5 Specific routing for V3F motor supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.6 Connecting the extension tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.7 Connecting travelling cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.8 Connecting machine room equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.9 Installing and connecting power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.10 Wiring other machine room equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7 COMMISSIONING FOR SERVICE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.2 Preparations before turning the power on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.3 Reset button at KMI (KONE Maintenance Interface) . . . . . . . . . . . . . . . . . . . . . . . . 83
7.4 Example of setting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.5 Checking of inverter parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.6 Non-rotational autotuning of K1000 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.7 Driving the elevator for the first time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.8 Preparation for driving the elevator on the car roof . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.1 Removing of old levelling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.2 Remove old limits and floor switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.3 Remove landing bands / support wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.4 Removing old travelling cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

2009 KONE Corporation 4 (258) AM-10.65.001


All rights reserved. (D) 2013-04-17
KONE ReSolve 200
Installation Instruction

10 INSTALLING THE HANGING WIRES AND POSITIONING MAGNETS . . . . . . . . . . . . . . 100


10.1 Hanging the wires at top of the shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10.2 Fixing the wires in the pit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
10.3 Installing bottom service limit ramp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.4 Installing positioning magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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 . . . . . . . . . . . . . . . . . . . . . . 131
12.1 Positioning of the car. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
12.2 Connection of landing door lock (serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
12.3 Wiring of landing call buttons (serial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
12.4 Connection of landing door lock (parallel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
12.5 Wiring of indicators and optional landing devices (parallel) . . . . . . . . . . . . . . . . . . 144
12.6 Connecting shaft bundle (signalization) in to the control panel . . . . . . . . . . . . . . . . 154
13 REMOVING THE OLD SHAFT BUNDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
14 INSTALLATION AND WIRING OF ALL CAR EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . 156
14.1 Dismantling old car equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
14.2 Installation of door control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
14.3 Installation of parallel I/O box (only with parallel signalization) . . . . . . . . . . . . . . . . 160
14.4 Installation of ACU box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
14.5 Wiring of car top connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
14.6 Wiring of old car light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
14.7 Wiring of old car fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
14.8 Wiring of ADV door operator (Isola 96, Athena 96, Renova 96) . . . . . . . . . . . . . . . 164
14.9 Wiring of retiring ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
14.10 Wiring of door inverter control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
14.11 Wiring of contactor control door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
14.12 Wiring of Starlift door operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
14.13 Wiring of ADF - ADX door operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
14.14 Wiring of AMD door operator (Drive 1, 1.5 and 2). . . . . . . . . . . . . . . . . . . . . . . . . . 178
14.15 Wiring of DC2000 door control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
14.16 Wiring of KOF230V, C-type door control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
14.17 Wiring of ADT 3PH 125V door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

2009 KONE Corporation 5 (258) AM-10.65.001


All rights reserved. (D) 2013-04-17
KONE ReSolve 200
Installation Instruction

14.18 Wiring of close command door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189


14.19 Wiring of FIAM B/S door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
14.20 Wiring of Sabiem C door operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
14.21 Wiring of ACC 230V door operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
14.22 Wiring of general 24V electronic control door operator . . . . . . . . . . . . . . . . . . . . . . 197
14.23 Wiring of Selcom 1PH 220V automatic door operator. . . . . . . . . . . . . . . . . . . . . . . 199
14.24 Wiring of no car door, EMO N, AT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
14.25 Wiring of BOF unit for non-automatic doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
14.26 Wiring of new COP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
14.27 Wiring of old COP and display (if any, parallel I/O module). . . . . . . . . . . . . . . . . . . 204
14.28 Connection of ACU, if applicable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
14.29 Connection of KRM, KSS ReVive signalization. . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
14.30 Connection of KRM, parallel signalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
14.31 Wiring of car extension door (CED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
15 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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Installation Instruction

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
17.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
17.2 Handover form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
17.3 Autocontrol form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
17.4 Ride comfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
17.5 Installation quality checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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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Installation Instruction

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 MMS package


Phase 14: New car interior
New car door
New signalization in car
Phase 5: New machinery
Phase 12: New landing signalization

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Installation Instruction

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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Installation Instruction

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

Installation phases one / two fitter(s)


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

2 Preparations OR
3 Installing travelling cables
4 Dismantling old machine room equipment
5 Installing and wiring of machine room equipment
6 Start-up
7 Installing top service limit ramp
8 Installing shaft lighting
9 Removing old elevator shaft equipment
10 Installing hanging wires
11 Installing shaft bundle and positioning magnets
12 Connecting landing door locks and buttons
13 Removing old shaft bundle
14 Installing and wiring of car equipment
15 Installing floor level flags
16 Full speed adjustment / commissioning
17 Removing old equipment

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Installation Instruction

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 man-
riding 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 manufacturers equipment where the level of training and information available may
vary and circuit diagrams are in an unfamiliar style.

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Installation Instruction

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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Installation Instruction

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 specialists 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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Installation Instruction

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 dont
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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Installation Instruction

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.

1034212.wmf

When not working at the Working on the car roof.


landing. Closed landing door or car
Closed landing door or at landing and fence closing
fence covering the whole the landing door area.
door opening.

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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Installation Instruction

Safety signs

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

Turn main Lock and tag Verify de- Push the stop Fall prevention
power OFF the switch energization button OFF 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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Installation Instruction

Step Action Note


1 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.
2 If the gap is 100 mm to 299 mm, fix the
kick plate.
3 If the gap is 300 mm to 850 mm, use at
least 0.7 m high balustrade.
4 If the gap is larger than 850 mm, use a
1.1 m high balustrade.
If the clearance between the balustrade 1039883.wmf

top bar and the lowest obstruction in NOTE!For hydraulic elevators, prevent
the headroom when the counterweight
upwards movement before working
is on the buffer or when the cylinder is
fully extended (hydraulic elevators) on car roof by disconnecting the up
would be less than 300 mm, direction solenoid.
temporarily increase the height of
counterweight buffer or use props.
5 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.

1065938.wmf

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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Installation Instruction

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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Installation Instruction

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) 1072100.wmf

KM50086979G01

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Installation Instruction

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.

1078746.wmf

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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 1013650.wmf

1063474.wmf

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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Installation Instruction

1 RECEIPT AND CONTROL OF MATERIAL

PHASE: 1
LOCATION: Unloading/storage area

1057961.wmf

1015363.wmf

Heading Page
1.1, Checking of packages 24
1.2, Transporting materials 24
1.3, Unloading materials 27

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1.1 Checking of packages

Step Action Note


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

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 Action Note


1 Ensure that all packages are intact. Take digital pictures of any damaged
components that need to be replaced.
2 Check that packages match the packing
list (quantities).
3 Store the material inside the machine Take the pit material box into the
room or a specifically designated pit.
storage place (refer to site survey). 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.

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Installation Instruction

C
E

60
m ax

C
A

E A

1070809.wmf

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Installation Instruction

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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Installation Instruction

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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Installation Instruction

2 PREPARATIONS OR

PHASE: 2
LOCATION: Shaft

Heading Page
2.1, Safety fences and signs 29
2.2, Checking the power sources 29
2.3, Checking safety gear operation and overspeed governor 30
2.4, Checking overtravels and safety spaces 31
2.5, Marking the sling and car position 32
2.6, Measuring travelling cable loop length 32
2.7, Checking the car and counterweight balancing 33
2.8, Preparing the access for the travelling cables and the shaft bundle 34
2.9, Installation of shaft lighting 35

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Installation Instruction

2.1 Safety fences and signs

Step Action Note


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

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 Action Note


1 Ensure that there are no energy For example lightning supply,
storage devices or alternative power emergency battery drive, backup power
supplies in the elevator under work. supply or emergency generator.
2 Always study the existing WARNING! The accuracy of the existing
documentation of the elevator carefully. documentation must be considered,
because the documentation may not
be up to date, if for example an old
installation was modified or
modernized.

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Installation Instruction

2.3 Checking safety gear operation and overspeed governor

If the overspeed governor is not OL35, refer to manufacturers 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 Action Note


1 Ensure that the overspeed governor
and safety gear operates correctly.
2 If TSS brake is delivered check that the TSS = Traction Sheave Shaft.
overspeed governor is electrically bi-
directional. Replace the overspeed
governor if necessary (for example
OL35).
3 Check that the overspeed governor
contact (A) is operational. A
Ensure manually that the tripping
direction is correct.

1080994.wmf

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Installation Instruction

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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Installation Instruction

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 Action Note


1 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.

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 Check the best place for the positioning The travelling cable location may be
system (DZS). Refer to site survey. changed if necessary.

2.6 Measuring travelling cable loop length

NOTE! Take these measurements in case of machinery below.

Step Action Note


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

B
1066910.wmf

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Installation Instruction

2.7 Checking the car and counterweight balancing

Step Action Note


1 Load 50 % of the rated load into the The counterweight to be balanced to
car. empty car weight + 50 % of the rated
load. In some old elevator installations
Check from the layout drawings which this figure may vary.
weight the elevator is balanced to. Most
of the elevators are balanced to 50 %.

1012226.wmf

2 Drive car and counterweight to the


same height in the elevator shaft.

1041126.wmf

3 Open the brake and check the traction The car should not move if car and
sheave to see if the car moves. counterweight are at same level.
4 Drive the car a little upwards.

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Installation Instruction

Step Action Note


5 Open the brake for a few seconds and The car should not move.
check the traction sheave to see if the
car moves.
6 Do the same in the other direction.
7 If the counterweight is not balanced to The method must be planned in design
empty car weight + 50 %, plan how to phase or by supervisor.
correct the balance before the end of
the motor/drive commissioning.
8 Remove the test weights from the car.

2.8 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 Machinery above


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

1057965.wmf
1057966.wmf

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Installation Instruction

Step Action Note


1 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.
2 If necessary, enlarge the access. (See SWITCH THE POWER OFF.
picture above, machinery below/ Use dust mask, gloves and goggles.
above).

3 Remember to place a plastic container SWITCH THE POWER ON.


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

2.9 Installation of shaft lighting

Step Action Note


1 If there are drive buttons at the car roof, For more information, see section 8,
install the shaft lighting at this phase. Installation of shaft lighting.
2 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. 1069951.wmf

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Installation Instruction

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 Page
3.1, Installing travelling cable: Machinery below 37
3.2, Installing travelling cables: Machinery above 41
3.3, Dismantling old car equipment 44
3.4, Installing car top connection box and inspection drive unit 45
3.5, Routing cables to car top connection box 45
3.6, Connecting the travelling cable in the car top connection box 47
3.7, Temporary wiring of car top connection box 48
3.8, Fixing sensor unit to car roof 49
3.9, Installing the wire hanger and limit switch in top of the shaft 50

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Installation Instruction

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.

3.1.1 At the middle of the elevator shaft

Step Action Note


1 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 1.
positions. 1.

500
The final fixing (1).
The temporary fixing (2)
about 500 mm lower. 2.
500

2.

1048542.wmf

2 Check that the text on the cable faces


the elevator shaft wall.

1048543.wmf

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Installation Instruction

Step Action Note


3 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.

1060605.wmf

4 Repeat step 3 for the second travelling


cable if delivered.
Fix the travelling cable first to the 2
temporary fixing (1) and then to the final
fixing (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) For dimensions A, B and C see section


of travelling cable needed for the loop 2.6, Measuring travelling cable loop
and up to the car top connection box. length.

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Installation Instruction

Step Action Note


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

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 Action Note


1 Remove the temporary fixing.

1048554.wmf

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Installation Instruction

3.1.3 Passing the travelling cables to the machine room

Step Action Note


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

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.

Pass spare length of cables back into 1060708.wmf

the pit. Place the spare shaft bundle


into the trunking.
3 Fix the travelling cables to the wall in
the pit.

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Installation Instruction

3.2 Installing travelling cables: Machinery above

Step Action Note


1 Position the car so that there is access
to the car roof from the topmost
landing.
2 Install the travelling cable hanger at the
top of the elevator shaft.
NOTE!Ensure that the position of the
travelling cable hanger is at a
straight angle relative to the car top. 1039502.wmf

3 Check the distance L between final


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

1039343.wmf

4 Fix all the travelling cables provided to


the new fixing. xx
xx
NOTE! Check that the text on the cable
faces the elevator shaft wall.

1039344.wmf

5 Fix the pull rope to the machine room


end (plug marking XC) of the travelling
cable.

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Installation Instruction

Step Action Note


6 In the machine room:

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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Installation Instruction

Step Action Note


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

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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Installation Instruction

3.3 Dismantling old car equipment

Step Action Note


1 Park the car so that you have access to Car roof approximately 0.8 m above the
the car roof from the topmost landing. topmost landing level.
2 Ensure the adequate lighting at the car Additional lighting may be needed if the
roof for installation purposes. Connect main switch switches OFF also the car
the lighting to socket at machine room if top and shaft lighting or the old elevator
necessary. does not have lighting at all.
3 Switch the mains power OFF.
Lock and tag the switch.

Isolate the car light supply. This may be


separate.
4 Verify de-energisation of mains supply
0V
and lighting supply (if separate).

1070189.wmf

5 Check the strength of the car roof. Refer to site survey.


Temporarily support the car roof, if
necessary.
6 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.

1060242.wmf

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Installation Instruction

3.4 Installing car top connection box and inspection drive unit

Step Action Note


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

The best place to fix car top connection


box is above the travelling cable.

1 = Advised position of the inspection 1


drive unit
2 = Possible positions of the car top
connection box
3 = Travelling cable
2 Fix a piece of plastic trunking close to
the car top connection box. Place extra 2
3
length of the cables to the trunking. 1067459.wmf

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

3.5 Routing cables to car top connection box

Step Action Note


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

1074431.wmf

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Installation Instruction

Step Action Note


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

1080342.wmf

3 Fix the cables with cable ties. Leave Note the cable earthing points.
approximately 10 cm cable ends after
cable ties.

XB9 + XB13
+

1074433.wmf

4 Fix the end plate.


5 Fix the DIN rail with the boards.
6 Connect the cables.
7 Close the car top connection box.

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Installation Instruction

3.6 Connecting the travelling cable in the car top connection box

Step Action Illustration


1 Fix the travelling cable inside the box.
2 Connect travelling cable:
XT1 on KCECCG board XT1
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 PE
this phase. 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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Installation Instruction

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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Installation Instruction

3.8 Fixing sensor unit to car roof

Step Action Note


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

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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Installation Instruction

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

3.9.1 Preparations

Step Action Note


1 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.

X+100
This guarantees that the final limit
switch operates 100 mm above top
floor.

1069961.wmf

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Installation Instruction

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 Wall fixing

Recommended: >30 40 >70 >110 >70

Distance between the


positioning magnet and car
is minimum 70 mm.

Additional fixings per 16 m


intervals.
>140 >180
1080378.wmf 1080379.wmf

Distance between the >30 40 >15 >110 >15


positioning magnet and car <70 <70
is > 15 mm and < 70 mm.

An additional intermediate
fixing at each floor is
required.

>85 >125
1080380.wmf 1080382.wmf

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Installation Instruction

Step Action Note


1 Fix the upper guide rail fixing or wall
fixing so that the lower edge of the
fixing is at the marked height (*).
2 Fix the piano wire fixing bracket and T- Ensure that there will be room to fix the
bolts. Select correct fixing holes service limit ramp (if any) later. For more
according to site survey / layout information, see section 4, Installing top
drawings / delivery documents. service limit ramp (optional).
Hanger fixed on the guide rail:
Pre-assemble the hanger on the car roof.

*
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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Installation Instruction

Step Action Note


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

1072281.wmf

4 Slide the C-profile ramp to T-bolts. All the magnets must be placed so that
5 Fix security bolt to top of the ramp. the Kone logo is at the top end of the
6 Place the topmost floor magnet 130:U magnet.
to bottom end of the ramp.
C-profile must not be visible below or
7 Place top final limit magnet(s) 151:U
between the magnets. This might cause
above the top floor magnet so that
errors in positioning.
there is no gap in between.
Each magnet has its own ID.
When counterweight is on fully
compressed buffer, sensor must read
magnet. Place all the delivered final
limit magnets to create a ramp.

