1.6 With KDH Drive

KONE MiniSpaceTM 1.
6 with KDH drive

Maintenance learning guide
KONE MiniSpace™ with
KDH drive
Release 1.6
1033600.wmf
Maintenance Learning Guide

FOR TRAINING PURPOSES AND INTERNAL USE ONLY.
The information in this training package is for training purposes and internal use only. Any technical information
relative to a product is relevant to training only, and must not be used by the recipient holder or passed on to any
other person for use in the design, manufacture, testing, installation, inspection, maintenance, modernisation or
repair of the product to which it refers. Where technical information is required by any person to carry out their job,
that person must access the authorised copy of the data from the relevant data files held in all regional offices and
maintained in the latest up to date state.
Copyright © 2005 KONE Corporation

All rights reserved.
All rights reserved under International Copyright Conventions. No part of the contents of this manual may be cop-
ied, reproduced or transmitted in any form or by any means or translated into another language or format, in whole
or in part, without the written consent of KONE Corporation.
TC06818W23-EN
Issue: -
2005-10-06
Produced by: Training Center, KONE Corporation (Hyvinkää)
Target group: Service engineers, Supervisors
Copyright © 2005 KONE Corporation 2 (113) TC06818W23-EN / Issue: -

Table of Contents
Table of Contents
How to use this training package ........................................................ 5

1. Introduction ..................................................................................... 7
2. KONE MiniSpace™ 1.6 with KDH drive concept ............................ 8
New features ............................................................................. 9
Exercises ................................................................................ 10
3. LCE electrification in general ........................................................ 11
LCE electrification for KCP931™ ............................................ 12
Exercises ................................................................................ 14
4. Machine room electrification ......................................................... 15
Main switch boxes .................................................................. 16
Control panel .......................................................................... 18
KDH drive panel ...................................................................... 21
Machine cabling ...................................................................... 23
Exercises ................................................................................ 24
5. Shaft electrification ........................................................................ 26
Landing door safety chain ....................................................... 27
Landing calls and signalisation ............................................... 29
Floor Control Board (LCEFCB) ............................................... 32
Floor option board (LCEFOB) ................................................. 34
Signalling devices at landing .................................................. 36
Exercises ................................................................................ 38
6. Car electrification .......................................................................... 41
Principle of the car electrification ............................................ 42
Car connection board (LCECCBN2) ....................................... 43
COP Multi-board (F2KMUL) ................................................... 46
Remote Interface board (KRMRIF) ......................................... 48
Car positioning system ........................................................... 49
Exercises ................................................................................ 50
7. Elevator system ............................................................................ 52
Group control operations ........................................................ 53
Roll call ................................................................................... 55
LCEGTWO board ................................................................... 56
LCECAN board ....................................................................... 57
KONE Group control computer (KGC) .................................... 58
Exercises ................................................................................ 59
8. LCE user interface ........................................................................ 60
How to use LCE user interface ............................................... 61
Exercises ................................................................................ 62
9. AMD door system ......................................................................... 63
Structure of the AMD doors .................................................... 64
Exercises ................................................................................ 66
10. Preventive maintenance ............................................................. 67
During a routine service visit ................................................... 68
Exercises ................................................................................ 70
11. Corrective maintenance .............................................................. 74
Elevator components .............................................................. 75
Replacing electrical components on site ................................ 78
LCE control cabinet ................................................................ 79
KDH drive panel ...................................................................... 80
MX machinery ......................................................................... 82

Table of Contents
KSS signalisation .................................................................... 83

AMD door system ................................................................... 87
Safety at AMD door maintenance ........................................... 88
Exercises ................................................................................ 90
12. Commissioning ........................................................................... 94
Commissioning procedure ...................................................... 95
Exercises ................................................................................ 98
13. Troubleshooting ........................................................................ 101
Locating a fault ..................................................................... 102
Exercises .............................................................................. 104
Glossary .......................................................................................... 105
Index ............................................................................................... 109
Version history ................................................................................ 112

How to use this training package
PURPOSE OF This training package provides a quick overview of maintenance tasks in

TRAINING
KONE MiniSpace™ with KDH drive elevator.
STRUCTURE OF This training package is divided into modules. Each module focuses on a
MODULES
single issue, item or aspect. Each module contains a set of content pages,
each of which follows a consistent structure for easy reference.
LEARNING METHOD This training package is written to self-study format, but can also be used in
organized classroom training. The material is available as a paper-based
publication only.
DURATION It will take you approximately 2 days to complete this training package.
REFERENCE MATERIAL • KONE MiniSpace™ 1.6 with KDH drive Technology book
NEEDED
(TC04818W21-EN)
• Site reference card
• Field reference guide for fault finding of KONE MiniSpace™ LCE (AS-
10.22.004)
• Repair instruction for KONE MiniSpace™ LCE electrification (AS-
10.22.007)
• KONE MiniSpace™ PT, Release 1.6, with KDH drive (AM-01.01.069)
• Advanced modular door, drive 1.5 car door operator electronic (AM-
03.35.024)
• Repair instruction for MX32 and MX40 (AS-04.05.043)
• Maintenance instruction for AMD doors (AS-03.12.036)
• Maintenance instruction for MCD car (AS-06.06.002)
• Maintenance of KSS range signalisation (AS-12.20.004)
• MiniSpace™ 1.6 with KDH drive commissioning and safety inspection
(AM-11.65.023)
• Brake MX32 & MX40 (AM-04.08.024)
• MX machines - enhanced check process (AS-04.05.051)
• Take Care (AS-01.01.004)
• Maintenance instruction for AMD doors (ASG-03.12.036)
• Preventive maintenance of KSS signalisation (ASG-12.20.004)
• Preventive maintenance for MX32 and MX40 (ASG-04.05.043)
• Rescue instruction for KONE MiniSpace™ elevator (AS-01.01.035)

• Site reference guide for KCP931™ and KDH (AS-10.80.001)