151:U

130:U
1070026.wmf

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Installation Instruction

Step Action Note


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

1071057.wmf

9 Align the sensor unit at the car roof


according to the magnets. Take
reference measurements from the A

B
guide rail.

The gap between the sensor unit and

B+15
magnet must be 15 5 mm.

A
1070027.wmf

10 Check the distance between the


magnet and sensor unit (X + 100 mm).
11 Turn the inspection drive unit on the car 1 = Normal, 2 = Inspection
roof 42:DS to NORMAL.
1 NORMAL I
N
S
2 NORMAL I
N
S
P P
E E
C C
T T
I I
O O
N N
1069822.wmf

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Installation Instruction

4 INSTALLING TOP SERVICE LIMIT RAMP (OPTIONAL)

PHASE: 7
LOCATION: Shaft

1072256.wmf

1015363.wmf

Heading Page
4.1, Installing top service limit ramp 56

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Installation Instruction

4.1 Installing top service limit ramp

Step Action Note


1 Assemble the service limit ramp if
necessary.

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.

There must be minimum 1.8 m space


left between the car roof and the
elevator shaft ceiling when the limit
switch operates.
3 Fix the guide rail bracket to the lower
end of the ramp.
4 Ensure that the ramp is correctly
aligned.

1070097.wmf

5 Check the operation of the service limit


switch.

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Installation Instruction

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 Page
5.1, Marking the wires in the old control panel 58
5.2, Removing old equipment 58

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Installation Instruction

5.1 Marking the wires in the old control panel

Step Action Illustration


1 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 5
Door earth wire = 5
4 2
3 1
2 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

5.2 Removing old equipment

Step Action Note


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

1015365.wmf

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Installation Instruction

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 Page
6.1, Position the control panel according to the site survey 60
6.2, Re-use / installation of trunking for travelling cable and elevator shaft wiring 63
6.3, Routing of wiring between controller panel and machinery 64
6.4, Snelis devices 64
6.5, Specific routing for V3F motor supply cable 65
6.6, Connecting the extension tool 66
6.7, Connecting travelling cable 67
6.8, Connecting machine room equipment 68
6.9, Installing and connecting power supply 75
6.10, Wiring other machine room equipment 79

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Installation Instruction

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 Action Note


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

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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Installation Instruction

Step Action Note


3 Keep the control panel door locked The weight of the KCE control panel is
when lifting or transporting it. 50 - 80 kg.
Lifting the control panel with chain hoist Two people lifting the control panel.
attached to lifting eye.

o
60
max

1070072.wmf 1070076.wmf

6.1.2 On the floor

Step Action Note


1 Mark and drill the control panel fixing Use hearing protection, dust mask,
holes to the floor. Use control panel gloves and goggles.
stand as drilling template.

For correct location refer to the site


survey and delivery documents.
2 Fix the stand to the control panel.
3 Tilt the control panel to the upright
position.
4 Lift and fix the control panel to the floor.

Safety Gloves must be worn.

1
1067615.wmf

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Installation Instruction

6.1.3 On the wall

Step Action Note


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

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).

1070820.wmf

3 Drill a hole in the wall through the fixing


hole at bottom end of the panel. Fix
with screw.

1067627.wmf

4 Fix the stand (if any) to the control


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

1067641.wmf

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Installation Instruction

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

Step Action Illustration


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

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
1057978.wmf
metal floor in machine Use hearing protection, dust mask,
room, the elevator shaft wiring and gloves and goggles.
travelling cable must be placed at
least 0.5 m above the floor.
WARNING! Before starting the
installation in elevator shaft, the motor
cable shield must be connected to
earth.

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Installation Instruction

6.3 Routing of wiring between controller panel and machinery

Step Action Note


1 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.
2 Continue with the cables between the
control panel and the main power
supply.
3 Continue with the cables between the
control panel and the machinery. 1067643.wmf

4 Use metal trunking if the wiring runs on


the floor across machine room.

1015367.wmf

6.4 Snelis devices

Step Action Note


1 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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Installation Instruction

6.5 Specific routing for V3F motor supply cable

KCE 0
1

M
20 cm

1067711.wmf

Step Action Note


1 Route V3F 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.
2 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.
CAUTION! If the motor has plastic 1058144.wmf

junction box, connect the cable shield


directly to earth terminal.
3 Pass V3F motor cable through the sprung cable clamp in the control panel. Ensure
that the braided shield comes into contact with the clamp.

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Installation Instruction

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
XH1
B

122
XH1

1
12
PE
1070087.wmf

A = New controller; B = Old controller

Step Action Note


1 Connect the extension tool plug to the connector XH1 on the KCEMSC board and
earth wire to PE bar.
2 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
3 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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Installation Instruction

6.7 Connecting travelling cable


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

Step Action Note


1 Connect the travelling cable plugs to Connect shield of serial transmission
the KCE control panel: twisted pairs to ground by fixing
XC1 on KCECPU board clamp* on back plate of control
XC3 to connector below cabinet.
KCECPU board
XT20 to connector below
KCECPU board (in case of
alternative travelling cable)

XC1
XC3

XT20
*

1070085.wmf

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Installation Instruction

6.8 Connecting machine room equipment

6.8.1 Connecting stop button and overspeed governor

XM1

XOSG1

1
PE1

1067688.wmf

1. = Stop button
2. = Overspeed governor

Step Action Note


WARNING! Ensure that the
power is switched off at the
main switch.
1 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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Installation Instruction

6.8.2 Installing machine room lighting (LMR, optional)

Step Action Note


1 Install the machine room lighting unit if
applicable.
XH157

If machine room > 12 m2, two lighting XH157/1
units are used.
XH157/2
2 Connect the machine room lighting to
adapter cable (XH157/2).
3 Connect the adapter cable (XH157) to
the control panel.

NOTE! The shaft lighting will be


1077365.wmf
connected to the adapter cable
(XH157/1) later.

6.8.3 Using spring loaded terminal

Step Action Note


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

1074458.wmf

1070972.wmf

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Installation Instruction

6.8.4 Connecting machinery V3F

A = Motor V3F
B = Fan XMF/
C = Brake 1, 2, 3, 4, 5
D = EMC clamp XBR/+, -
PE

Refer to the old and


new elevator circuit D
diagrams and
component instructions. A
C
B 1067708.wmf

Component connections Control panel connections


1 Motor V3F:
Phase 1 terminal U
Phase 2 terminal V
Phase 3 terminal W
Earthing (green/yellow) terminal PE
10 Fan (1 phase):
Controlled phase terminal XMF/1
Continuous phase terminal XMF/2
Neutral terminal XMF/3
Earthing (green/yellow) terminal PE
10 Fan (2 or 3 phase):
Controlled phases terminal XMF/1
terminal XMF/2
terminal XMF/3
Thermal contact terminal XMF/4
terminal XMF/5
Earthing (green/yellow) terminal PE
11 Brake:
Brake wire (+) terminal XBR/+
Brake wire (-) terminal XBR/-
Earthing (green/yellow) terminal PE

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Installation Instruction

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 THD filter (pre-wired) Control panel


Mains cable 1 Mains cable 2
1U1 1U1 1U2 1U2
1V1 1V1 1V2 1V2
1W1 1W1 1W2 1W2
PE PE

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Installation Instruction

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 Control panel


Mains power supply cable 1L1
1L2
Connection to MAS-M must be done according to section 6.9.2, 1L3
Connecting power supply cables to control panel (new cables)
1N1
obeying the safety rules!
PE
Lighting supply cable 2L1
2N1
PE

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Installation Instruction

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 XMF/
C = Brake 1, 2, 3, 4, 5
D = EMC clamp XBR/+, -
PE

Refer to the old and


new elevator circuit D
diagrams and
component instructions. A
C
B 1067708.wmf

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Installation Instruction

Component connections A Control panel connections B


1 Motor:
terminal U
terminal V
terminal W
terminal PE
10 Fan (1 phase):
Controlled phase terminal XMF/1
Continuous phase terminal XMF/2
Neutral terminal XMF/3
Earthing (green/yellow) terminal PE
10 Fan (2 or 3 phase):
Controlled phases terminal XMF/1
terminal XMF/2
terminal XMF/3
Thermal contact terminal XMF/4
terminal XMF/5
Earthing (green/yellow) terminal PE
11 Brake:
Brake wire (+) terminal XBR/+
Brake wire (-) terminal XBR/-
Earthing (green/yellow) terminal PE

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Installation Instruction

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 Action Illustration


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

2 Switch the mains power OFF.


Lock and tag the switch.

Isolate the lighting supply. This may be


separate.
3 Verify de-energisation of mains supply
0V
and lighting supply (if separate).

1070189.wmf

4 Install the new main power supply and


power supply for car light.

6.9.2 Connecting power supply cables to control panel (new cables)

Table 1: Safety precautions.


Step Action Note
1 Switch the mains power OFF.
Lock and tag the switch.
Isolate the lighting supply. This may be
separate.
2 Verify de-energisation of mains supply
0V
and lighting supply (if separate).

1070189.wmf

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Installation Instruction

Table 2: Connection.

1L1 1L2 1L3 1N1 PE

2L1 2N1 PE
1070323.wmf

Step Action Note


1 Connect the mains supply cable: Label on cable: 20
L1 (brown) to 1L1 When MAS-M is used, the THD filter
L2 (black) to 1L2 connection must be done before the
L3 (grey) to 1L3 mains supply connection.
N (blue) to 1N1 The connection may have already been
PE (green/yellow) to PE prepared in section 6.8.6, check the THD
filter connection at this stage.
2 Connect the lighting supply cable Label on cable: 20:1
(3x1.5 mm2):
L (brown) to 2L1
N (blue) to 2N1
PE (green/yellow) to PE
3 Connect the additional earth wire (if With adjustable speed drive systems
required) from PE to PE. 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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Installation Instruction

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

Step Action Note


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

Isolate the lighting supply. This may be


separate.
2 Verify de-energisation of mains supply
0V
and lighting supply (if separate).

1070189.wmf

3 Connect the mains supply cable: The THD filter connection must be done
L1 (brown) to Q20/1 before the mains supply connection.
L2 (black) to Q20/3 The connection may have already been
L3 (grey) to Q20/5 prepared in section 6.8.6, check the THD
N (blue) to N filter connection at this stage.
PE (green/yellow) to PE
4 Connect the lighting supply cable
(3x1.5 mm2):
L (brown) to Q29/1
N (blue) to Q29/3
PE (green/yellow) to PE

6.9.4 Connecting power supply cables to control panel (old cables)

Table 3: Safety precautions.


Step Action Note
1 Switch the mains power OFF.
Lock and tag the switch.

Isolate the lighting supply. This may be


separate.
2 Verify de-energisation of mains supply
0V
and lighting supply (if separate).

1070189.wmf

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Installation Instruction

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

1L1 1L2 1L3 1N1 PE

2L1 2N1 PE
1070323.wmf

Step Action Note


1 Mark each wire of the different functions (see table).
Refer to the elevator circuit diagrams.
2 Identify each wire by numbered marking bands and register this number in the
space corresponding (column A) to the function found.
3 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 A Control panel terminal B


Mains supply cable: Phase 1 1L1
Phase 2 1L2
Phase 3 1L3
Neutral 1N1
Earth PE
Lighting supply cable: Phase 2L1
Neutral 2N1
Earth PE
Lighting supply cable Phase 2L1
(in case of 230 VAC Phase 2N1
mains supply): Earth PE
Additional PE wire Earth PE
(if required)

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Installation Instruction

6.10 Wiring other machine room equipment

Step Action Note


1 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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Installation Instruction

7 COMMISSIONING FOR SERVICE SPEED

PHASE: 6 STOP TESTS SPEED m/s


0.6
SB-COMM
RUN
0.3 DZI SB-1

LOCATION: Machine room, car roof OFF


261
0.02
0.02 SB-2

zone
Unlocking
0.3
263 0.6 SB-3

STOP TEST SB-4

INSPECTION CALLS TESTS

NORM UP TOP CALL SETUP

RUN BOOST

INSP

BOTTOM OSG
DOWN
CALL

TERMINAL STOP BYPASS FAULTS


Self check
ETS Bypass Overspeed RESET

NTS Bypass SELECT Unintended movement


Normal Decel Run time limiter
Bypass
Safety chain open

PENDANT
SERVICE
REMOTE
Use jumpers SB-1 to SB-4 for safety chain bypass

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 )

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 Page
7.1, Safety measures 81
7.2, Preparations before turning the power on 81
7.3, Reset button at KMI (KONE Maintenance Interface) 83
7.4, Example of setting parameters 84
7.5, Checking of inverter parameters 86
7.6, Non-rotational autotuning of K1000 drive 87
7.7, Driving the elevator for the first time 89
7.8, Preparation for driving the elevator on the car roof 90

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Installation Instruction

7.1 Safety measures

The following safety items must be carried out before starting actual work:
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.

7.2 Preparations before turning the power on

Ensure that the elevator is balanced to 50%.

7.2.1 On the car roof

Step Action Note


1 ENSURE THAT THE POWER SUPPLY
IS SWITCHED OFF.
2 Check that the inspection drive unit on 1 = Normal, 2 = Inspection
the car roof in switched to normal.
1 NORMAL I
N
S
2 NORMAL I
N
S
P P
E E
C C
T T
I I
O O
N N
1069822.wmf

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Installation Instruction

7.2.2 In machine room

Step Action Illustration


1 Turn the elevator to RDF drive STOP TESTS

RUN

(INSPECTION switch to low position). OFF


261

2 Ensure that the STOP switch is set to STOP TEST


263

run. The STOP LED must not be lit. INSPECTION

NORM UP
CALLS

TOP CALL

RUN

INSP
1069929.wmf

3 Open the cover of the drive unit.


Verify the setting of the jumpers.
LO
ESC
RE

RESET ENTER

RUN STOP

1070101.wmf

4 SWITCH THE POWER ON from control


panel or external main switch unit. 1

Q220 0

1069933.wmf

5 Check the status of the LEDs and


display at the drive unit:
bb blinking on display
ALM LED blinking
LO
ESC
RE

RESET ENTER

RUN STOP
1069826.wmf

6 Only the INSP LED at the KMI should If the elevator is on the door zone the
be lit. Unlocking zone LED is lit.

NOTE! Ensure that the safety chain is


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

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Installation Instruction

7.3 Reset button at KMI (KONE Maintenance Interface)

Step Action Note


1 Turn test switch to position 263 and TESTS

push the Reset button at KMI if any of


OFF
the LEDs beside the reset button is lit. 261
263

TEST
1069941.wmf
1069633.wmf

Reset button does not work if KCEMSC KCEMSC may go to Safe Mode if the
is in the Safe Mode. elevator has been in fault more than 10
hours.
Make a power break (both 24 V and
battery) for KCEMSC. Fault code 1175 appears on display.
Push the Reset button within 10
minutes after power break.

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Installation Instruction

7.4 Example of setting parameters

The following example explains how to set the parameter A1-02 value to 2.

Step Action Display


1 At the beginning bb is blinking on
display.
1069865.wmf

2 Press the key until PAr



appears on display. 1069864.wmf

3 Press the key to view the


ENTER
parameter setting display. 1069866.wmf

4 Press the key until 01 is


RESET
blinking on the display. 1069867.wmf

5 Press the key until A1-02



appears on display. 1069868.wmf

6 Press the key to view the


ENTER
current parameter value. 1069869.wmf

7 Press the key until the digit to


RESET
be changed is blinking on the display. 1069870.wmf

8 Press the key until 2



appears on display. 1069871.wmf

9 Press the key to confirm the


ENTER
change. End blinks on display. 1069872.wmf

10 The display automatically returns to


show A1-02.
1069868.wmf

11 Press the key until F0.00


ESC

appears on the display. 1071663.wmf

Otherwise the elevator will not run.


12 bb starts blinking on display after a
while if any buttons are not pressed.
1069865.wmf

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Installation Instruction

7.4.1 Menu structure for digital LED operator

Description of Key Operations

:
Turn the power on

*
*Pressing RUN will start the motor.

Forward Selection Reverse Selection


:
DRV light is on.

:
Output Frequency

Output Current

Note: XX characters are shown in this manual.


The drive will display the actual setting values.
Output Voltage

XX
Monitor Display

XX

XX XX XX
Verify Menu
*Drive cannot operate the motor.

XX XX XX
DRV light is off.

XX
Set Up Mode

XX XX XX

XX
Parameter Setting Mode

XX

Auto-Tuning

XX

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Installation Instruction

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 Action Note


Set the following parameters:
1 Control method selection (A1-02) Value 2 = Open loop vector control
parameter to 2.
2 MA-19-20 Terminal function Value 61 = KCE Controller
selection (H2-01) parameter to 61.
3 Inverter input voltage (E1-01) (Volt) According to main supply voltage.
parameter.
4 Inverter input current (E2-01) (A) Refer to machine data plate.
parameter.
5 KONE control selection (D1-18) Value 11 = KCE Controller
parameter to 11.
6 Nominal speed (D1-01) parameter. (Hz) Refer to machine data plate
(50 or 33).
7 Inspection drive speed (D1-02) (Hz) 15 corresponds 0.3 m/s if nominal
parameter to 15. speed is 1 m/s and D1-01 is 50 Hz.
8 Correction drive speed / Inspection (Hz)
slow speed (D1-04) parameter.
9 Levelling speed (D1-17) parameter (Hz)
to 4.
10 Acceleration time (C1-01) parameter (s) See table below.
11 Deceleration time (C1-02) parameter
12 Press the key until F0.00
ESC

appears on the display. 1071663.wmf

Otherwise the elevator will not run.

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Installation Instruction

Acceleration / deceleration time (C1-01 / C1-02)


Speed (m/s) 0.3 0.4 0.5 0.63 0.7 0.8 0.9 1.0
Light flywheel 0.6 0.8 0.9 1.0 1.2 1.4 1.4 1.5
Medium flywheel 0.9 1.1 1.2 1.3 1.5 1.6 1.7 1.8
Heavy flywheel 1.2 1.3 1.4 1.6 1.8 1.9 2.0 2.1

7.6 Non-rotational autotuning of K1000 drive

Step Action Note


1 Press the key until ATun

appears on display. 1071358.wmf

2 Press the key to view the autotuning parameter setting display.


ENTER
3 Set the parameter T1-01 value to 01 to perform Stationary Auto-Tuning.
4 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

1071383.wmf
appears on display.

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Installation Instruction

Step Action Note


6 Press simultaneously RUN and UP (or INSPECTION CALLS

UP TOP CALL

RUN and DOWN) RDF buttons on KMI. NORM

Wait until the main contactor energise INSP


RUN

(contactor makes clank sound). DOWN


BOTTOM
CALL
1069937.wmf
Press the key on the drive
RUN

Keep the RDF buttons pressed down
unit once. Tun11 is blinking on the
until the whole autotuning procedure is
display and the green light on the RUN
over.
key is lit.
7 When END appears on the display, If something else than END appears on
release the RDF buttons. the display (for example END1), the
autotuning did not succeed. Refer to
V3F10 fault codes 878327.Correct the
problem and repeat non-rotational
autotuning.
8 Press the key until F0.00
ESC

appears on the display. 1071663.wmf

Otherwise the elevator will not run.

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Installation Instruction

7.7 Driving the elevator for the first time

Step Action Note


1 If there is a retiring ramp, block it
mechanically.
2 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.
3 Ensure that the elevator is on RDF
mode.
4 Check the safety chain using KONE For more information, see KONE fault
KMI (KONE Maintenance Interface). code list 958174D02.
5 Check motor rotation direction in RDF INSPECTION CALLS

UP TOP CALL

mode. NORM

Push simultaneously RUN and INSP


RUN

DOWN buttons to drive the car DOWN


BOTTOM
CALL
1069938.wmf
downwards a short distance only.
Observe the rotation direction.
6 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.
7 Check visually the rotation of motor and If necessary, adjust the brake
operation of brake. mechanically. Check also that the brake
voltage is correct. Measures between
terminals XBR/+ and XBR/-.
8 If there is a stop button in machine
room, test it.

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Installation Instruction

7.8 Preparation for driving the elevator on the car roof

7.8.1 First: on the machine room

Step Action Illustration


1 Switch ON:
Switch 290:1 (car lighting) 1

Switch 290:2 (socket in the pit and 0

shaft lighting)
1069939.wmf

7.8.2 Second: on the car roof

Step Action Illustration


1 Turn the inspection drive unit on the car 1 = Normal; 2 = Inspection
roof 42:DS to INSPECTION.
1 NORMAL I
N
S
2 NORMAL I
N
S
P P
E E
C C
T T
I I
O O
N N
1069822.wmf

2 Check the socket power and earthing


on the car top connection box using
multimeter.

1074482.wmf

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Installation Instruction

7.8.3 Third: on the car roof

Step Action Note


1 Push the stop button on the inspection
drive unit.
2 Try to drive the car to both down and up The elevator must not drive.
directions.
3 Release the stop button.
4 Try to drive the car to both down and up The elevator should drive.
directions.
5 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.
6 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.

7.8.4 If the elevator will not run check following

Step Action Note


1 If the car can not run in up direction,
check the state of the inspection drive
limit switch 68:U.
2 If there is a retiring ramp, block it
mechanically.
3 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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Installation Instruction

8 INSTALLATION OF SHAFT LIGHTING

PHASE: 8
LOCATION: Shaft

1072258.wmf

1015363.wmf

Heading Page
8.1, Installing elevator shaft lighting, if applicable (PT) 93
8.2, Installing elevator shaft lighting, if applicable (PU) 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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Installation Instruction

8.1 Installing elevator shaft lighting, if applicable (PT)

Step Action Note


1 Fix the first light fitting to the elevator

max. 0.5m
shaft wall so that:
top of the light fitting is max. 0.5 m
below the slab.
2 Plug the cable on the light fitting.
Tie the elevator shaft lighting cable to

X
the pull rope.
3 Continue by installing the other light
fittings. Refer to layout drawings.
Lower the last light fitting to the bottom
of the pit.

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

max. 0.5m
1079689.wmf

5 Make an adapter wire between the


lighting unit and socket.

Molex 1 - phase (black)


Molex 2 - neutral (blue)
Molex 5 - earth (green / yellow)
6 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. 1069949.wmf

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Installation Instruction

8.2 Installing elevator shaft lighting, if applicable (PU)

Step Action Note


1 On the car roof:

max. 0.5m
Place elevator shaft lighting equipment
on the car roof.
2 Fix the first light fitting so that:
top of the light fitting is max. 0.5 m
below the slab.

X
3 Plug the cable to the light fitting.
Continue by installing the other lights.
Use the car as a working platform.

X = 6 m for standard lighting


X = 3 m for slim lighting

X
4 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).
X

5 Pass the cable into machine room with


help of a pull rope if necessary.

max. 0.5m

1079689.wmf

6 Make an adapter wire between the


lighting unit and socket.

Molex 1 - phase (black)


Molex 2 -neutral (blue)
Molex 5 - earth (green / yellow)
7 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. 1069951.wmf

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Installation Instruction

9 REMOVING OLD ELEVATOR SHAFT EQUIPMENT

PHASE: 9
LOCATION: Shaft

Remove all old elevator shaft material, except the old shaft bundle.

Heading Page
9.1, Removing of old levelling system 96
9.2, Remove old limits and floor switches 96
9.3, Remove landing bands / support wires 97
9.4, Removing old travelling cable 98

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

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Installation Instruction

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 Action Illustration


1 Position the car at a convenient working Ensure that the inspection drive unit on
height. the car roof operates correctly.
PUSH THE STOP Use harness,
BUTTON helmet and
gloves.
2 Cut the switch wires to the old elevator shaft wiring.
3 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).
RELEASE THE STOP BUTTON
4 Continue as above, level by level.

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Installation Instruction

9.3 Remove landing bands / support wires

Step Action Illustration


1 Use
harness,
helmet and
gloves.
Dismantle, if existing, the intermediate
fixing of the Landing bands.
2 In the pit remove all the lower fixings of
the Landing bands.
3 Position the car to have access to the
upper support of the Landing bands.

PUSH THE STOP


BUTTON DOWN

4 At the upper support, remove 1 Landing Use harness,


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

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Installation Instruction

9.4 Removing old travelling cable

Step Action Illustration


1 Use At the top of the shaft.
harness, Or at the middle of elevator shaft if a
helmet and halfway box exists
gloves.

Position the car at a safe working height


just below the old travelling cable
support.
PUSH THE STOP
BUTTON

1015432.wmf

2 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.
3 Repeat for the other travelling cables.
4 RELEASE THE STOP BUTTON
Position the car to access to the
travelling cable fixing.
PUSH THE STOP
BUTTON

1039604.wmf

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Installation Instruction

Step Action Illustration


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

1058200.wmf

7 RELEASE THE STOP BUTTON The old travelling cables may be


temporarily stored in car.

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Installation Instruction

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 Page
10.1, Hanging the wires at top of the shaft 101
10.2, Fixing the wires in the pit 102
10.3, Installing bottom service limit ramp (optional) 105
10.4, Installing positioning magnets 106

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Installation Instruction

10.1 Hanging the wires at top of the shaft

Step Action Note


1 PUSH THE STOP
BUTTON

2 Fix a weight (for example a spanner) to


the piano wire.
3 Unwind the piano wire until the weight
touches the pit floor.

1070121.wmf

4 Cut the wire, route and secure it in


position.

CAUTION! Be careful not to bend the


wire.
5 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 Secure the piano wires to the bracket


with cable ties.
7 RELEASE THE STOP BUTTON

1070824.wmf

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Installation Instruction

10.2 Fixing the wires in the pit

Step Action Note


1 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.
2 Mark the door zone sensor level to the
guide rail.

1070152.wmf

3 Drive the car down to the buffer.


4 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.
5 Fix the piano wire fixing bracket.
6 Hand tighten the piano wire and cut it to correct length. Leave approximately
150 mm free end below fixing bracket.
7 Route and fix the wire end to the tensioning device (1). Leave the wire hand tight.
8 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.

1
300

1067779.wmf

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Installation Instruction

Step Action Note


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

L
f
tables.

1067780.wmf

Fixing distance L (m) Wire extension f (mm) Wire extension f (mm)


F=200N F=300N
8 15 22
10 19 28
12 23 33
14 27 39
16 31 45
18 34 50
20 38 56
22 42 61
24 46 67
26 50 73
28 53 78
30 57 84
32 61 90
34 65 95
36 69 100
38 72 105
40 76 110
42 80 115
44 84 120
45 86 125

Guide rail Permitted tensioning F


70/49/16, 70/53/16, 89/62/15.9, (70/70/8) 200N
(90/65/14), 125/82/16, 125/89/15.9 300N

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Installation Instruction

Step Action Note


11 One or two final limit magnets: Three or more final limit magnets:
Make an opening* to the ramp. Do not make an opening to the ramp.
12 One or two final limit magnets: All the magnets must be placed so that
Place the lowest floor magnet 130:N the Kone logo is at the top end of the
just below the opening* in the ramp. magnet.

Three or more final limit magnets: C-profile must not be visible above or
Place the lowest floor magnet 130:N to between the magnets. This might cause
the top edge of the ramp. errors in positioning.
13 Place bottom final limit magnets 151:N
below the lowest floor magnet so that Each magnet has its own ID.
there is no gap in between.

When car is on fully compressed buffer,


sensor must read magnet. Place all the
delivered final limit magnets to create a
ramp.
14 Fix security bolt to top end of the ramp.
15 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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Installation Instruction

10.3 Installing bottom service limit ramp (optional)

Step Action Note


1 Assemble the service limit ramp if
necessary.

1070100.wmf

2 Fix the ramp to bottom guide rail


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

1070154.wmf

5 Check the operation of the service limit


switch.

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Installation Instruction

10.4 Installing positioning magnets

Step Action Illustration


1 Fix the lowest floor deceleration For LD refer to the following table.
magnet 136:N to the piano wires.

All the magnets must be placed so that


the Kone logo is at the top end of the 136:N
magnet.

LD
NOTE! Minimum distance between
floors is 2600 mm (136 must be 130:N
positioned maximum 1000 mm from 151:N
door zone and minimum distance
between magnets is 400 mm).
1070294.wmf

2 Drive the car to the next floor. Locate


the car exactly at the floor level 131:N
according to the marking made at the
beginning of the installation.
LD

3 Mark the door zone sensor (centre line)


level to the shaft wall or to the guide
rail. 130
4 Drive the car downwards. Fix the door
positioning magnet 130 to the piano
LD

wires.
5 Fix the deceleration magnets 131:U
and 131:N to the piano wires. 131:U
For LD refer to the following table. 1070183.wmf

6 Continue installing the positioning and


deceleration magnets at each floor 131:U
while driving to top of the elevator shaft.
=
>3.6m

NOTE! With long to floor distance: 138


If the distance between the 131:U
=

and 131:N deceleration magnets is


more than 3.6 m, install position
131:N
reference magnet 138 between the
deceleration magnets. 130
131:U 1080305.wmf

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Installation Instruction

Step Action Illustration


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

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.

For LD refer to the following table. 151:U


130:U
LD

136:U

1070292.wmf

Deceleration distance LD (mm)


Speed (m/s) Light flywheel Heavy flywheel
0.50 410 700
0.63 540 800
0.70 660 950
0.80 800 1100
1.00 1100 -

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Installation Instruction

11 INSTALLATION OF SHAFT BUNDLE

PHASE: 11
LOCATION: Shaft

1015363.wmf
1072268.wmf

Heading Page
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

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Installation Instruction

Principle of serial electrification Principle of parallel electrification

* *

FCB

FCB

FCB

1074490.wmf 1074491.wmf

*) Control panel in machine room

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Installation Instruction

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

Step Action Illustration


1 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.

1070829.wmf

2 Fix the first length of trunking on the WARNING! Ensure that the
elevator shaft side wall. inspection drive and stop
Find an optimum position as near as buttons on the car roof
possible to entry hole from machine
operate correctly.
room to elevator shaft and the existing
connection point of the door lock wiring. Use hearing
NOTE! If there is no car door, place the protection,
dust mask,
trunking so that it is possible to
harness,
install an automatic door later. helmet,
Fix each 2 meter piece of trunking with gloves and
3 or 4 fixings. goggles.

7 mm hole for soft concrete


8 mm hole for hard concrete

7
8

1039495.wmf

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Installation Instruction

Step Action Illustration


3 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.

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 p12


2
floor: 1
Door lock wiring (1.) 2
Wiring for landing call buttons (2.)
Indicator wiring (if any) (3.)
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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Installation Instruction

Step Action Illustration


7 Continue by installing simultaneously
the trunking, shaft bundle and branch
cables at each level.
8 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.

1058003.wmf

9 WARNING! PUSH DOWN Use hearing protection, dust mask,


THE STOP BUTTON ON gloves and goggles.
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.
10 Finish the trunking and shaft bundle
installation.

WARNING! In case of deep pit, use


working stool or scaffolds.

1072137.wmf

11 Fix the pit switch unit and the cables to Refer to the delivery documents / site
the wall. survey.
12 Connect the cables from the pit switch Switch unit:
unit to the shaft bundle.
2 1 = no
STOP BUTTON plug P112 elevator shaft
SOCKET plug XH157 lighting.
2 = elevator
1 shaft lighting
NOTE! The XH157 will be connected to
is applicable.
the lowest shaft light if elevator shaft
lighting is applicable.