• Repair instruction for KCP931™ electrification (AS-10.80.002)
• Repair instruction for KDH drive systems (AS-11.65.013)
• Preventive maintenance instruction for KDH drive systems (ASG-
11.65.013)
• Instruction for handling electrostatic-discharge-sensitive-devices on
site (AS-12.02.001)
• Troubleshooting instruction for AMD drive 2 (AM-03.35.020)
OTHER RELATED • LCE and KCP931™ electrification for KONE MiniSpace™ elevators
DOCUMENTS
(AR-10.22.002)
• Spare parts manual for KDH drive systems (AR-11.65.013)
• LCE and KCP931™ electrification for KONE MiniSpace™ elevators
(AR-10.22.002)
• AMD landing door (AR-03.12.076)
• AMD car door (AR-03.12.037)
• Spare part manual for safety devices used with AMD automatic doors
(AR-03.18.006)
• KSS range signalisation spare parts (AR-12.20.004)
• Spare parts manual for MCD concept (KONE MiniSpace®, Mono-
Space® Special & Alta ™ elevators) (AR-06.10.001)
• Axial motor machinery MX32 (AR-04.06.006)
• Axial motor machinery MX40 (AR-04.06.007)

Introduction
1. Introduction
1037858.wmf
The Maintenance Learning Guide workbook has been designed by the

Training Center specially for KONE MiniSpace™ with KDH drive field train-
ing. Use this workbook together with KONE MiniSpace™ 1.6 with KDH
drive Technology book (TC04818W21-EN).
This Learning Guide introduces all new and important items that must be
taken into consideration when performing maintenance for KONE MiniS-
pace™ with KDH drive elevator. All important new or critical safety items are
introduced. Related documents become familiar by completing the tasks in
this workbook.

KONE MiniSpace™ 1.6 with KDH drive concept
2. KONE MiniSpace™ 1.6 with KDH drive

concept
1033600.wmf
Product in a nutshell:
– KONE EcoDisc® machine (MX32 or MX40)

– AMD doors
– MCD car (Modular Car Design)
– KSS signalisation
– LCE electrification for KCP931™ (KONE Controller Performance)
– KDH drive system

New features
What kind of new features does KONE MiniSpace™ with

KDH drive include?
SUMMARY KONE MiniSpace™ with KDH drive extends the elevator performance to
cover higher speeds with heavier loads.
1037448.wmf
KEY POINTS – Higher speed up to 6.0 m/s with a load 2050 kg

– Stronger hoisting machine MX40
– New LCE electrification called KCP931™
– New KONE Drive system called KDH
Refer-to:KONE MiniSpace™ 1.6 with KDH drive Technology book
(TC04818W21-EN)
reference/TC06xxxxx.pdf
KDH DRIVES The KONE Drive for High rise elevator (KDH) is based on ABB drive panel
and KONE motion control (DCBH-module). The KDH family is composed of
drive types: KDH100, 150, 200 and 300. The KDH300 drive together with
MX40 machine achieve the maximum performance of the
KONE MiniSpace™ with KDH drive elevator. (6.0 m/s with 2050 kg load)

Exercises
EXERCISE 2.1 What are the main new items in KONE MiniSpace™ with KDH drive?
EXERCISE 2.2 Give the correct product information for KONE MiniSpace™ with KDH drive
elevator.
(TC04818W21-EN).
Maximum number of floors:____
Maximum speed is:____
Load range is up to:____
Signalisation used is:____
Machinery used is:____
Drive used is:____

LCE electrification in general
3. LCE electrification in general
1037450.wmf

LCE electrification for KCP931™
What is KCP931™?
SUMMARY The KCP931™ is a new LCE electrification system. (KONE Controller Per-
formance).
Main switch unit
Supply for
segmented
shaft network
LCE control
panel
1037451.wmf
KEY POINTS – The KCP931™ is a new electrification system is based to KONE LCE
electrification
– New control panel for KCP931™ is used with the KDH drives in mid
and high rise elevators
– Control panel includes also a DCBH module which is actually a part of
the KDH drive
MAIN SWITCHES The main switch unit for elevator and supply for segmented shaft network
are located in separate boxes in machine room wall.

LCE ELECTRIFICATION The KONE MiniSpace™ with KDH drive electrification system is divided in
SECTIONS
following sections.
KONE MiniSpace™1.6 with KDH drive

electrification system
Control panel for KCP931™
KDH drive panel
Machine room electrification
Car electrification
Shaft electrification
1037452.wmf

Exercises
EXERCISE 3.1 Identify the LCE components.

(TC04818W21-EN)
1 7
8
9
10
11
12
13
3 14
4
5 15
16
6 17
1037453.wmf
1. 10.
2. 11.
3. 12.
4. 13.
5. 14.
6. 15.
7. 16.
8. 17.
9. 18.

4. Machine room electrification
1037454.wmf

Main switch boxes
Where are the supply switches for elevator?
SUMMARY There are two main switch boxes on the machine room wall. One for the el-
evator and the other for segmented shaft network.
L3
L1 L2
F1 F2 F3 F4
N N N N PE PE PE PE PE
387
Q1
I
N
L1 N T
N N PE PE
0
Q5
Q2 F6 F5 F4
F5/2
F4/2
1L1
3L2
5L3
1037455.wmf
KEY POINTS – Main switches for the elevator and segmented shaft network are
placed inside two separate boxes on the machine room wall
– The elevator main switch box provides also the power for car and shaft
lighting
– The power supply for the segmented shaft network needs an own riser
POWER SUPPLY FOR The power supply for segmented shaft network is always needed when
SEGMENTED SHAFT
NETWORK
there are more than 11 floors in a single elevator.
In case when there are more than four elevators, two separate power sup-
plies for segmented shaft network are needed. In other words, one power
supply for elevators 1 to 4 and the other one for elevators 5 to 8.