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Installation Instruction

Step Action Illustration


13 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 1

3 2
2 2
1071033.wmf

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

1058058.wmf

15 Connect the overspeed governor 123:1 = overspeed governor tension


tension weight and/or buffer switch, if weight contact (car)
used. 123:2 = overspeed governor tension
Disconnect old wires from the weight contact (counterweight)
contact. 125:1 = buffer switch
Connect new cables in the 125:2 = buffer switch
contact.

123/125 123/125 123/125 123/125

123/125 123/125

1071034.wmf

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Installation Instruction

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 Action Note


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

Fix the cables and connect


them.

1058007.wmf

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Installation Instruction

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

Step Action Note


1 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.

1070829.wmf

2 Fix the first length of trunking. WARNING! Ensure that the


Place it to the side wall in top of the inspection drive and stop
elevator shaft. buttons on the car roof
operate correctly.
NOTE! If there is no car door, place the
Use hearing
trunking so that it is possible to install
protection,
an automatic door later. dust mask,
harness,
helmet,
gloves and
goggles.
Elevator with pulley room Elevator without pulley room

1058008.wmf 1058009.wmf

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Installation Instruction

11.2.3 Installing shaft bundle (serial, machinery below)

Step Action Note


1 WARNING! Ensure that the
inspection drive and stop
buttons on the car roof
operate correctly.
Use harness and
helmet.

Place the shaft


bundle in the trunking.

Place the first FCB board approximately


to the door lock level.

1. Stop switch 2
2. Overspeed governor 1 3
3. Door lock
4. Landing call (FCB) 4
5. Indicator (if existing)

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,
indicators, etc.) later in phase 14 (see section
12, Connecting landing doors locks and
1058012.wmf buttons).

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Installation Instruction

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

Step Action Note


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


1 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.
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.
3 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.
4 Fix the cables for the pit switch unit to
the wall.

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Installation Instruction

Step Action Note


5 Connect the cables from the pit switch Switch unit:
unit to the shaft bundle.
2 1 = no
STOP BUTTON plug P112 elevator shaft
SOCKET plug XH157 lighting.
2 = elevator
1 shaft lighting
NOTE! The XH157 will be connected to
is applicable.
the lowest shaft light if elevator shaft
lighting is applicable.

6 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 1

3 2
2 2
1071033.wmf

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

1058058.wmf

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Installation Instruction

Step Action Note


8 Connect the overspeed governor 123 = car overspeed governor tension
tension weight and/or buffer switch, if weight contact
used. 123 = counterweight overspeed
Disconnect old wires from the governor tension weight contact
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

11.3 Installation of shaft bundle and trunking (parallel, machinery above)

Step Action Illustration


1 Move the car to the top of shaft.
2 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.

1070829.wmf

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Installation Instruction

Step Action Illustration


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

7 mm hole for soft concrete


8 mm hole for hard concrete
7
WARNING! Ensure that the 8
inspection drive and stop
buttons on the car roof 1039495.wmf
operate correctly.
4 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.

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 mf

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Installation Instruction

Step Action Illustration


6 Route the branching of shaft wires in
plastic tubes to the door.
Fix the tubes to the shaft wall with the
delivered fixing clips.
NOTE! Wires will be connected later.
7 Continue by installing simultaneously
the trunking, shaft bundle and branch
wires in plastic tubes at each level. 1058002.wmf

8 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.
1058003.wmf

9 Go to the bottom of the pit. WARNING! Push down the stop button
Check that the shaft bundle will be free on the car roof.
to move and will not get damaged when
it is passed to the machine room.
10 Finish the trunking and shaft bundle
installation.

1072138.wmf

11 Cut the plug at the shaft bundle away and connect the wires to the new pit stop
button.
12 Route the new wires to the overspeed governor tension weight contact(s) and
buffer switche(s).
13 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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Installation Instruction

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 Action Illustration


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

Fix the cables and connect them.

1058007.wmf

11.4.2 In top of the shaft (parallel, machinery below)

Step Action Note


1 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.

1070829.wmf

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Installation Instruction

Step Action Note


2 Fix the first length of trunking. WARNING! Ensure that the
Place it to the side wall in top of the inspection drive and stop
elevator shaft. buttons on the car roof
operate correctly.
NOTE! If there is no car door, place the
Use hearing
trunking so that it is possible to install
protection,
an automatic door later. dust mask,
harness,
helmet,
gloves and
goggles.
Elevator with pulley room Elevator without pulley room

1058008.wmf 1058009.wmf

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Installation Instruction

11.4.3 Installing shaft bundle (parallel, machinery below)

Step Action Illustration


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

a10607bz.wmf

3 Fix the tubes to the shaft wall with the


delivered fixing clips.
Refer to the delivery documents for the
devices on each floor.
NOTE! Connect the wires later. See
section 12, Connecting landing doors
locks and buttons.

a10607vl.wmf

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Installation Instruction

11.4.4 Wiring pulley room devices (at the top of the shaft)

Step Action Illustration


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

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

Step Action Illustration


1 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.

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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Installation Instruction

11.5 Finalising new elevator shaft lighting (if included)

Step Action Note


1 Push the stop button down when
entering the pit.
2 Fix the last light of the elevator shaft

max 500 mm
lighting into vertical position as shown.

Use hearing protection, dust mask,


gloves and goggles.

1015277.wmf

3 Machine room above:


Connect the shaft lighting to the pit
switch unit.

P112

XH157 1070348.wmf

4 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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Installation Instruction

11.6 Finalising the travelling cable installation

Step Action Note


1 Position the car so that you have access WARNING! In case of deep pit, use
to the pit and reach to the car sling from working stool or scaffolds.
pit floor and car roof.
2 Remove the old travelling cable from
under the car.
3 Install the new travelling cable support
under car. 1 2
WARNING! Remember to
use safe access
procedures.

1015285.wmf

4 Measure the distance (II) between the


car and car buffer(s).
5 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. 400mm
Adjust the distance from the pit floor to
the bottom of the cable loop to 150 mm.
100mm
150mm
1010076-1.wmf

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Installation Instruction

Step Action Note


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

1027312.wmf

7 Route the travelling cable under the car.


8 Fasten excess length (if any) to the car
floor with cable ties.
9 Lower a pull rope from car roof below
the car.
10 Attach the pull rope to the end of the
new travelling cable and other cables
that may be located below the car, for 1040852.wmf
example load weighing device or safety
gear contact cables.

11.7 Re-connecting travelling cables, if necessary

Step Action Illustration


1 Switch the mains power OFF.
Isolate the lighting supply. This may be
separate.
2 Verify de-energisation of mains supply
0V
and lighting supply (if separate).

1070189.wmf

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Step Action Illustration


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

1039533.wmf

5 Fix the travelling cable inside the box.


6 Connect travelling cable to:
XT1 on KCECCG board XT1
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 PE
XT3
In case of 3PH car door or retiring ramp
connect the wires to terminal X49 and/ 1067599.wmf
or KCEREL board. Refer to circuit
diagrams.

11.8 Taking the shaft bundle to the machine room

Step Action Note


1 WARNING!Ensure that the
inspection drive and stop
buttons on the car roof
operate correctly.
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
be free to move and will not get 1058004.wmf

damaged while pulling up.


2 Go to the machine room and pull the shaft bundle up into the machine room.

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Installation Instruction

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

XH11
XH1

XH1

PE1

XH157
XH1

1071116.wmf

Step Action Note


1 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,
Do not connect parallel signalization KCEPIO and/or KCEOPT boards after
yet. connections at the shaft have been
Do not connect FRD, FID or OSS yet. done.

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Installation Instruction

12 CONNECTING LANDING DOORS LOCKS AND BUTTONS

PHASE: 12
LOCATION: Shaft

1
122 3
2 121
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 Page
12.1, Positioning of the car 132
12.2, Connection of landing door lock (serial) 133
12.3, Wiring of landing call buttons (serial) 135
12.4, Connection of landing door lock (parallel) 136
12.5, Wiring of indicators and optional landing devices (parallel) 144
12.6, Connecting shaft bundle (signalization) in to the control panel 154

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Installation Instruction

12.1 Positioning of the car

Step Action Note


1 Turn the elevator on inspection drive. Use harness, helmet and gloves.
2 Place the car so as to have access to
the landing.
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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Installation Instruction

12.2 Connection of landing door lock (serial)

Use harness, helmet and gloves.

12.2.1 Swing door

Step Action Note


1 PUSH THE STOP BUTTON.
Verify de-energisation of door lock
contacts.
0V

1070189.wmf

2 Disconnect the old door lock (122) and


contact (121) wires. Overconnect with 122
the terminals included in the delivery (at
new cables).

122

121
121 1058221.wmf
1058223.wmf

3 Door lock circuit 1 = Old elevator shaft wiring


Connect the cable n122 on the 2 = New elevator shaft wiring
contacts 3 = Green / yellow wires (G/Y)
Connect the wire G/Y on the earth
4 Door contact circuit
Connect the cable n121 on the
contacts
Connect the wire G/Y on the earth
5 Check that neither the new wires 1
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
or the movement of the car. 1058219.wmf

6 RELEASE THE STOP BUTTON.


7 Check that opening the landing door stops movement of the car.
8 Repeat for all landing doors. Lift the car up so that you can reach the
lowest level landing door lock.

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Installation Instruction

12.2.2 Automatic door

Step Action Note


1 PUSH THE STOP BUTTON.
Verify de-energisation of door lock
contacts.
0V

1070189.wmf

2 Disconnect the old door lock (122)


wires. Overconnect with the terminal 122
included in the delivery (at new cable).

122
1058224.wmf

1058222.wmf

3 Door lock circuit 1 = Old elevator shaft wiring


Connect the cable n122 on the 2 = New elevator shaft wiring
contacts 3 = Green / yellow wires (G/Y)
Connect the wire G/Y on the earth
4 Check that the new wires connected to
the lock and that the old shunted wires,
with terminal block, will not interfere with 1
the function of the door, or the
movement of the car. 3

2 122
1058225.wmf

5 RELEASE THE STOP BUTTON


6 Check that opening the landing door
stops movement of the car.
7 Repeat for all landing doors. Lift the car up so that you can reach the
lowest level landing door lock.

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Installation Instruction

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 Action Note


1 PUSH THE STOP BUTTON.

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

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

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Installation Instruction

12.4 Connection of landing door lock (parallel)

Use harness, helmet and gloves.

12.4.1 Swing door

Step Action Note


1 PUSH THE STOP BUTTON.
Verify de-energisation of door lock
contacts.
0V

1070189.wmf

2 Select the correct shaft wires. Refer to


the delivery documents for the color 122 bn
codes.
121 bn

G/Y
1070867.wmf

3 Disconnect the old door lock (122) and


contact (121) wires. Overconnect with
the terminals included in the delivery.
4 Door lock circuit: 1 = Old shaft wiring
Connect the wires on the 122 2 = New shaft wiring
contacts 3 = Green / yellow wires (G/Y)
Connect the wire G/Y on the earth
5 Door contact circuit:
Connect the wires on the 121
contacts
Connect the wire G/Y on the earth
6 Check that neither the new wires 1
connected to the lock nor the old
shunted wires with terminal block will 122 3
not interfere with the function of the door 2 121
nor the movement of the car. a10607br.wmf

7 RELEASE THE STOP BUTTON.


8 Check that opening the landing door
stops the movement of the car.
9 Repeat for all landing doors. Lift the car up so that you can reach the
lowest level landing door lock.

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Installation Instruction

12.4.2 Automatic door

Step Action Note


1 PUSH THE STOP BUTTON.
Verify de-energisation of door lock
contacts.
0V

1070189.wmf

2 Select the correct shaft wires. Refer to


the delivery documents for the color 122 bn
codes.
G/Y
1070868.wmf

3 Disconnect the old door lock (122)


wires. Overconnect with the terminal
included in the delivery.
4 Door lock circuit 1 = Old shaft wiring
Connect the wires on the 122 2 = New shaft wiring
contacts 3 = Green / yellow wires (G/Y)
Connect the wire G/Y on the earth
5 Check that neither the new wires
connected to the lock nor the old
shunted wires with terminal block will 1
not interfere with the function of the door
nor the movement of the car. 3

122
2
a10607bs.wmf

6 RELEASE THE STOP BUTTON


7 Check that opening the landing door
stops the movement of the car.
8 Repeat for all landing doors. Lift the car up so that you can reach the
lowest level landing door lock.

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Installation Instruction

12.4.3 Connection of PB or DC control with micromovement button

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color bk
codes.
rd
bk = black wire (- 24V indicator lamp,
common for calls) gy
1070871.wmf
rd = red wire (+ 24V indicator lamp)
gy = grey wire (direct call for the floor
level)
3 Connect the wires to the button and
indicator lamp terminals in the landing 102
call button.

bk
+24 V rd
102:n gy
1070870.wmf

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Installation Instruction

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

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color bk
codes.
rd
bk = black wire (- 24V indicator lamp,
common for calls) gy
1070871.wmf
rd = red wire (+ 24V indicator lamp)
gy = grey wire (direct call for the floor
level)
3 Connect the wires to the button and
indicator lamp terminals in the landing
call button.

bk
rd

gy 1070873.wmf

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Installation Instruction

12.4.5 Connection of PB or DC control with WMS button

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color bk
codes.
rd
bk = black wire (- 24V indicator lamp,
common for calls) gy
1070871.wmf
rd = red wire (+ 24V indicator lamp)
gy = grey wire (direct call for the floor
level)
3 Connect the wires to the button and
indicator lamp terminals in the landing
call button.

bk
rd
gr
1070875.wmf

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Installation Instruction

12.4.6 Connection of FC control with micromovement button

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color bk
codes.
rd
bk = black wire (common for calls)
rd = red wire (+ 24V indicator lamp) gy (103:n)
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)
3 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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KONE ReSolve 200
Installation Instruction

12.4.7 Connection of FC control with mechanical (Arnould) button

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color bk
codes.
rd
bk = black wire (common for calls)
rd = red wire (+ 24V indicator lamp) gy (103:n)
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)
3 Connect the wires to the button and
*
indicator lamp terminals in the landing
call button. 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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Installation Instruction

12.4.8 Connection of FC control with WMS button

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color bk
codes.
rd
bk = black wire (common for calls)
rd = red wire (+ 24V indicator lamp) gy (103:n)
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)
3 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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Installation Instruction

12.5 Wiring of indicators and optional landing devices (parallel)

Use harness and helmet.

Step Action Note


1 PUSH THE STOP BUTTON DOWN.
2 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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Installation Instruction

12.5.1 Connection of hall lantern in FC control

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color rd
codes.
gy (163)
rd = red wire gy (164)
gy (163) = grey wire 1070890.wmf

gy (164) = grey wire


3 Connect the wires to the landing hall lanterns and gong.
165 164

165 163

gy (164)
gy (163)

rd
1070896.wmf

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Installation Instruction

12.5.2 Connection of In use light in DC and FC control

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color
codes. rd
gy (161)
rd = red wire (common +24V) 1070897.wmf
gy (161) = grey wire (common for
indicators)
3 Connect the wires to the In use light.

gy (161)
rd
1070898.wmf

12.5.3 Connection of HSL with secondary door lock contact

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color rd
codes.

rd = red wire (+24V) bk 1077371.wmf

bk = black wire (ground)


3 Connect the wires to the HSL.

rd
bk
1077369.wmf

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Installation Instruction

12.5.4 Connection of direction arrows with micromovement device

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color rd
codes.
gy (173)
rd = red wire (common) gy (174)
gy (173) = grey wire (common down) 1070931.wmf
gy (174) = grey wire (common up)
3 Connect the wires to the direction
174
arrows.

X1

173

X1

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

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Installation Instruction

12.5.5 Connection of car here light

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color
103
codes. &
104
103 & 104 = wires for the landing call
buttons
rd = red wire (analog floor select signal) rd
gy = grey wire (HSL signal) gy 1070935.wmf

3 Connect the wires to the car here light.

104

rd

162

gy

103
1070936.wmf

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Installation Instruction

12.5.6 Connection of Out of service key switch (OSS)

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to gy = grey wire (OSS key output/signal)
the delivery documents for the color bk = black wire (ground)
codes.
If there is only one key switch: If there are more than one key switches:
gy gy

bk 1070937.wmf bk
1070938.wmf

3 Connect the wires to the out of service 116


key switch.

gy
bk 1070940.wmf

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Installation Instruction

12.5.7 Connection of floor indicators with lamps

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color
codes.
3 Connect the floor indicators.
176:1 176:T

164 1 2 11 12 163

gy(C1) 176:10

gy(E1) 176:12
gy(D1) 176:11
gy(A1) 176:8
gy(B1) 176:9
gy(G) 176:7
gy(C) 176:3
gy(D) 176:4

+24V
gy(A) 176:1
gy(B) 176:2

gy(E) 176:5
gy(F) 176:6

gy(164) 164
gy(163) 163
rd

1070943.wmf

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Installation Instruction

12.5.8 Connection of floor indicators with 7 segment displays

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color
codes.
3 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

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Installation Instruction

12.5.9 Connection of floor indicators with DOT matrix or 16 segment displays

Step Action Note


1 PUSH THE STOP BUTTON.

2 Select the correct shaft wires. Refer to


the delivery documents for the color
codes.
3 Connect wires to the display element:

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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Installation Instruction

12.5.10 Connection of floor indicators with WMS displays

Step Action Note


1 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
ST2/ red or green to ST1 (rd)
grey 18 ST2 (bl)
ST3 (gn)
The correct
alternatives of wire
rd gn

rd gn

rd gn

G Y

colors are depending


wh

wh

wh
ye

ye

ye
bl

bl

bl

on the manufacturing
time (before or after
01/1996)
1 2 3 4 5 6 - 17 18 G V
Do not leave any wires
unconnected.
Connect the free wires a10607ef.wmf
to spare terminals.

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Installation Instruction

12.6 Connecting shaft bundle (signalization) in to the control panel

X3
X2
X1 XS2
KCEPIO
X3
X2
X1

X1
X2
X5
KCEOPT
X1
X2
X5

1070324.wmf

Step Action Note


1 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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Installation Instruction

13 REMOVING THE OLD SHAFT BUNDLE

PHASE: 13
LOCATION: Machine room, shaft

Step Action Note


1 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 Ensure that the new safety circuit is


functioning properly:
Open a door and try to run the elevator.
The elevator must not move.
3 Remove the old shaft bundle from the
elevator shaft.
4 Fix the trunking covers to place.

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Installation Instruction

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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Installation Instruction

Heading Page
14.1, Dismantling old car equipment 158
14.2, Installation of door control box 159
14.3, Installation of parallel I/O box (only with parallel signalization) 160
14.4, Installation of ACU box 160
14.5, Wiring of car top connection box 161
14.6, Wiring of old car light 163
14.7, Wiring of old car fan 163
14.8, Wiring of ADV door operator (Isola 96, Athena 96, Renova 96) 164
14.9, Wiring of retiring ramp 168
14.10, Wiring of door inverter control 169
14.11, Wiring of contactor control door operator 171
14.12, Wiring of Starlift door operator 173
14.13, Wiring of ADF - ADX door operator 175
14.14, Wiring of AMD door operator (Drive 1, 1.5 and 2) 178
14.15, Wiring of DC2000 door control 182
14.16, Wiring of KOF230V, C-type door control 185
14.17, Wiring of ADT 3PH 125V door operator 187
14.18, Wiring of close command door operator 189
14.19, Wiring of FIAM B/S door operator 191
14.20, Wiring of Sabiem C door operator 193
14.21, Wiring of ACC 230V door operator 195
14.22, Wiring of general 24V electronic control door operator 197
14.23, Wiring of Selcom 1PH 220V automatic door operator 199
14.24, Wiring of no car door, EMO N, AT 201
14.25, Wiring of BOF unit for non-automatic doors 202
14.26, Wiring of new COP 203
14.27, Wiring of old COP and display (if any, parallel I/O module) 204
14.28, Connection of ACU, if applicable 207
14.29, Connection of KRM, KSS ReVive signalization 208
14.30, Connection of KRM, parallel signalization 208
14.31, Wiring of car extension door (CED) 209

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Installation Instruction

14.1 Dismantling old car equipment

Step Action Note


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

1040859.wmf

6
5
4

6
5
4

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Installation Instruction

14.2 Installation of door control box

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

Step Action
1 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

1080998.wmf

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Installation Instruction

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

Step Action Illustration


1 Use
harness,
helmet and
gloves.
1
Install the I/O box to the car roof.
The position of this box is not critical
2
unless there is a car position indicator
far away from the COP.
In that case fix the I/O box mid-way 3
between the COP and the indicator.
1 = Position indicator
2 = I/O box
3 = COP 1015305.wmf

14.4 Installation of ACU box

Step Action Note


1 Use
harness,
helmet and
gloves.
Find place for ACU box on the car roof
near the car top connection box and I/O
box. 5
1 = Position indicator, 2
2 = I/O box,
3 = COP 1
4 = ACU box 3 4
1070980.wmf
5 = car top connection box
2 Open and fix the ACU box to the car
roof.

1072315.wmf

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Installation Instruction

14.5 Wiring of car top connection box


XT1 XB18 XO2
X19
XB7 XB3 X20
XB11 24VIN X18
XB6
XB10 X17
XB2 KCEREL
X16
XB12
X15
XB15
X14
XB14 XS1 X13
XS2
XB8 KCECCG XT3
XS3
XS4 X42
XB16 X41
XS5
XB13 XS6 X21
XB9 XS7
XS8
XB17
XB19 XS9
XS10

XB20 1069992.wmf

Car equipment
XT1 Travelling cable XO2 LON OPT 24VIN 24V supply input
XB2 Battery / test resistor XB3 24V optional output XB6 KCEREL
XB7 Alarm bell XB8 Front door operator XB9 Front door zone sensor
XB10 Front door photocell XB11 Front door 3D sensor XB12 Rear door operator
XB13 Rear door zone sensor XB14 Rear door photocell XB15 Rear door 3D sensor
XB16 Absolute positioning XB17 LWD 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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Installation Instruction

Step Action Note


1 Route and connect all cables (for Use harness,
miscellaneous devices) on the car roof. helmet and
gloves.
2 Remove the jumpers from plugs XS1,
XS2, XS3, XS4, XS5, XS6, XS7, XS8,
XS9 and XS10.
3 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)

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Installation Instruction

14.6 Wiring of old car light

Step Action Note


1 Route the car lighting power supply Use harness,
cable to the car top connection box. helmet and
gloves.
2 Connect the cable to KCEREL:
X14/1
X14/2
PE bar

14.7 Wiring of old car fan

Step Action Note


1 Route the car fan power supply cable to Use harness,
the car top connection box. helmet and
gloves.
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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Installation Instruction

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 Action Note


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

1015328.wmf

14.8.2 Connections on ADV board for curtain of light/photo cell

Step Action Note


Curtain of light/photo cell, power supply 24 VDC
1 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
2 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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Installation Instruction

14.8.3 Door contact and power supply (two cases)

Step Action
1
P1

X1 X2 D1
D2
A B

A: ADV B: Isola, Renova, Athena


P1
Bk 1.
D1 D1 Bk
D2 D2 Bl
Br

Gn/Ye
12.

1039539.wmf

Insert the plugs of the cable from car Connect the cable from car top box to
top connection box in ADV door: terminals of connector P1 in Isola,
Renova or Athena door:
The door contact plug in The door contact in 1 (Bk = Black)
connector D2 and 2 (Bk = Black)
The power supply plug in The power supply in 3 (Bl = Blue)
connector D1 and 4 (Br = Brown)
The earth in 12 (GnYe = Green-
Yellow)

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Installation Instruction

14.8.4 Connections on the ADV board

1/wh G S1
X1 X2 4/ye 17 X1

1. 2. 3. 4.

ON
3/gn 16
5/gy 10
30
7/pk 31

32 X2
2/bn SD
14
7/bu 41
44
A 45
46
1071040.wmf

A = control cable wh = white ye = yellow


gn = green gy = grey pk = pink
bn = brown bu = blue

Step Action Note


1 Connect the The phoenix plug in X1 and X2.
2 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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Installation Instruction

14.8.5 Connections of ADV door cables in the car top connection box

Step Action Note


1 Use
harness,
helmet and X17
gloves.
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 XB10
clamp terminals X16 on KCEREL XB12
board.

If there is a rear door, connect:


Micro molex plugs XB12 and XB14
XB14 on KCECCG board. XB8
Power supply cable in spring
clamp terminals X17 on KCEREL
board.
1070006.wmf

For more information on connectors,


see section 14.5, Wiring of car top
connection box.

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Installation Instruction

14.9 Wiring of retiring ramp

Step Action Note


1 Route the retiring ramp cable. Use harness,
helmet and
gloves.
2 Connections at the retiring ramp:
Blue wire to the minus of the X20
ramp coil.
Brown wire to the positive of the
ramp coil.
Green / yellow to the ramp frame.
3 Connections in the car top connection PE
box:
Brown wire to X20/1 on KCEREL
board.
Blue wire to X20/2 on KCEREL
board.
Green / yellow to PE bar.

1070002.wmf

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Installation Instruction

14.10 Wiring of door inverter control

14.10.1 Preparations

Step Action Note


1 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.

1070004.wmf

14.10.2 Connections and settings in the Door operator on LCEDIC board

Connections on LCEDIC board: NOTE! Connect earthing to the


PC7: 85 Door motor/inverter motor earth terminal.
The maximum inverter output voltage is 230 VAC. If the
rated voltage of motor is more use DELTA connection. S1
LCEDIC

X18: 82:1 Mechanical safety edge 2 (NC contact) X18


X17: 82 Mechanical safety edge 1 (NC contact) X17

PC8: 67:E Locking of automatic car door (NC or NO contact) X16

PC6: 85:SB Close slow limit (NC or NO contact) X15

PC5: 85:OB Open slow limit (NC or NO contact) PC8


X1-X3
PC4: 85:SG Close limit (NC contact) PC7
PC3: 85:OG Open limit (NC contact) U V W

Settings on the LCEDIC board:


Set Jumper A according to 85OB and 85:SB contacts:
A If 85OB and A If 85OB and 1081922.wmf
85:SB are 85:SB are
NC contact NO contact
X1 X2 X3 X1 X2 X3
Set DIP switches S1: (ON = Normal Open and OFF = Normal Closed contacts.)
Switch S1/4 = 82:1 (X18) Mechanical safety edge 2 Example:
Switch S1/3 = 82 (X17) Mechanical safety edge 1 Mechanical
Switch S1/2 = 88 & 89 (X15 & X16)Photocell safety edge 82
is normal open.
Switch S1/1 = 67:E (PC8) Locking of car door

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Installation Instruction

14.10.3 Connections in the car top connection box

Step Action Note


1 Use
harness,
helmet and X17
gloves.
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 XB10
clamp terminals X16 on KCEREL XB12
board.

If there is a rear door, connect:


Micro molex plugs XB12 and XB14
XB14 on KCECCG board. XB8
Power supply cable in spring
clamp terminals X17 on KCEREL
board.
1070006.wmf

For more information on connectors,


see section 14.5, Wiring of car top
connection box.

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Installation Instruction

14.11 Wiring of contactor control door operator

14.11.1 Preparations

Step Action Note


1 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. 1070004.wmf

Other cables to the door operator.

14.11.2 Connect the door operator

NOTE! Connect earth wire to motor earth


PC8
terminal. PC4
Connect cables to connectors on the KCEDCC PC3 KCEDCC
board: X18
85 Door Motor X17
PC8: 67:E Locking of automatic car door (NC PC14
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)
1083160.wmf

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Installation Instruction

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 S2 S1
S1 / 4 = 82:1 (X18) Mechanical safety edge 2
DIP switches S2: (ON = Normal Open and OFF =
1081918.wmf
Normal Closed contacts.)
S2 / 1 = Example:
S2 / 2 = 85:SG (PC4) Close limit Mechanical safety
S2 / 3 = 85:OG (PC3) Open limit edge 2. (82:1) has
Normal open contact
S2 / 4 = ON If No 67:E (PC8) Locking of car door
=> S1/4 to ON.

14.11.4 Connect car connection box

Step Action Note


1 Use
harness,
helmet and
gloves.

Connect the front door cables in the car


top connection box:
X49
Micro molex plugs XB8 and XB10
on KCECCG board.
XB10
If there is a rear door, connect: XB12
Micro molex plugs XB12 and
XB14 on KCECCG board.

For more information on connectors, XB14


see section 14.5, Wiring of car top XB8
connection box.
2 Connect the module supply cable to the
car top connection box spring clamp
1070011.wmf
terminals X49/1-3 and PE bar.

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Installation Instruction

14.12 Wiring of Starlift door operator

14.12.1 Preparations

Step Action Note


1 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. 1070004.wmf

Other cables to the door operator.

14.12.2 Connect the door operator

NOTE! Connect earth wire to motor earth


PC8
terminal. PC4
Connect cables to connectors on the KCEDCC PC3 KCEDCC
board: X18
85 Door Motor X17
PC14: Belt slip PC14
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)
1082038.wmf
X17 82 Mechanical safety edge 1 (optional)

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Installation Instruction

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 S2 S1
S1 / 4 = 82:1 (X18) Mechanical safety edge 2
DIP switches S2: (ON = Normal Open and OFF =
1081918.wmf
Normal Closed contacts.)
S2 / 1 = Example:
S2 / 2 = 85:SG (PC4) Close limit Mechanical safety
S2 / 3 = 85:OG (PC3) Open limit edge 2. (82:1) has
Normal open contact
S2 / 4 = ON If No 67:E (PC8) Locking of car door
=> S1/4 to ON.

14.12.4 Connect car connection box

Step Action Note


1 Use
harness,
helmet and
gloves.

Connect the front door cables in the car


top connection box:
X49
Micro molex plugs XB8 and XB10
on KCECCG board.
XB10
If there is a rear door, connect: XB12
Micro molex plugs XB12 and
XB14 on KCECCG board.

For more information on connectors, XB14


see section 14.5, Wiring of car top XB8
connection box.
2 Connect the module supply cable to the
car top connection box spring clamp
1070011.wmf
terminals X49/1-3 and PE bar.

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Installation Instruction

14.13 Wiring of ADF - ADX door operator

14.13.1 Wiring of car top connection box

Step Action Note


1 Route and connect the car door cables. Use harness,
WARNING! Ensure that the helmet and
gloves.
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 SAFETY
EDGE DET.
RE5 H12
SERVICE MODE

H7 PHOTO
CELL DET.
ENABLE SELF RE4 H11
REOPENING

H6
REOPEN
REQUEST
LOW
SPEED RE3 H10
LOW
H5
AKTIV
HIGH
S2 S1 CLOSE
NUDING END
D ESR LS N OB C O RE2 H9
H4
OPEN
BUTTON OPEN
END
H3 S3 RE1 H8

BUZZER ON
COMMAND
CONTINUES
H2 H1
CLOSE OPEN

D2
10 11 14 30 16 17 36 41 + 9 13 28 12 SM

D1

D3
1039558.wmf D4

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Installation Instruction

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

Step Action Note


1 Safety ray power supply 24 VDC:
Connect transmitter: Connect receiver:
the + (grey) to terminal 49 the + (brown) to terminal 45
the - (black) to terminal 48 the - (blue) to terminal 46
the contact (black) to terminal 44
2 Safety ray power supply 230 VAC:
Connect the contact of safety ray Connect the supply for safety ray to car
Contact between terminal 44 and 46. 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 Action Note


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

1039559.wmf

14.13.4 Connect ADF - ADX board and Dip-switch positions

Step Action Note


1 Connect: X2 X3
X
4 X
5
The phoenix plug in X2 and X4

1039560.wmf

2 Position of DIP switches: S1 S2 S3


S1/4 = OFF = safety ray (1) is connected ON
S2/2 = OFF = mechanical edge is
connected OFF
S2/3 = OFF if electronic edge is connected 1 2 3 4 1 2 3 4 1 2 3 4
S2/4 = OFF if safety ray (2) is connected
J1 1039561.wmf

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Installation Instruction

14.13.5 Connect car connection box

Step Action Note


1 Connect the front door cables in the car
top connection box:
Micro molex plugs XB8 and XB10 X17
on KCECCG board.
Power supply cable in spring X16
clamp terminals X16 on KCEREL
board.