ELECTRICAL SAFETY Be familiar with the instruction AM-01.03.002 “Electrical safety when work-
WHEN WORKING WITH
ELEVATORS
ing with elevators”.
Lock and tag the main switches:
OT
DO N CH
SWIT
1017329.wmf ON
5 steps to ensure electrical safety:

• 1) Disconnect power supply completely
• 2) Secure against re-connection
• 3) Verify that the installation is de-energised
• 4) Check the requirements for earthing in special circumstances
• 5) Provide protection against adjacent live parts

Control panel
What components does the control panel include?
SUMMARY The control panel includes an elevator controller which is the main part of
the LCE electrification system.
STOP switch Switch

module
CPU module
(User interface)
LCEADO
board
LCEETSL DCBH
board module
1037457.wmf
KEY POINTS – Control panel includes elevator controller

– The main part of the elevator controller is a CPU module
– The DCBH module which is actually a part of the KDH drive is located
in the control panel also
(TC04818W21-EN)

HIGH SPEED DRIVE The motion control of the elevator is done with the DCBH module. Notice
CONTROL MODULE
(DCBH)
that the power for DCBH module is taken separately from the inverter inter-
mediate circuit. (24 VDC)
DCBH PWR
board
DCBH
CPU board
KDNTS
board
1037458.wmf

TRAFFIC SUPERVISION The traffic supervision display is located in the supervision room (if any).
DISPLAY (TSD)
The connection to the control panel is done through a serial link interface.
The traffic supervision display contains an LCECOB board. Also an LCER-
AL board is needed for alarm connections. It is located in the control panel.
Machine room Supervision room
Traffic supervision display
Control panel
LCERAL
LCECOB
1037459.wmf

KDH drive panel
What components does the drive panel include?
SUMMARY The KDH drive is based on ABB drive panel and KONE motion control. The
drive panel consists of line bridge (ISU), motor bridge (INU) and brake con-
trol units.
KDH150
Line bridge (ISU)
Motor bridge
(INU)
LCL filter unit
Brake control
Du/dt units
filter
1037460.wmf
KEY POINTS – The KDH drive family consists of models KDH100, 150, 200 and 300
– The KDH drive panel contains line bridge (ISU), motor bridge (INU)
and brake control units
– The KDH drive cabinets are designed to be maintained from the front
of the cabinet
KDH MAINTENANCE Notice that only a trained maintenance personnel is allowed to work with the
AND TRAINING
KDH drive panel.
INVERTER UNIT INU INverter motor control Unit (INU) supplies a power from the DC-link to the
motor and feeds regenerated power back to the DC-link.

INVERTER UNIT ISU Inverter Supply Unit (ISU) supplies a power to the DC-link and feeds back
the regenerated power from the DC-link to network.
NOTE! The KDH drive system is using the ISU as a normal braking and
resistor braking is used only in an emergency situation.
LCL FILTER An LCL filter is used at the input of the IGBT supply module to suppress volt-
age and current distortion across a wide frequency range.

Machine cabling
What are the special requirements for machine cabling?
SUMMARY The low voltage (signal) cables must be separated from the high voltage ca-
bles.
Resolver cable
Encoder cable
Thermistor cable
Machine supply cable
Main supply cable
1037461.wmf
KEY POINTS – The machine supply and main supply cables must be separated from
the low voltage cables; resolver, encoder and thermistor with a dis-
tance more than 100 mm
– Cables can cross each other in angle of 90 degrees
WORKING WITH Before making any changes to the cabling, remember to open and lock the
CABLES
mains switch!

Exercises
EXERCISE 4.1 Name the machine room components.

(TC04818W21-EN)
EXERCISE 4.2 What drive component does the LCE control panel include?

EXERCISE 4.4 What is an ISU unit?
EXERCISE 4.5 If making changes to the machine cabling, what precautions must be taken
care of to ensure that the power supply is not unexpectedly switched on?

5. Shaft electrification
1037690.wmf

Landing door safety chain
How is the shaft bundle built?
SUMMARY The shaft bundle of landing door safety chain contains two standard wire
sets.
4-floor cable (a)

5 121 122
Y-cable (b)
4
121 122
121 122
Connector (c)
3
121 122
2 121 122 Extra floor cable (d)
121 122
1 Door and door lock

contacts (e)
1037477.wmf
KEY POINTS – One shaft bundle contains two standard cables: a 4-floor cable and an
extra floor cable
– The door and door lock contactsof a B-door is connected to the shaft
bundle with an Y-cable
– The shaft bundle contains cable plugs for connections
STANDARD FLOOR TO The standard floor to floor distance is 5 meters and the excess length of the
FLOOR DISTANCE
cable is coiled and fitted inside the trunking.

CONNECTION TO LCE The landing door safety chain cable is connected to the LCE safety circuit
CONTROL PANEL
board (LCEADO).
CABLING Cables installed in shaft pit must be protected against damage with alumin-
REQUIREMENTS IN PIT
ium conduit.
Cable trunking (plastic)
Aluminium conduit
1037692.wmf

Landing calls and signalisation
What cables are used in signalling network?
SUMMARY The signalling network consists of wires for the power supply and serial
transmission plus floor control boards for every door.
5 meters
5
5 Floor control board (A-side setting)
0.5 meters
5
4 5
5 Floor control board (B-side setting)

3
5 Floor option board
2
PRL Termination plug
5
1
1037693.wmf
KEY POINTS – The standard length of cables are 5 and 0.5 meters
– The safety chain bundle must be placed at the bottom of the trunking
and the network bundle on top
– A termination resistor is connected at the end of the communication
line
TE RMINAT ION OF THE A serial communication line must always be terminated with a resistor (ter-
SERIAL NETWORK
mination plug). Otherwise the communication line may malfunction.

PCB BOARDS IN The floor control board (LCEFCB) is used for every landing door. The land-
TRUNKING
ing calls and displays are connected to this board.
The floor option board (LCEFOB) is used for floor option signals (e.g. prior-
ity landing call). The board is connected to the signalling network right after
the floor control board.
The safety chain bundle must be placed at the bottom of the trunking and
the network bundle on top.
Floor control board
High-voltage cables
at the bottom of the
trunking
1037694.wmf
Caution! The high-voltage cables may not cross over the floor control
board in no circumstances.