If there is a rear door, connect:


Micro molex plugs XB12 and XB10
XB14 on KCECCG board. XB12
Power supply cable in spring
clamp terminals X17 on KCEREL
board.
XB14
For more information on connectors, XB8
see section 14.5, Wiring of car top
connection box.
1070006.wmf

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Installation Instruction

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 Action Note


1 Route and connect the car door cables. For more information on connectors, see
section 14.5, Wiring of car top
connection box.
2 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.
3 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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Installation Instruction

14.14.2 Connect the cable into AMD door operator

Step Action Note


1 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 D1
D2

X1

1071362.wmf

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

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Installation Instruction

14.14.3 Parameters of AMD (Dip-switch)

DRIVE 1 DRIVE 2

ON OFF S1 ON OFF S1
S1/1 Speed selection S1/1 Photocell 1 Photocell 1
disabled enabled
S1/2 S1/2 Photocell 2 Photocell 2
disabled enabled
S1/3 Open force No open S1/3 Safety Safety
limit active force limit edge 1 edge 1
disabled enabled
S1/4 Switching S1/4 Safety Safety
causes sw edge 2 edge 2
reset disabled enabled
S1/5 Speed
selection
DRIVE 1.5 S1/6
S1/7 Open force No open
ON OFF S1 limit active force limit
S1/1 Speed selection S1/8 For railing 1 For railing 2
(ADV)
S1/2
S1/3 Open force No open
limit active force limit

S1/4 Railing 1 is All railings


existing on are of
operator or railing 2
in any of type (car
the landing and
doors landings)

ON OFF S2 ON OFF S2
S2/1 30 30 potential S2/1 30 30 potential
grounded free grounded free
S2/2 N/C contact N/C contact S2/2 N/C contact N/C contact
to +24V to GND to +24V to GND

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Installation Instruction

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

Step Action Note


1 Connect the front door cables in the car
top connection box:
Micro molex plugs XB8 and XB10 X17
on KCECCG board.
Power supply cable in spring X16
clamp terminals X16 on KCEREL
board.

If there is a rear door, connect:


Micro molex plugs XB12 and XB10
XB14 on KCECCG board. XB12
Power supply cable in spring
clamp terminals X17 on KCEREL
board.
XB14
For more information on connectors, XB8
see section 14.5, Wiring of car top
connection box.
1070006.wmf

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Installation Instruction

14.15 Wiring of DC2000 door control

14.15.1 Preparations

Step Action Note


1 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. 1070004.wmf

Other cables to door operator.

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Installation Instruction

14.15.2 Connecting the DC door operator

DC 2000 Terminal Signal Colour


A1 Armature Brown
A2 Armature Blue

SPEED
F1 Field Black C
SS
F2 Field Grey OL
OM
CL
C Common White CM

SS Soft Start Brown


OL Open Low Green

120VAC
OM Open Medium Yellow

HOT
NEU
CL Close Low Grey

A2
A1
F1
F2
NUDGE OPEN CLOSE
- + - + - +
CM Close Medium Pink
CCBS Terminal Signal Colour
2 1 6 5 4 3 2 1

XP1

XD1
XB28/6 Common n3

0/24VDC
+24VDC

SERVICE
OPEN
CLOSE
NUDGING
COMMON
COMMON
XB28/7 Open End n1 230
120
0

FORCE LIMIT
XB28/5 Close End n2

CLOSE END
OPEN END

0/24V
XB8/XB12
Legend: 85:SG = Close limit (NC contact)

XD2
1 2 3 4

M = motor 85:OG = Open limit (NC contact) 1081930.wmf

BU = blue SS = Soft Start (NO contact)


BN = brown OL = Open Low (NO contact)
BK = black OM = Open Medium (NO contact)
G/Y = green/yellow CL = Close Low (NO contact)
CS = cam switch CM = Close Medium (NO contact)

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Installation Instruction

14.15.3 Door operator without cam switch

Step Action Note


1 If there is no cam switch for soft start or/ Wire n5 Terminal SS for Soft Start
and open medium or/and close Wire N3 Terminal OM for Open Medium
medium: Wire N1 Terminal OM for Close
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.

14.15.4 Connecting the DC door cables to car top connection box

Step Action Note


1 Use harness, helmet and gloves.

Connect the front door cables in the car X17


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

For more information on connectors,


see section 14.5, Wiring of car top
1070006.wmf
connection box.

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Installation Instruction

14.16 Wiring of KOF230V, C-type door control

14.16.1 Preparations

Step Action Note


1 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. 1070004.wmf

Other cables to door operator.

14.16.2 Connecting door operator

X2/1 Door motor cable Core 1


X2/2 Core 2
X2/3 Core 3
X2/4 Core 4
X2/5 Core 5
X2/6 Core 6 C1

X2/7, Earth GN / YE
X2/8 Limit switch cable Black
X2/10 Blue
X2/9 Limit switch cable Black
X2/10 Blue X1,X2
KCEDCC
211:0

X1/1 Supply cable Black


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

1 0

X1/2 Blue F1 0 F2 0
211:S

KCEDCC / PC1 Signal cable


1 0

KCEDCC / PC2 SRC cable


KCEDCC / PC3 Limit switch cable R3

KCEDCC / PC4 Limit switch cable 1082023.wmf

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Installation Instruction

14.16.3 Connecting the DC door cables to car top connection box

Step Action Note


1 Use harness, helmet and gloves.

Connect the front door cables in the car X17


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

For more information on connectors,


see section 14.5, Wiring of car top
1070006.wmf
connection box.

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Installation Instruction

14.17 Wiring of ADT 3PH 125V door operator

14.17.1 Preparations

Step Action Note


1 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. 1070004.wmf

Other cables to the door operator.

14.17.2 Connect the door operator

NOTE! Connect earth wire to motor earth


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

1082060.wmf

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KONE ReSolve 200
Installation Instruction

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 S2 S1
S1 / 4 = 82:1 (X18) Mechanical safety edge 2
DIP switches S2: (ON = Normal Open and OFF =
1081918.wmf
Normal Closed contacts.)
S2/1 = Example:
S2 / 2 = 85:SG (PC4) Close limit Mechanical safety
S2 / 3 = 85:OG (PC3) Open limit edge 2. (82:1) has
Normal open contact
S2 / 4 = ON If No 67:E (PC8) Locking of car door
=> S1/4 to ON.

14.17.4 Connect car connection box

Step Action Note


1 Use
harness,
helmet and
gloves.

Connect the front door cables in the car


top connection box:
X49
Micro molex plugs XB8 and XB10
on KCECCG board.
XB10
If there is a rear door, connect: XB12
Micro molex plugs XB12 and
XB14 on KCECCG board.

For more information on connectors, XB14


see section 14.5, Wiring of car top XB8
connection box.
2 Connect the module supply cable to the
car top connection box spring clamp
1070011.wmf
terminals X49/1-3 and PE bar.

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Installation Instruction

14.18 Wiring of close command door operator

Preparations

Step Action Note


1 Use
harness,
helmet and
gloves.

Route and connect the car door cables:


Cables with connectors XB8/
XB12 to the car top connection
box. 1071369.wmf

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.

14.18.1 Connect the door operator

Step Action Note


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

1081921.wmf

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KONE ReSolve 200
Installation Instruction

14.18.2 Connect car connection box

Step Action Note


1 Use
harness,
helmet and X17
gloves.
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 XB10
clamp terminals X16 on KCEREL XB12
board.

If there is a rear door, connect:


Micro molex plugs XB12 and XB14
XB14 on KCECCG board. XB8
Power supply cable in spring
clamp terminals X17 on KCEREL
board.
1070006.wmf

For more information on connectors,


see section 14.5, Wiring of car top
connection box.

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Installation Instruction

14.19 Wiring of FIAM B/S door operator

14.19.1 Preparations

Step Action Note


1 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. 1070004.wmf

Other cables to the door operator.

14.19.2 Connect the door operator

NOTE! Connect earth wire to motor earth


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

1071371.wmf

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KONE ReSolve 200
Installation Instruction

14.19.3 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 S2 S1
S1 / 4 = 82:1 (X18) Mechanical safety edge 2
DIP switches S2: (ON = Normal Open and OFF =
1081918.wmf
Normal Closed contacts.)
S2/1 = Example:
S2 / 2 = 85:SG (PC4) Close limit Mechanical safety
S2 / 3 = 85:OG (PC3) Open limit edge 2. (82:1) has
Normal open contact
S2 / 4 = ON If No 67:E (PC8) Locking of car door
=> S1/4 to ON.

14.19.4 Connect car connection box

Step Action Note


1 Use helmet harness, and gloves.

Connect the front door cables in the car


top connection box: X49
Micro molex plugs XB8 and XB10
on KCECCG board.
If there is a rear door, connect: XB10
Micro molex plugs XB12 and XB12
XB14 on KCECCG board.

For more information on connectors, XB14


see section 14.5, Wiring of car top
connection box. XB8
2 Connect the module supply cable to the
car top connection box spring clamp
terminals X49/1-3 and PE bar. 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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KONE ReSolve 200
Installation Instruction

14.20 Wiring of Sabiem C door operator

14.20.1 Preparations

Step Action Note


1 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. 1070004.wmf

Other cables to the door operator.

14.20.2 Connect the door operator

NOTE! Connect earth wire to motor earth


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

1081919.wmf

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KONE ReSolve 200
Installation Instruction

14.20.3 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 S2 S1
S1 / 4 = 82:1 (X18) Mechanical safety edge 2
DIP switches S2: (ON = Normal Open and OFF =
1081918.wmf
Normal Closed contacts.)
S2/1 = Example:
S2 / 2 = 85:SG (PC4) Close limit Mechanical safety
S2 / 3 = 85:OG (PC3) Open limit edge 2. (82:1) has
Normal open contact
S2 / 4 = ON If No 67:E (PC8) Locking of car door
=> S1/4 to ON.

14.20.4 Connect car connection box

Step Action Note


1 Use harness, helmet and gloves.

Connect the front door cables in the car


top connection box: X49
Micro molex plugs XB8 and XB10
on KCECCG board. XB10
If there is a rear door, connect: XB12
Micro molex plugs XB12 and
XB14 on KCECCG board.

For more information on connectors, XB14


see section 14.5, Wiring of car top XB8
connection box.
2 Connect the module supply cable to the
car top connection box spring clamp
1070011.wmf
terminals X49/1-3 and PE bar.

14.20.5 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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KONE ReSolve 200
Installation Instruction

14.21 Wiring of ACC 230V door operator

14.21.1 Preparations

Step Action Note


1 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. 1070004.wmf

Other cables to the door operator.

14.21.2 Connect the door operator

NOTE! Connect earth wire to motor earth


PC8
terminal. PC4
Connect cables from door module (KCEDCC PC3 KCEDCC
board) to door operator: X18
85 Door Motor X17
PC8: 67:E Locking of automatic car door (NC
contact) PE
PC4: 85:SG Close limit (NC contact) XR1
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)

1081937.wmf

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KONE ReSolve 200
Installation Instruction

14.21.3 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 S2 S1
S1 / 4 = 82:1 (X18) Mechanical safety edge 2
DIP switches S2: (ON = Normal Open and OFF =
1081918.wmf
Normal Closed contacts.)
S2/1 = Example:
S2 / 2 = 85:SG (PC4) Close limit Mechanical safety
S2 / 3 = 85:OG (PC3) Open limit edge 2. (82:1) has
Normal open contact
S2 / 4 = ON If No 67:E (PC8) Locking of car door
=> S1/4 to ON.

14.21.4 Connect car connection box

Step Action Note


1 Use harness, helmet and gloves.

Connect the front door cables in the car


top connection box: X49
Micro molex plugs XB8 and XB10
on KCECCG board. XB10
If there is a rear door, connect: XB12
Micro molex plugs XB12 and
XB14 on KCECCG board.

For more information on connectors, XB14


see section 14.5, Wiring of car top XB8
connection box.
2 Connect the module supply cable to the
car top connection box spring clamp
1070011.wmf
terminals X49/1-3 and PE bar.

14.21.5 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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KONE ReSolve 200
Installation Instruction

14.22 Wiring of general 24V electronic control door operator

Preparations

Step Action Note


1 Use
harness,
helmet and
gloves.

Route and connect the car door cables:


Cables with connectors XB8/
XB12 to the car top connection
box. 1071369.wmf

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.

14.22.1 Connect the door operator

Step Action Note


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

NOTE: KCEDRB board is located


under the KCECCG board, on the lower
DIN rail.
2 Connect the separate photocell cable to
photocell device (if any).

1071384.wmf

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KONE ReSolve 200
Installation Instruction

14.22.2 Connect car connection box

Step Action Note


1 Use
harness,
helmet and X17
gloves.
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 XB10
clamp terminals X16 on KCEREL XB12
board.

If there is a rear door, connect:


Micro molex plugs XB12 and XB14
XB14 on KCECCG board. XB8
Power supply cable in spring
clamp terminals X17 on KCEREL
board.
1070006.wmf

For more information on connectors,


see section 14.5, Wiring of car top
connection box.

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Installation Instruction

14.23 Wiring of Selcom 1PH 220V automatic door operator

14.23.1 Preparations

Step Action Note


1 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. 1070004.wmf

Other cables to the door operator.

14.23.2 Connect the door operator

NOTE! Connect earth wire to motor earth


PC8
terminal. PC4
Connect cables to connectors on the KCEDCC PC3 KCEDCC
board: X18
85 Door Motor X17
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)
1082059.wmf

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Installation Instruction

14.23.3 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 S2 S1
S1 / 4 = 82:1 (X18) Mechanical safety edge 2
DIP switches S2: (ON = Normal Open and OFF =
1081918.wmf
Normal Closed contacts.)
S2/1 = Example:
S2 / 2 = 85:SG (PC4) Close limit Mechanical safety
S2 / 3 = 85:OG (PC3) Open limit edge 2. (82:1) has
Normal open contact
S2 / 4 = ON If No 67:E (PC8) Locking of car door
=> S1/4 to ON.

14.23.4 Connect car connection box

Step Action Note


1 Use
harness,
helmet and
gloves.

Connect the front door cables in the car


top connection box:
X49
Micro molex plugs XB8 and XB10
on KCECCG board.
XB10
If there is a rear door, connect: XB12
Micro molex plugs XB12 and
XB14 on KCECCG board.

For more information on connectors, XB14


see section 14.5, Wiring of car top XB8
connection box.
2 Connect the module supply cable to the
car top connection box spring clamp
1070011.wmf
terminals X49/1-3 and PE bar.

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Installation Instruction

14.24 Wiring of no car door, EMO N, AT

Step Action Note


1 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

1072302.wmf

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Installation Instruction

14.25 Wiring of BOF unit for non-automatic doors

Step Action Note


1 Fix the BOF unit close to the car door BOF = Buttons to operate (open / close)
operator. car doors for service purposes
2 Connect the BOF unit between XB12 for rear door.
connector XB8 and KCECCG board at
the car top connection box.

XB8
XB8

KCECCG

1071375.wmf

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Installation Instruction

14.26 Wiring of new COP

Step Action Note


1 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).

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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Installation Instruction

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 Action Note


1 Install the KCEPIO board behind the
existing COP.

Check the assembly location so that


when the elevator runs, boards do not
hit any structures in the elevator shaft.