SEGMENTED SHAFT The segmented shaft network is needed when one LCEREC board is not
NETWORK
enough to supply power for all floor control boards and signalisation. In seg-
mented shaft network each segment contain a shaft network module. The
module includes a power supply unit and an LCEGTWO(G02) board.
The segmented shaft network is used in mid- and high-rise elevators.
Shaft network module
LCEGTWO(G02)
board
Power supply unit
1037695.wmf
NOTE! The main switch for segmented shaft network is installed in a sep-
arate box on the machine room wall.
(TC04818W21-EN).

Floor Control Board (LCEFCB)
What role plays the LCEFCB board in signalisation net-

work?
SUMMARY The floor control board is the communication link between the floor signal
devices and the CPU.
1037720.wmf
Door side
selection
KEY POINTS – Connects floor signals to LCECPU

– Connected to LCECPU through the LON serial network
DOOR SIDE The door side (A or B) is selected with the jumper X1. For example, in case
SELECTION
of the B-door, the jumper is placed so that it over connects pins 2 and 3.
FLOOR SETTINGS No floor settings are needed because the system sets them automatically
on the setup drive.

CONNECTORS ON Connectors on LCEFCB board.

LCEFCB BOARD
Connector Description Connector Description
XF1 calls XS1 signalisation net-

work plugs
XF2 display unit XS2
XF3 out-of-service key X4 out-of-service indi-

switch inputs cation lamp
LEDS ON LCEFCB LEDs on LCEFCB board.

BOARD
LED Description LED Description
L1 power OK L2 board broken
JUMPERS ON LCEFCB Jumpers on LCEFCB board.

BOARD
Jumper Description
X1 door side selection

(A=front door)

Floor option board (LCEFOB)
What purpose the LCEFOB board has in signalisation net-

work?
SUMMARY The LCEFOB is used as an interface board for DOM devices (DOM reset
switch on bottom floor level etc.). Also optional devices like a Fireman’s
Drive Switch (FRD) are connected to the LCEFOB board.
1037725.wmf
Door side
selection
KEY POINTS – LCEFOB connects floor option signals to LCECPU

– LCEFOB is connected to LCECPU through the LON serial network
DOOR SIDE The door side (A or B) is selected with the jumper X1. For example, in case
SELECTION
of the B-door, the jumper is placed so that it over connects pins 2 and 3.
FLOOR SETTINGS In case of replacing the LCEFOB board, the roll call automatically detects
and defines a floor number to the board. Therefore the floor number jump-
ers (X2-X6) are not used.

CONNECTORS ON Connectors on LCEFOB board.

LCEFOB BOARD
XS1 signalisation net- XF8 DOM indication

work plugs
XS2 XF9 input PRL or HEL
key switch
XF5 DOM reset (key XF10 output PRL or HEL

switch/button) indication
XF6 DOM buzzer (shaft XF7, XF11, not used

pit) XF12
LEDS ON LCEFOB LEDs on LCEFOB board.

BOARD
L1 power OK L2 board broken
JUMPERS ON LCEFOB Jumpers on LCEFOB board.

BOARD
Jumper Description
X1 door side selection

(A=front door)

Signalling devices at landing
What signalling devices are used at landing?
SUMMARY KONE MiniSpace™ with KDH drive elevator uses KSS signalisation sys-
tem. The signalling devices at landing are surface- or flush mounted.
Picture shows devices used in a surface mounted signalisation.
1037696.wmf
KEY POINTS – KSS signalisation devices are used

– New button and switch constructions (button/switch includes a small
PCB board)
– Signalisation devices are connected to the LCEFCB board
THREE DIFFERENT The product range of signalisation devices in KSS is splitted in three sets.
PRODUCT SETS
1 Surface mounted signalisation
2 Thinline signalisation
3 Flush mounted signalisation
Refer-to:Maintenance of KSS range signalisation (AS-12.20.004) for more
detailed information of these three different sets.

FIXING PRINCIPLE OF There are pre-drilled holes on door frame for fixing screws of signalling de-
SIGNALLING DEVICE
vices, cables and any key switches. The picture shows how the buttons and
landing call stations are fixed on the door frame in surface mounted type of
devices.
Landing call station
Button
Button cable
(std. length 7 m.)
Fixing ring nut

(max. torque 5 Nm)
1037697.wmf
NOTE! Notice that the button contains a small PCB board. Therefore pay
special care to not to damage the PCB board when e.g. replacing
the pressel.

Exercises
EXERCISE 5.1 What cable do you need for B door and how is it connected to the safety
chain?
EXERCISE 5.2 Where the floor option board is placed on the signalling network?
EXERCISE 5.3 When is the segmented shaft network needed?

EXERCISE 5.4 Identify and mark the device with the correct number.
1 6
7
2 8
3 8
8
4
10
1037698.wmf
____ Floor control board LCEFCB (A-side setting)

____ Floor control board (B-side setting)
____ Y-cable
____ Floor option board LCEFOB
____ Shaft bundle for the door safety chain
____ Door contact
____ Signalisation network LON
____ Signalisation devices
____ Shaft pit safety circuit
____ Termination resistor

EXERCISE 5.5 When replacing the last floor control board on network line, how do you end
the serial network line?

Car electrification
6. Car electrification
1037699.wmf

Car electrification
Principle of the car electrification
What devices does the car electrification contain?
SUMMARY The main parts of the car electrification are the car connection box on car
roof and car operating panel (COP) inside the car.
Car operating panel
Car connection box
F2KMUL
board
KNXRIF or
KNX99 board
1037700.wmf
KEY POINTS – The car connection box includes an LCECCBN2 board and either a
F2KX99 or KRMRIF board
– The car operating panel contains an F2KMUL board
– Two travelling cables for serial network and high voltage connections
TRAVELLING CABLES One of the travelling cables is a flat cable with a twisted pair. This cable is
ARE ROUTED IN THE
CAR CONNECTION BOX
for low voltage signals and wired directly to the control panel. The other ca-
ble is for the high voltage connections, such as the car lighting, door oper-
ator power supply, ventilator and safety chain.