1082103.wmf

2 Pass cable with plug X02 from I/O If there is a stop button in car route cable
module to car top connection box. with plug XS3 or XS4 from old COP to
3 Route existing COP cables to I/O KCECCG board.
module.

Mark wires and remove connectors (if


any). Connect the cables to KCEPIO
boards in I/O module. Refer to circuit XS3/XS4
diagrams. 2
1
2
XO
3 1070839.wmf

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

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Installation Instruction

14.27.2 Connect the old COP

Connection Note
First case: - 31 - 31 For connection points and DIP switch settings
Without common on KCEPIO board refer to wiring diagrams.
wire between + 31 31
lamp and button.
XXX KG
XX PERSONS
KCEPIO
1 = Positive lamp
1058129.wmf 2 = Call lamp
Second case:
STOP

3 = Common call
OVER
LOAD

- 31
With common 4 = Call button
11
9
7
12
10
8

wire between 5
3
6
4

31 31 1 2

lamp and +
button.
- 31
31 1
1058131.wmf 31 2
31 3
31 4
1080995.wmf

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Installation Instruction

14.27.3 Connect the existing car position indicator

Step Action Note


1 7 Segments or Binary display. For connection points on KCEPIO board
Use the mark on wire: refer to wiring diagrams.
+ COM
A / BC1
B / BC2 KCEPIO
C / BC4
D / BC8
E / BC16
F / BC32
G
D.P.
0V
A 1072156.wmf

F B
G

E C
D 1019625.wmf

2 Analog display. For connection points on KCEPIO board


Use the mark on wire: refer to wiring diagrams.
+ COM
1
2 KCEPIO
3
4
5
6
7
8
0V
1072159.wmf

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Installation Instruction

14.27.4 Connect on the car connection box

Step Action Note


1 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). KCECCG
XS3
connect to XS3 or XS4 XS4

If ACU is used, see section 14.4,


Installation of ACU box.
1072683.wmf

14.28 Connection of ACU, if applicable

Step Action Note


1 WARNING! Ensure that the power
is off. XB18
Use harness, helmet and gloves.

Route and connect the cable between


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

OVER
LOAD

15 16
13 14
11 12

Route the cable between the speaker


9 10
7 8 SPEAKER
5 6
3
1
4
2
VOLUME
XS2 XS1
and SPEAKER plug on the ACU board.

1070847.wmf

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Installation Instruction

14.29 Connection of KRM, KSS ReVive signalization

Step Action Note


1 WARNING! Ensure that power is off.
Use harness, helmet and gloves.
XT20

XS12 X7 KCECCG
XS1 XB18
XC9B XB19
2 Route and connect cables between
KRMRIF module and car top
connection box.
3 Route and connect the cable between F2KMUL/COPMUL
COP and KRMRIF module. J2

1072289.wmf

14.30 Connection of KRM, parallel signalization

Step Action Note


1 WARNING! Ensure that power is off.
Use harness, helmet and gloves.
XT20

XS12 X7 KCECCG
XS1 XB18
XC9B XB19
2 Route and connect cables between
KRMRIF module and car top
connection box.
3 Route and connect cables between KRMSIG
KRMSIG and KRMRIF module. XS12

NOTE! KRM modernization package is


used with parallel signalization.
1072684.wmf

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Installation Instruction

14.31 Wiring of car extension door (CED)

Step Action Note


1 WARNING! Ensure that power is off.
72 X72
Use harness, helmet and gloves.

XS4

2 Route and connect cables between X35


CED (72), PRC on COP (35) and car
top connection box.

35 1077367.wmf

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Installation Instruction

15 FULL SPEED ADJUSTMENT / COMMISSIONING / SAFETY INSPECTIONS

PHASE: 15 STOP TESTS SPEED m/s


0.6
SB-COMM
RUN
0.3 DZI SB-1

LOCATION: Machine room, shaft OFF


261
0.02
0.02 SB-2

zone
Unlocking
0.3
263 0.6 SB-3

STOP TEST SB-4

INSPECTION CALLS TESTS

NORM UP TOP CALL SETUP

RUN BOOST

INSP

BOTTOM OSG
DOWN
CALL

TERMINAL STOP BYPASS FAULTS


Self check
ETS Bypass Overspeed RESET

NTS Bypass SELECT Unintended movement


Normal Decel Run time limiter
Bypass
Safety chain open

PENDANT
SERVICE
REMOTE
Use jumpers SB-1 to SB-4 for safety chain bypass

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 )

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 Page
15.1, Balancing 211
15.2, Selecting roll call type 212
15.3, Selecting LWD type 212
15.4, Shaft setup 213
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

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Installation Instruction

Heading Page
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
15.28, Ride comfort /Special V3F10 Adjustments 237
15.29, Setting the elevator to normal use 240
15.30, Troubleshooting 240

The basic commissioning for nominal speed includes 4 steps:


Shaft setup
Deceleration distance learning
Positioning synchronization magnets
Floor level adjustments

15.1 Balancing

Step Action Note


1 Check and adjust balancing of car and The counterweight to be balanced to
counterweight. empty car weight + 50 % of the rated
load. In some old elevator installations
Check from the layout drawings which this figure may vary.
weight the elevator is balanced to. Most
of the elevators are balanced to 50 %.
2 Ensure that the LWD is connected and
the switch is working properly.

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Installation Instruction

15.2 Selecting roll call type

Step Action Note


1 If landing call buttons and displays are Roll Call Direction parameter (ID 280)
connected to FCB board, set the value can be found under Lift Structure /
of parameter ID 280 to 1. Building categories.

If landing call buttons and displays are 0 = roll call for car and machine room
connected to KCEPIO board, set the networks only
value of parameter ID 280 to 0. 1 = roll call for shaft from top to bottom
2 = roll call for shaft from bottom to top

15.3 Selecting LWD type

Step Action Note


1 Set the value of parameter ID 1082 0 = analog LWD device, load info
according to the load weighing device through CCG analog input
type. 1 = digital LWD device, load info through
CCG digital & analog inputs
2 If there is no load weighing device: Over load polarity (ID 1161)
Set the value of parameters ID 1161 Full load polarity (ID 1162)
and ID 1162 to 1.
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 Action Note


1 Ensure that the elevator is on RDF.
2 Set test switch to position 263. The test TESTS

LED turns ON. OFF


261
263

TEST
1069941.wmf

3 Push setup button.

1069629.wmf

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Step Action Note


4 Turn the elevator to normal drive (RDF
switch to normal). The setup drive
begins.
NOTE! RDF switch must be switched to
normal within 10 seconds after setup
button has been pushed.
Do not interrupt the setup drive. 1069628.wmf

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
5 Turn test switch to OFF position after
setup is completed.

6 If the elevator does not run after setup, For door parameter values, see section
check the door parameter values (515, 15.12, Commissioning of the car door.
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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Installation Instruction

15.5 Connecting FRD / FID (optional)

Step Action Note


1 Check and identify the over connecting For more information, see wiring
plugs at the option board. diagrams.
2 Remove the plugs and connect the
FRD / FID devices.
3 Check the FRD / FID device
functionality.

15.6 Adjusting motor no load current

Step Action Note


1 Give a car call to the topmost floor. The car must be empty.
2 Record the value of Output current
parameter U1-03 when the car is
passing the middle floor.
3 Set the Motor no-load current Value = Measured current / Nominal
parameter E2-03 to calculated value. current (E2-01) x 100.

15.7 Checking creeping time

Step Action Note


1 Drive the empty car to the middle floor
level from both directions.
2 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.
3 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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Installation Instruction

15.8 Motor slip compensation

15.8.1 Checking the need for adjusting motor slip compensation

Step Action Note


1 Drive the empty car from the bottom Use the same middle floor in each
floor to the middle floor. phase of the adjustment procedures.
2 Check the stopping distance from Correct the magnet position in the shaft
KONE Mini Console. if necessary.
Example: Mini Console shows +5 mm
Check that the car door sill and the and the car sill is 20 mm above, move
landing door sill are at the same level the floor magnet 15 downwards.
with each other. NOTE! If position magnet is moved, the
deceleration magnets must be moved
accordingly.
3 Drive the empty car to the middle floor
level from both directions.

Check the stopping distance from


KONE Mini Console.
4 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 Action Note


1 Adjust Motor rated slip parameter If the value is too high, it may cause
E2-02 value in small steps. vibration during nominal speed run.

If creeping speed running time is


shorter when driving to light direction,
increase the value.
2 Make test run in both directions.
3 Repeat as many times as necessary.

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Installation Instruction

15.9 Floor level adjustment

Step Action Note


1 Drive the car from the bottom floor to
the middle floor.

Check the stopping accuracy from


KONE Mini Console.
2 Adjust the value of parameter 1207 Example:
(Final stopping point) according to the If car stops 20 mm before the landing
values to improve the stopping when driving to up direction, reduce the
accuracy. value of parameter 1207 by 20.

Switch the power OFF and ON after Parameter 1207 can be found under
adjusting the parameter value. parameter category Drive interface /
Limits.
3 Check the stopping accuracy by Write down the values to the table below.
measuring distance between car and
landing sills at each landing.
4 Correct the magnet position in the shaft
if the gap between sills is more than
10 mm.

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.

NOTE! If position magnets are moved,


the deceleration magnets must be 1070401.wmf
moved accordingly.
5 If magnets were moved, perform the
shaft setup again.
6 Make a new test run and ensure that
the stopping accuracy is acceptable at
each landing.

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Installation Instruction

LEVELS DESCRIPTION MEASURED FROM CAR


Up Down
32 X
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 X

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Installation Instruction

15.10 Final steps

Step Action
1 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).
2 Make the settings for the KRM according to AM-13.25.008.
3 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 Connector Note


External OSS L KSS signalization: Only for potential free.
Out of service switch XF3 on LCEFCB board

Parallel signalization:
KCEPIO board, refer to
circuit diagrams
FID Fire detection Refer to circuit diagrams.
External FRD fireman drive

15.11.2 External outputs

Input Connector Note


OSI A KSS signalization:
Out of service indication XF4 on LCEFCB board
Parallel signalization:
KCEPIO board, refer to
circuit diagrams
DAL-GP KCEOPT board, refer to
Disturbance alarm circuit diagrams
FRD Fireman drive return Refer to circuit diagrams.
FRD Fireman drive service

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Installation Instruction

15.11.3 Connections of the remote alarm

Step Action Note


1 Connect the remote alarm output cable Refer to the circuit diagrams.
and alarm reset cable (if any) to the
connector XM30 on the LCERAL
board.
2 Check the required alarm method. 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.

3 Test and reset the remote alarms.

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Installation Instruction

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.

Parameter ID
Door type 515 520 529 530 531 536 546 547 548 549
AMD, drive 1 1 1 1 1 1 0 20 0 0 1
AMD, drive 1.5 1 1 1 1 1 0 20 0 0 1
AMD, drive 2 1 1 1 1 1 0 20 0 0 1
ADT
ADV 1 1 1 1 1 0 20 0 0 1
ADX / ADF 1 1 1 0 1 0 20 0 0 1
Close command 24V, 230V 1 1 0 0 0 1 20 0 0 1
Close command 48V 1 1 0 1 0 1 20 0 0 1
Close command 110V 1 1 0 1 0 1 20 0 0 1
Contactor control, 3 phase 1 1 0 0 0 0 20 1 1 1
Fermator C2T 1 1 0 0 0 0 20 0 0 1
Fermator C4T 1 1 0 0 0 0 20 0 0 1
Fermator VVVF 1 1 1 1 0 0 20 0 0 1
FIAM B 1 1 0 0 0 0 20 1 1 1
FIAM S 1 1 0 0 0 0 20 1 1 1
Inverter control 1 1 0 0 0 0 20 0 0 1
No car door 4 1 1 1 0 0 20 0 0 1
Sabiem C 1 1 0 0 0 0 20 1 1 1
Selcom, 1 phase 1 1 0 0 0 0 20 1 1 1
Selcom/Wittur ECO Auto 1 1 1 1 0 0 20 0 0 1
Selcom/Wittur MIDI Auto 1 1 1 1 0 0 20 0 0 1
Selcom/Wittur MSUPRA Auto 1 1 1 1 0 0 20 0 0 1
24V Electronic 1 1 1 1 0 0 20 0 0 1

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Installation Instruction

Parameter Default Min Max Comment Cate


ID name value value value gory
515 Door type 1 0 6 0 = no door
1 = automatic door, parallel interface
2 = automatic door, serial interface Doors /
3 = swing door at landing, manual car gate Miscella
4 = swing door at landing, safety ray in car neous
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
SRC 1 = photocell input enabled
529 Door open 1 0 1 Door open limit in use Doors /
limit present 0 = open limit doesnt exist Limits
1 = open limit exists
530 Door close 1 0 1 Door close limit in use
limit present 0 = close limit doesnt exist
1 = close limit exists
531 Door nudging 0 0 4 Nudging service:
type 0 = not in use
1 = in use, DOB inoperative
2 = in use, DOB remains operative Doors /
3 = in use, DOB inoperative, load detection Miscella
4 = in use, DOB remains operative, load detection neous
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 Doors /
ramp full Defines time to keep full voltage in RR circuitry when RR Times
voltage time energized in 0.1 s (*)
547 Door close 0 0 1 Defines the polarity of door close limit input
limit polarity 0 = not inverted, NO-contact
1 = inverted, NC-contact
548 Door open 0 0 1 Defines the polarity of door open limit input Doors /
limit polarity 0 = not inverted, NO-contact Miscella
1 = inverted, NC-contact neous
549 Door opened 1 0 1 Door torque control when door is open
torque 0 = door open torque released when door fully opened
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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Installation Instruction

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 Function Yaskawa Door


initial operator
setting
b1-02 Run command selection 1 1
b1-01 Frequency reference selection 1 1
H1-05 Multi-function input selection 5 3 8
H1-04 Multi-function input selection 4 14 7
H1-03 Multi-function input selection 3 24 6
L2-01 Momentary power loss ride through method 0 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 Door


initial operator
setting
E1-04 Max. output frequency 60 From name Hz
plate
E1-05 Max. voltage 200* From name V
plate
E1-06 Max. voltage output frequency (base freq.) 60 Same than Hz
n09
E1-07 Mid. output frequency 3.0 3.3 Hz
E1-08 Mid. output frequency voltage 16* 20 V
E1-09 Min. output frequency 1.5 3.3 Hz
E1-10 Min. output frequency voltage 12* 20 V
E2-01 Motor rated current From name A
plate

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15.13.3 Open and close curve parameters

Parameter Function Yaskawa Door


initial operator
setting
C1-01 Acceleration time 1 10 0.0...1.0 s
C1-02 Deceleration time 1 10 0.0...0.2 s
d1-01 Open braking frequency 0 4...20 Hz
d1-02 Close braking frequency 0 4...20 Hz
d1-03 Nudging frequency 0 4...20 Hz
d1-04 Nudging frequency 0 Same as n23 Hz
d1-05 Open frequency 0 15...50/60 Hz
d1-06 Close frequency 0 15...50/60 Hz
d1-07 Nudging frequency 0 Same as n23 Hz
d1-08 Nudging frequency 0 Same as n23 Hz

15.13.4 Fine adjusting parameters

Parameter Function V3F Door


initial operator
setting setting
d3-04 DC injection braking current 1.0 0...100 %
b2-02 DC injection braking time at stop 50 0.0...2.0 s
C4-01 Torque compensation gain 1.00 0.0...2.5
E2-02 Motor rated slip - 0.0...20 Hz
E2-03 Motor no-load current - 50...80 %
C3-01 Slip compensation gain 0.0 0.0...2.5
C3-02 Slip compensation time constant 2000 0.0...25.5 s

15.14 Checking KCE board versions

Step Action Note


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

1079581.wmf

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15.15 Testing landing door locks

Step Action Note


1 Open the landing door lock contact and The elevator must not run.
try to drive the elevator.
2 Repeat for each landing door lock.