Car electrification
Car connection board (LCECCBN2)
What is a purpose of the LCECCBN2 board?
SUMMARY The LCECCBN2 board is used for the connections of all the electrical de-
vices on the car roof.
KEY POINTS – Connects all electrical devices on the car roof

– Travelling cables are connected to this board
– The LCECCBN2 communicates with the F2KMUL board and elevator
control system through a LON network
LEDS GIVE The LCECCBN2 board has LEDs for the magnetic switches, network, pow-
INFORMATION
er supply and alarm battery. The fail (L1) and 24V OK (L2) LEDs on the
LCECCB board indicate the condition of the board. L8 LED indicates wheth-
er the battery fuse F2 is OK. A current position of the car can be determined
from the LEDs L11-L17.

Car electrification
CONNECTORS ON Connectors on LCECCBN2 board.

LCECCB BOARD
XB1 Final limit switch XB25 Deceleration switch

51. up 77:U.
XB2 Safety gear 52. XB26 Deceleration switch

down 77:N.
XB3 Inspection station XB27 Synchronisation

42. switch 77:S.
XB4 Rear door stop but- XB28 Door operator A /

ton B41. A84.
XB5 Safety lock 63. XB29 Photocell A / A90.
XB6 Trap door 57. XB30 Door operator B /

B84.
XB7 Door contact A87. XB31 Photocell B / B90.
XB8 Door contact B87. XB32 Battery 227.
XB11 Isolation test. XB33 KoneXion.
XB12 Inspection station XB34 Emergency light for

24 VDC signals 42. car roof.
XB13 230 VAC plug 45. XB35 Alarm bell 65.
XB14 Car light 44. XB37 DSS (door set

speed) B output
XB15 Car ventilation 43. XB40 Stop switch in car

40
XB16 Door A supply. XB45 Service drive limit

switch 68:U
XB17 Door B supply. XB50 Load weighting

device 64
XB18 To Car Operating XB56 EXT SUPPLY

Panel. 230VAC/6A
XB21 Door zone A30. XT1 To the LCECPU

board --> XC11.
XB22 Step up 61:U. XT2 To LCECPU -->

XC12.
XB23 Step down 61:N. XT3 To LCE230 --> XC3

and XC4.
XB24 Door zone B / B30. XT4 To LCECPU -->

XC1.

Car electrification
LEDS ON LCEFCB LEDs on LCECCBN2 board.

BOARD
L1 24 VDC power sup- L11 30

ply OK
L2 Battery OK L12 61U
L3 LON fail L13 61N
L4 Battery test L14 B30
L5 Car light OK L15 77U
L6 Car light OFF L16 77N
L7 Car ventilation L17 77S

OFF.
L8 Battery indication
FUSES ON LCEFCB Fuses on LCECCBN2 board.

BOARD
Jumper Description Jumper Description
F1 24 VDC power F2 Battery.

supply

Car electrification
COP Multi-board (F2KMUL)
What role plays the F2KMUL board in KSS signalisation?
SUMMARY The F2KMUL board works like an interface between the controller and COP
panel.
From LCE
To next COP
Display connector
Car communication
line 2 connector
Car communication
line 1 connector
Alarm button
connector
1037705.wmf
KEY POINTS – Devices controlled by COP are connected to this board

– F2KMUL board is connected to the LCECCBN2 board throughout the
KNXRIF board
INTERFACES The board has interfaces for the display (J5), alarm button (J4), buzzer and
gong (J1) and LON network (J2, J3). The so called intelligent buttons and
switches in the COP are connected to F2KMUL board by the button buses
(J6, J8).

Car electrification
CONNECTORS ON Connectors on F2KMUL board.

F2KMUL BOARD
J1 Audio equipment J5 Display

(loudspeaker and
microphone)
J2 Network in J6 Car button bus 1
J3 Network out J8 Car button bus 2
J4 Alarm button
TW O C OMMUNICATION The F2KMUL board has two communication lines, one for A and one for B-
LINES FOR A AND B-
SIDES
side. The buttons and switches on COP panel are connected to the commu-
nication lines (flat cables).
CAR
XT1 XS1
XB18
KNX- RIF
XS2
LCE CCB
X12
Speak now
Help is F2K EML
coming
J2 J3
J5
DISPLAY
F2KMUL J4 F2K ALM
J1
J6 J8
Communication line 1(A side) Communication line 2(B side)
F2K KIB Floor 1
F2K KIB Floor 3 F2K KIB Floor 4

Buttons /
F2K KIB Floor n-1 F2K KIB Floor n switches
Buttons / F2K KS2 Option 1 F2K CIR
switches
F2K KS2 Option 2
F2K KS2 Option n-1
F2K KS2 Option n

1037707.wmf

Car electrification
Remote Interface board (KRMRIF)
Where is this board and why is it needed?
SUMMARY The KRMRIF board is located inside the car connection box. This board in-
terfaces the F2KMUL board to the LCECCBN2 board. It also handles all
voice link functions, data communication and telephone line handling.
1037712.wmf
KEY POINTS – Needed to interface the F2KMUL board to the LCECCBN2 board in
KSS signalisation system
– If the elevator uses the KoneXion version KX99 the KRMRIF board is
replaced by a F2KX99 board
– Handles also other functions like a communication between elevator
and KONE Service Center.
REPLACES KONEXION The KRMRIF board replaces the following KoneXion KX99 parts:.
KX99 PARTS
• Base unit
• Car unit box
• LCEKNX, LCEADJ and LCEVOI boards

Car electrification
Car positioning system
What are the positioning system components?
SUMMARY The car positioning is done with the High Speed Positioning system (HIPO-
M-a). Also the car top encoder gives an exact information of the current car
position.
Car top encoder
HIPO-M-a
Reader unit
FLoor code plate
1037715.wmf
KEY POINTS – HIPO-M-a system consists of a reader unit and floor code plates
– Car top encoder ensures that the position of the car is always known
HIPO-M-A The HIPO-M-a is a magnetically operating positioning system that gener-

ates the door zone (30), floor code and levelling (61:U and 61:N) signals. It
consists of a reader unit and floor code plate. The floor code plates are fixed
to landing door sills and the reader unit is fixed to the car door sill.
CAR TOP ENCODER The car top encoder is mounted on the car sling and its wheel rotates
against the car guide rail surface. The current car position is always known,
even if the ropes stretch during a deceleration.

Car electrification
Exercises
EXERCISE 6.1 Identify parts of the car electrification.
1
2
5
6
7
77:U
51 77:N
8
3
64
52
1037745.wmf
Place the correct number from the picture.

____ COP Multi-board F2KMUL
____ Signalisation cable
____ Safety gear contact
____ HIPO floor code plate
____ Car connection board LCECCBN2
____ Final limit switch
____ High-voltage cable
____ HIPO reader unit
____ Termination resistor
____ Car encoder

Car electrification
EXERCISE 6.2 How the communication between LCECCBN2 and F2KMUL boards has
been arranged?
EXERCISE 6.3 What are the main parts of the HIPO-M-a positioning system?

Elevator system
7. Elevator system
LCE
KONE Group
UPS-Device
Control
X1
X2
XG4A XG4B
Elevator 3
Monitoring Control Panel
Workstation 5V DC OK
LCECAN-boardT2A
POWER OK XG4A KElevator

ON E
XG4B 3
HIGH TEMP
Control Panel
LCECAN-board
GROUP CONTROL COMPUTER
657490 G04 rev._._
X3 X4 POWER SUPPLY
230/115VAC
XG4A XG4B
Elevator 4
X2
Control Panel
LCECAN-board
LD FUNCTION
01
02
XG4A
LIFT 1
LIFT 2
XG4B
Elevator 4
03 LIFT 3
04 LIFT 4
05 LIFT 5
06 LIFT 6
01 LIFT 7
Control Panel
02 LIFT 8
03 CALLS
04 MON WS
05 WATCHDOG
LCECAN-board
06 MASTER
03 ALLOCATION
04 ECONOMY
05 TF
06 FAULT
X1 X2
WORKSTATION XG4A XG4B

MONITORING LED-TEST
CONTROL
SYSTEM
LED-INVERT
1037747.wmf

Elevator system
Group control operations
How the group control operates between elevators?
SUMMARY The group control system uses the LON and CAN networks for communi-
cation between elevators.
ELEVATOR 1 ELEVATOR 2 ELEVATOR 3 ELEVATOR 8
KDH KDH KDH KDH

Group
Control
Computer
LCECPU40 LCECPU40 LCECPU40 CAN LCECPU40
network
LCECAN LCECAN LCECAN LCECAN
LCEGTWO LCEGTWO LCEGTWO LCEGTWO
LON
network
Connections for shaft and car electrification
LCECCBN
or
LCEFCB
F2KX99 KRMRIF
LCEFCB
LCEFCB
F2KMUL
LCEFCB
1037748.wmf
KEY POINTS – Duplex elevator group uses LON network

– Triplex and special duplex elevator groups use CAN and LON net-
works
– Landing calls and their backup supply are connected to LON network
via an LCEGTWO board
– When there are more than 4 elevators in an elevator group the group
control computer is needed
GROUP CONTROL The group control handles the landing calls, recognizing of traffic patterns
FUNCTIONS
and group parking.
(TC04818W21-EN).

Elevator system
GROUP CONTROL When there are more than 4 elevators in an elevator group the group control
COMPUTER
computer is used.
Principle of group control system
LCE
KONE Group Elevator 1

UPS-Device
Control Control Panel
LCECAN-board
BACK-UP
Powered
XG4A XG4B
Pattery
Power
Sypply Group Network
X1
X2
Elevator 2
Power Supply
Control Panel
LCECAN-board
Monitoring Network
XG4A XG4B
Power Supply Monitoring

(socket outlet) Workstation
Elevator 3
Control Panel
LCECAN-board
XG4A XG4B
X2
Elevator 4
Control Panel
LCECAN-board
XG4A XG4B
= Terminal resistor 120 OhM !
1037749.wmf
NOTE! It is important to connect the terminal resistors to ensure correct

operation of the networks.

Elevator system
Roll call
How does the roll call operate?
SUMMARY The LCE identifies LCEFCB boards at landings with the roll call. The roll call
notifies from which floor it is receiving calls and whether all boards are op-
erating.
+24V 0/24V
LCECPU40
LCEFCB LCEFCB
LCEFCB
XH12
XS1
XS2
XS2
XS1
R
TX-/RX+ Roll call Termination

wire resistor 120 ohm
1037750.wmf
KEY POINTS – Failed LCEFCB board can be identified with the User Interface
– The “hoistway communication OK” LED illuminates when the shaft roll
call is operating properly
– Same roll call method is used on the car side also. The “car communi-
cation OK” LED illuminates when the car roll call is operating properly
BASIC FUNCTION OF Roll Call takes place every time when the power is switched on. The LCE
ROLL CALL
control sends a reset signal to the nearest floor control board through the
Roll Call wire.
‘The floor control board sends an identification number and jumber setting
to LCE and a reset signal to the next FCB board.
When all the floor control boards have answered, the “hoistway communi-
cation OK” LED on the LCECPU board illuminates. If one of the floor control
boards fails to answer the LCE, the landing calls and signalisation on that
floor and below it do not operate and the FAIL LED illuminates.
The same system is used on the car side also. The LCE calls the car con-
nection board, car operation board and any extension boards. After an ac-
ceptable roll call the “car communication OK” LED illuminates.

Elevator system
LCEGTWO board
What is the purpose of LCEGTWO board?
SUMMARY Landing calls and their backup supply in group elevators are connected by
a LON network via a LCEGTWO board.
Power supply OK led
Group supply OK led
Elevator fail led
Group fail led
1037751.wmf
KEY POINTS – Four LEDs indicate how the board and LON network operate
– If the elevator fail (V101) or group fail (V102) LED illuminates the
board is broken (change the board)
– LED V110 indicates that power supply voltage is OK and V210 indi-
cates that group supply is OK
LOCATION OF BOARD The LCEGTWO(G01) board is located in the control panel.