15.16 Testing safety contacts

Step Action Note


1 Activate each safety contact one at the The elevator must not run.
time. Try to drive the elevator by
inspection drive from the car roof.

15.17 Measuring insulation resistance

Step Action Note


1 Ensure that the power is off. Both main switch and lighting switch
must be turned off.
2 Ensure that all the other switches and
circuit breakers are turned on.
3 Measure insulation resistance between
PE and main switch (L1, L2, L3, (N)) Use 500V (d.c.) test voltage.
load side.
4 Measure insulation resistance between Insulation resistance must be minimum
PE and lighting switch (L, N) load side. 1.0 M (Mohm).
5 Measure insulation resistance between
PE and machine terminals (U, V, W).

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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 Action Note


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

6 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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Step Action Note


8 Check that the main power supply is These markings match only if the mains
safely disconnected by measuring switch is in control panel.
voltage between the main switch If old mains switch unit is used, the
terminals (Q220: L1-PE, L2-PE, and correct measuring points must be
L3-PE). defined on site.
9 Check that the lighting power supply is
safely disconnected by measuring
between the lighting switch terminals L2
(Q262:2-PE and 4-PE). L1 L3

L1 L2
L3 1080520.wmf

10 Measure the resistance of the test Calibrate the meter to exclude the
leads if it is not possible to reset the measuring lead resistance. If not
continuity meter (compensate the test possible, measure and record the
lead resistance). measuring lead resistance. Subtract the
resistance value from the measurement
results.
11 Connect the earth continuity meter: WARNING! When measuring the
(-) to earth bar or PE terminal landing doors:
(+) to test point
Close the car top box and keep the
Measure the earth continuity (a (-) lead connected to car top box
resistance of the earth connection). PE terminal.
Press the car roof stop button
If required calculate the resistance: down before making any
Result of measurement - resistance of measurements.
test leads.

Pressing the car roof stop button


switches the power of the landing
door safety chain OFF.

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Test points in the machine room:


1. Drive - Machine
2. Drive - Car top box
3. Controller - Car top box

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. Car top box - Car door operator


2. Car top box - Car shell
3. Car top box - Car fan
4. Car top box - Car light
5. Car top box - Any optional device
6. Car top box - Landing door top track
7. Car top box - Landing door frame
8. Car top box - Shaft network module, if any
9. Controller - Car top box
R

7
R

9
R

1
2
R R

R = Earth continuity meter


8 R
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 Action Note


1 Check that the 24V OK LED on the
KCEMSC board is lit. KCEMSC
2 Switch the main power OFF.
3 Disconnect the travelling cable (XC1) 24V OK
from KCECPU board. XTTS
4 Connect a short circuit wire
(KM796185G10100) between a free
KCECPU
XTTS connector on KCEMSC and PE
bar on the control panel.
5 Switch the power ON. PE
A multifuse on KCECPU board XC1
disconnects power to KCEMSC board.
6 Check that the 24V OK LED on the PE
KCEMSC board is not lit. If the 24V OK *
LED is lit, check the PE connection* on
1079583.wmf
KCECPU and repeat the test.
7 Switch the power OFF. A multifuse resets itself automatically.
8 Remove the short circuit wire.
9 Connect the travelling cable XC1. The emergency battery on the car roof
energizes the KCEMSC board. 24V OK
LED turns on.
10 Switch the power ON.

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15.20 Testing operation of RCD

Step Action Note


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


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

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15.22 Current measurement

Step Action Note


1 Select the Monitor display menu on
drive unit. Mon appears on display.
1071113.wmf

2 Activate parameter U1-03. 0.00A appears on display.


3 Read the parameter value while driving
the car to both up and down directions
at nominal speed.
4 Press the key until F 0.00
ESC

appears on display.

15.23 Testing the final limit switches

Step Action Note


1 Call the car to the top floor. Check that there is no one in the car.
2 Set test switch to position 263. The test STOP TESTS

LED turns ON.


RUN
OFF
261

3 Switch the elevator to RDF STOP TEST


263

(INSPECTION switch to low position). INSPECTION

NORM UP
CALLS

TOP CALL

RUN

INSP
1074498.wmf

4 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).
5 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).
6 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.
7 Drive the car away from the final limit switch with RDF.
8 Switch the elevator to NORMAL (INSPECTION switch to up position).
9 Repeat the same at bottom landing for the lower limit switch.

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15.24 Drive time supervision (DTS) test

Step Action Display


1 Drive the elevator to the bottom landing.
2 At the beginning bb is blinking on the
drive unit display.
1069865.wmf

3 Press the key at the drive unit



user interface until PAr appears on 1069864.wmf

display.
4 Make a car call by pushing top call
button on KMI.

The main contactor energises but the


elevator does not run.

1069628.wmf

DTS supervision operates after DTS time:


fault code 1040 appears
the main contactor de-energises
run time limitter LED turns ON at KMI
5 To reset the fault:
Set test switch to position 263. TESTS

Push the Reset button at KMI.


OFF
The run time limitter LED turns OFF. 261
263

TEST
1069941.wmf
1069633.wmf

Press the key at the drive unit


ESC
user interface until F 0.00 appears on
display.
6 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 Action Note


1 Drive the elevator to the top floor.
2 Set test switch to position 263. The test TESTS

LED turns ON. OFF


261
263

TEST
1069941.wmf

3 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 Drive the car to the bottom floor level


with RDF.
6 Turn test switch to OFF position.

1069625.wmf

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15.25.2 Counterweight buffer test with empty car

Step Action Note


1 Drive the elevator to the bottom floor.
2 Set test switch to position 263. The test TESTS

LED turns ON. OFF


261
263

TEST
1069941.wmf

3 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 Drive the car to the topmost floor level


with RDF.
6 Turn test switch to OFF position.

1069625.wmf

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15.26 Overspeed governor test

Step Action Note


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

1015446.wmf

3 Measure the overspeed governor speed Check the correct electrical contact
using a manual tachometer. Accelerate operation speed from the type label.
the overspeed governor manually until
the electrical contact (pos. 22) operates.
Read the operation speed.
4 Measure the overspeed governor speed Refer to the table below for correct
using a manual tachometer. Accelerate tripping area.
the overspeed governor manually until it
trips. Rotate the overspeed governor to
the tripping direction. Read the tripping
speed.
5 Place the rope back to the groove.

Correct tripping area:


Nominal speed Tripping range
Vn x 1.15 Vn x 1.25 + (0.25/Vn)
0.6 m/s > 0.70 m/s < 1.17 m/s
1.0 m/s > 1.15 m/s < 1.50 m/s
1,2 m/s > 1.38 m/s < 1.71 m/s
1.4 m/s > 1.61 m/s < 1.93 m/s
1.6 m/s > 1.84 m/s < 2.16 m/s
1.78 m/s > 2.04 m/s < 2.37 m/s

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15.27 Safety gear test

Step Action Note


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

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 Action Note


1 Adjust Motor rated slip parameter If the value is too high, it may cause
E2-02 value in small steps. vibration during nominal speed run.

If creeping speed running time is


shorter when driving to light direction,
increase the value.
2 Make test run in both directions.
3 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 U1-
03 (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 Related Def Range Adjustment


performance
Acceleration time 1 C1-01 Time to accelerate 2.0 0-10 s
(Accel Time 1) from zero to maximum
frequency
Deceleration time 1 C1-02 Time to decelerate 2.0 0-10 s
(Decel Time 1) from maximum
frequency to zero
S-curve C2-01 Rounding time at start 1.0 0.50 - 2.50
characteristic time at of acceleration s
acceleration start
(SCrv Acc @ Start)
S-curve C2-02 Rounding time at end 0.5 0.50 - 2.50
characteristic time at of acceleration s
acceleration end
(SCrv Acc @ End)
S-curve C2-03 Rounding time at start 0.5 0.50 - 2.50 (recommended)
characteristic time at of deceleration s (possible)
deceleration start
(SCrv Dec @ Start)
S curve at C2-04 Overshoot at 0.8 0.50 - 2.50 Overshoot at
deceleration end deceleration end s deceleration end
-> increase
setting
Brake open delay S1-06 Speed reference is 0.2 0.0-10.0 s elevator runs
held at zero during against the
this time to let brake brake at start:
open -> increase
setting

Extensive roll
back at start:
->reduce setting
Brake closing delay S1-07 Defines the time to 0.1 s 0 - 10.0 s. Try to find good
wait after zero speed compromise to
has reached before get good
brake is closed. levelling.

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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.

Nominal speed
Up or Down command command Levelling speed command
from KCE to V3F10 to V3F10 from KCE to V3F10

4
V
5

3 6

8
1 7
2 9

1072308.wmf

1 2 3 and 4 5, 6 and 7 8 9
Brake Brake Brake open Brake command from V3F10 Brake close Brake closed
closed open delay
delay

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Fine tuning hints:

Section of drive Operation Correction Note


curve
1 DC injection/Start S1-02
2 Brake open delay Extensive roll back Increase S1-20
S-curve/ start Start against brake Increase S1-06
Rough and jerky start Increase C2-01
3 Acceleration time Too slow acceleration Reduce C1-01
Too fast acceleration Increase C1-01
4 Deceleration time Too slow deceleration Reduce C1-02
Too fast deceleration Increase C1-02
5 DC-injection/Stop S1-03

15.29 Setting the elevator to normal use

Step Action Note


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

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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KONE ReSolve 200
Installation Instruction

18 APPROVALS AND VERSION HISTORY

Compiled by: Information Product Author / Tiina Halonen


Checked by: Global Installation Support / Franois Le Maut
Approved by: Global Installation Support / Hkan Brneman

Issue Date Description of Change Ref CR Approved by


- 2011-02-14 First issue for piloting. Hkan Brneman
A 2012-03-27 Second issue for piloting. Updated Hkan Brneman
positioning system. Other changes, see
change bars.
B 2012-09-17 Additions and improvements, see change Hkan Brneman
bars.
C 2012-11-22 Additions and improvements, see change Hkan Brneman
bars.
D 2013-04-17 Added new options, see change bars. Hkan Brneman

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KONE ReSolve 200
Installation Instruction

APPENDIX A. Changing the characteristics / V3F10 K1000 LED user interface

A.1 User Interface

For more information, see AS-11.65.004.

12 13
1 11
5

15
3
14

STOP

7 8
10
4 6

1064941.pdf

Figure A1. Digital LED operator

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Installation Instruction

Table A1. Keys and displays on the LED operator


No Name Function
1 Data display area Displays the frequency reference, parameter number, etc.
2 ESC key Returns to the previous menu.
3 RESET key Moves the cursor to the right.
Resets the drive to clear a fault situation.
4 RUN key Starts the drive.
5 Up Arrow key Scrolls up to select parameter numbers, setting values, etc.
6 Down Arrow key Scrolls down to select parameter numbers, setting values, etc.
7 STOP key 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).
8 ENTER key Selects all modes, parameters, settings, etc.
Selects a menu item to move from one display screen to the
next.
9 LO/RE selection key 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.
10 RUN light Lit while the drive is operating the motor.
11 LO/RE light Lit while the operator (LOCAL) is selected to run the drive.
12 ALM LED light Lit when drive detects an alarm or error
13 REV LED light Lit when motor is rotating in reverse
14 DRV LED light Lit when in drive mode.
Drive mode allows motor operation and parameter monitoring.
Parameter settings cannot be changed in drive mode (
programming mode).
15 FOUT LED light Output frequency is displayed

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Installation Instruction

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

:
Turn the power on

*
*Pressing RUN will start the motor.

Forward Selection Reverse Selection


:
DRV light is on.

:
Output Frequency

Output Current

Note: XX characters are shown in this manual.


The drive will display the actual setting values.
Output Voltage

XX
Monitor Display

XX

XX XX XX
Verify Menu
*Drive cannot operate the motor.

XX XX XX
DRV light is off.

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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Installation Instruction

A.2.3 U-parameters

U1 Status monitor constants U2 Fault Trace U3 Fault History


KONE LIFT ACCESS U2-01 Current Fault U3-01 Last Fault
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
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
5th last to 10th last fault
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
Acumulatived time of 5th to 10th fault
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
1027720.pdf
U1-50 Speed Comp Value

Figure A3. U-parameters

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Installation Instruction

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 1 11
(optional) 2 12
3. KCEFUI board
4. KCEPIO board (optional)
5. KCECPU board (optional) 13
3
6. Travelling cable optional
terminals 4
7. PE1 earthing bar 5
8. KCEOPT board
14
6
9. 24 VDC power supply 15
10.Power supply and THD-filter
7
terminals 16
11.KCEMSC board 17
12.Drive unit
13.Braking resistor module 8 18
14.EMI suppression ferrite 19
15.Contactor module 9
16.RFI filter
17.Control power module 23 20
18.Brake and ramp voltage 21
transformer (optional) 10
19.Lighting module 22
20.Hoisting motor interface
terminals
21.Door transformer (optional) / 21
THD filter
22.EMC clamp for motor cable
23.FRD FR amplifier

1067571.wmf

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Installation Instruction

B.2 Switches and fuses

Pos.No Switch / Fuse


Q220 Main switch in control cabinet
Q262 Main switch for lighting
F281 Main fuse in control cabinet
F290 Residual current circuit breaker for lighting circuits
F290:1 Car lighting fuse
F290:2 Shaft lighting fuse
F286 Residual current circuit breaker for control circuits
F286:1 Car door circuit breaker
F286:2 Control system circuit breaker
F286:3 Circuit breaker of safety circuit and start permit chain
F288:1, Autotransformer primary circuit breaker (optional)
F288:2 Autotransformer secondary circuit breaker (optional)
brake power supply
F207 Retiring ramp and DC breaking fuse (optional)
F283 Fuse for 3-phase door operator (optional)

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Installation Instruction

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 Action Note


1 At the beginning bb is blinking on
display.
1069865.wmf

2 Select the PAr menu.

1069864.wmf

3 Set the parameter A1-04 value to 1410.


4 Set the parameter A1-01 value to 1410.
5 Press the key until bb is
ESC

1069865.wmf
blinking on the display.
Otherwise the elevator will not run.

C.2 Locking parameter menu

Step Action Note


1 At the beginning bb is blinking on
display.
1069865.wmf

2 Select the PAr menu.

1069864.wmf

3 Set the parameter A1-04 value to 1410.


4 Set the parameter A1-01 value to 0000.
5 Press the key until bb is
ESC

1069865.wmf
blinking on the display.
Otherwise the elevator will not run.

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Installation Instruction

APPENDIX D. Estimating the mass of the counterweight

Step Action
1 Calculate CWT volume.

H C D cm
-------------------------------------
1000
2 Draw a line from CWT volume value to concrete or steel/cast iron line.
3 Draw a line left to CWT weight value.
4 Use this value as estimation of CWT weight.

8000 3.
7000

6000

5000
4.
4000

3000 2.
2000

1017856.wmf 1000

0
100 200 300 400 500 600 700 800 900 1000
1. 1017855.wmf

1. CWT volume (H x C x D /1000)


2. Concrete
3. Steel / cast iron
4. CWT weight (kg)

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KCE control, d1-18=11 Nominal speed, m/s
Lift drive function Speed level Par Default 0,3 0,4 0,5 0,63 0,7 0,8 0,9 1,0
value
f m/s f m/s f m/s f m/s f m/s f m/s f m/s f m/s
Normal run High speed d1-01 50 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

All rights reserved.


Inspection drive, high speed Inspection drive speed d1-02 15 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
50,0 0,5 39,7 0,5 35,7 0,5 31,3 0,5 27,8 0,5 25,0 0,5
Correction drive, Correction drive speed d1-04 10 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

2009 KONE Corporation


inspection drive slow speed,
Installation Instruction

recall drive, setup drive


KONE ReSolve 200

Levelling Levelling speed d1-17 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
APPENDIX E. Speed parameters

258 (258)
delivery documents (wiring diagrams).
For more information on correct parameter values, see also

AM-10.65.001
(D) 2013-04-17