(TC04818W21-EN).

Elevator system
LCECAN board
When LCECAN board is needed?
SUMMARY The group control data is transmitted through a faster CAN network that op-
erates via a LCECAN board. The only exception is in standard duplex
where everything is managed via the LCEGTW without LCECAN board.
1037752.wmf
KEY POINTS – The LEDs on the boards indicate how the elevator group and elevator
communication networks are operating
– The system is operating normally when the green POWER and CPU
running LEDs are on and the red FAIL and change board LEDs are off
LOCATION OF BOARD The LCECAN board is located in the LCE control panel on top of the
LCECPU board.
(TC04818W21-EN).

Elevator system
KONE Group control computer (KGC)
When the group control computer is needed?
SUMMARY The group control computer is needed when there are more than 4 eleva-
tors in an elevator group. If there are group of elevators (e.g. two elevators)
and more than 36 floors the group control computer is needed also.
KEY POINTS – KGC is needed when there are more than 4 elevators in an elevator
group
– KGC is needed if group of elevators (e.g. two elevators) and more than
36 floors
(TC04818W21-EN)
LEDS Operation LEDs of KGC unit are located on the upper left corner. There are
two green LEDs for indication that the power supply line voltages inside the
computer unit are OK. If a temperature of the computer gets too high the red
high temp LED starts to blink and a beeping alarm sound is being generat-
ed.
In the middle of the computer unit the user interface LEDs shows a current
status of the software during a boot-up, software installation and normal
software run.

Elevator system
Exercises
EXERCISE 7.1 You are on a maintenance visit. When you entered the building you noticed
the following situation: In a two-elevator group, one elevator was already
parked at the entrance floor and after a moment the other elevator also
came down with an empty car and parked on the same floor. Is that OK?
How are you going to check group operation?
EXERCISE 7.2 User interface shows the fault code “1403”. Landing call from 2nd floor do
not function. What is the possible reason?
Refer-to:Site reference card.
EXERCISE 7.3 What are the “tasks” of the LCEGTWO board in duplex and triplex elevator
groups?
EXERCISE 7.4 When the group control computer is needed?

LCE user interface
8. LCE user interface
1037851.wmf

LCE user interface
How to use LCE user interface
What can I do with the LCE user interface?
SUMMARY In a service engineer perspective the LCE User Interface is a tool for fine
tuning and troubleshooting the elevator. Also adjustments like an adjust-
ment of load weighing device are carried out with the LCE user interface.
The LCE user interface is located inside the control cabinet.
1037854.wmf
KEY POINTS – The user interface contains different function modes and menus
– With the buttons you can change the parameter values, give a car call
and the display shows a current status of the elevator all the time
– LEDs on the middle of the board give information about elevator oper-
ation
FUNCTION MODES Different function modes are: Fault log (E), elevator parameters (1), floor
markings (3), display and tests (4), commissioning (5), drive parameters (6)
and elevator parameters (7).
NOTE! The menu (2) is not used with the drive V3F25. The drive param-
eters are set in menu (6).

LCE user interface
Exercises
EXERCISE 8.1 The car is at the bottom floor. Describe how you give a car call to the 3rd
floor by using the user interface.

AMD door system
9. AMD door system
Correct operation of the doors is a crucial part of elevator performance.

Therefore, a lot of effort should be directed at door maintenance. The AMD
door does not need more maintenance than the other door types.

AMD door system
Structure of the AMD doors
What are the main parts of the AMD doors?
SUMMARY AMD is a modular door system with pre-defined landing- and car door pack-
ages. Both the AMD landing door (AMDL) and car door (AMDC) consists of
four main elements.
Drive 1.5 or 2.0 Landing doors

Car doors
Railing 2
Railing 2
Door coupler
Hanger plate
Door panels
Door panels
Guide shoes
Sill
Sill
Apron
Toe guard 1031737.wmf

1031736.wmf
KEY POINTS – Main parts of AMD landing door are: a frame, railing, door panel and
sill
– Main parts of AMD car door are: a drive, railing, door panel and sill
VARIOUS On the landing side, the frames/fronts are not specified to the railings. So
COMBINATIONS
they can be mixed according to the customers needs. On the car side, both
drives can be used with all car door panels.
There are two models of the door drive used in KONE MiniSpace™ 1.6,
drive 1.5 and drive 2. The railing used is type 2.
Refer-to: KONE MiniSpace™ 1.6 with KDH drive Technology book
(TC04818W21-EN)

AMD door system
AMD DOOR PRODUCT

CODES
AMDC1C - 1100x2000
Car door Type 1 Centre opening Width x height
Landing door Type 2 Right opening
Type 3 Left opening

AMD door system
Exercises
EXERCISE 9.1 How many main parts the AMD car door consists of? Does the AMD doors
require more maintenance than the other door types?
EXERCISE 9.2 What drive type and railing are typically used in KONE MiniSpace™ 1.6?

Preventive maintenance
10. Preventive maintenance
Maintenance of the LCE components follows the KONE Quality Mainte-

nance concept. It is based on the number of starts, visual observation and
knowledge about components.

During a routine service visit
What does a routine maintenance visit include?
SUMMARY Routine maintenance tasks do not differ from the same tasks for conven-
tional elevators.
1037858.wmf
KEY POINTS – Maintenance work must be carried out by a competent and qualified
personnel only
– Familiarize yuorself with special care about the safety items described
in ASG document, especially the chapter “Maintenance method safety”
BRAKES OF THE MX Pay special attention to the brakes on the MX machine. Routine brake test
MACHINE
must be carried out at a frequency of once every 6 months. (One-side brake
test).
Refer-to: MX machines - enhanced check process (AS-04.05.051)

PREVENTIVE Normal routine maintenance work is similar to the other elevators. The fol-
MAINTENANCE
INSTRUCTIONS
lowing table contains preventive maintenance instructions used with KONE
MiniSpace™ with KDH drive elevator. The latest version of document can
be found from the KONE EDMS intranet.
Document Elevator
Description
number part
ASG-04.05.043 Preventive maintenance for MX32 and Machine

MX40
ASG-11.65.013 Preventive maintenance instruction for Electrifica-

KDH drive systems tion
ASG-03.12.036 Maintenance instruction for AMD Doors

doors
ASG-12.20.004 Preventive maintenance of KSS sig- Signalisa-

nalisation tion

Exercises
EXERCISE 10.1 What safety aspect must be remembered when working with inverter?
Refer-to:Preventive maintenance instruction for KDH drive systems (ASG-
11.65.013)
EXERCISE 10.2 What checks you will carry out during a routine service visit of the drive pan-
el? Name at least 4 items.
11.65.013)
EXERCISE 10.3 It is important to keep the drive comfort at the optimal level. Therefore dur-
ing a service visit you will check, what?

EXERCISE 10.4 What “routine” checks and tasks the maintenance of MX32 machinery con-
tain? Write down all tasks you can remember and then compare to the ASG-
document.
Refer-to:Preventive maintenance for MX32 and MX40 (ASG-04.05.043)
EXERCISE 10.5 What shaft devices should be especially checked during a service visit?
Does the LCEFCB boards need any preventive maintenance?
EXERCISE 10.6 What safety measures there are during a lighting replacement in MCD car.
Refer-to: Maintenance instruction for MCD car (AS-06.06.002)

EXERCISE 10.7 Make a list of actions during a normal service visit for the AMD door.
Refer-to:Maintenance instruction for AMD doors (ASG-03.12.036).
EXERCISE 10.8 Why and when should you check the vertical straightness of the top track
trail?

EXERCISE 10.9 You are checking AMD doors. Mark the suitable values in the following pic-
tures.
Refer-to:Maintenance instruction for AMD doors (ASG-03.12.036).
mm mm
mm
mm mm
mm
mm
mm mm
mm
mm
1037859.wmf
Side opening Center opening
N N N
max. mm max. mm
1037860.wmf

Corrective maintenance
11. Corrective maintenance
1037861.wmf
Maintenance work must be carried out by a competent and qualified per-

sonnel only.
Remember also to take care of the waste materials according to the require-
ments of the local authorities and KONE environment policy.

Elevator components
How to replace a broken component?
SUMMARY It is important to be familiar with the instructions concerning the component

you are going to work with.
1037862.wmf
KEY POINTS – Before starting the maintenance work, be familiar with the mainte-
nance instruction concerning the component you are about to working
with
– Familiarize yourself with special care the safety items described in AS
document, especially the chapter “Maintenance method safety”
– Remember, that the maintenance work must be carried out by a com-
petent and qualified person only

CORRECTIVE The following table contains corrective maintenance instructions used in

MAINTENANCE
INSTRUCTIONS
KONE MiniSpace™ with KDH drive elevator. The latest version of docu-
ment can be found from the KONE EDMS intranet.
Document Elevator
Description
number part
AS-04.05.043 Repair instruction for MX32 and MX40 Machine
AS-04.05.051 MX machines - enhanced check proc-

ess
AS-10.80.001 Site reference guide for KCP931™ Electrifica-

and KDH tion
AS-10.80.002 Repair instruction for KCP931™ elec-

trification
AS-12.02.001 Instruction for handling electrostatic-

discharge-sensitive-devices on site
AS-11.65.013 Repair instruction for KDH drive sys-

tems
AS-03.12.036 Maintenance instruction for AMD Doors

doors
AS-06.06.002 Maintenance instruction for MCD car Car
AS-12.20.004 Maintenance of KSS range signalisa- Signalisa-

tion tion
SPARE PARTS The following table contains spare parts instructions for KONE MiniSpace™
INSTRUCTIONS
1.6 elevator. The latest version of document can be found on the KONE
EDMS intranet.
Document Elevator
Description
number part
AR-04.06.006 Axial motor machinery MX32 Machine
AR-04.06.007 Axial motor machinery MX40
AR-10.22.002 LCE and KCP931™ electrification for Electrifica-

KONE MiniSpace™ elevators tion
AR-11.65.013 Spare parts manual for KDH drive sys-

tems

Document Elevator
Description
number part
AR-03.12.037 AMD car door Doors
AR-03.12.076 AMD landing door
AR-03.18.006 Spare part manual for safety devices

used with AMD automatic doors
AR-06.10.001 Spare parts manual for MCD concept Car

(KONE MiniSpace®, MonoSpace®
Special & Alta ™ elevators)
AR-12.20.004 KSS range signalisation spare parts Signalisa-

tion
RESCUE AND SAFETY The following table contains rescue and safety instructions for KONE Min-
INSTRUCTIONS
iSpace™ 1.6 elevator. The latest version of document can be found on the
KONE EDMS intranet.
document elevator
description
number part
AS-01.01.035 Rescue instruction for KONE MiniS- Elevator

pace™ elevator
AS-01.01.004 Take Care Elevator

Replacing electrical components on site
How to prevent spare part boards from damaging by cause

of an electrostatic discharge?
SUMMARY Electrostatic discharge sensitive devices like PC boards must be handled

so that they do not be exposed to electrostatic discharges coming from e.g.
service engineers hands.
S
ESD
1037796.wmf
KEY POINTS – Usage of ESD protective clothing is recommended (coats, shoes etc.)
– Do not unpack packages marked with ESDS sign before actual
replacement work
– Handle PC boards by taking a grip from the board edges
HANDLING OF PC The PC boards should be handled by taking a firm grip from the board edg-
BOARDS
es. Never touch components or connectors if not necessary. The old boards
should always be handled the same way as new ones.

LCE control cabinet
How do I transfer an old LCE software to a new LCECPU

board?
SUMMARY The main controller of the elevator (LCECPU40 board) is located in the con-
trol cabinet. In case the LCECPU40 board is replaced the LCE software
stored in EPROM should be moved from the old board to the new.
1037863.wmf
KEY POINTS – Elevator LCE software is stored in the EPROM

– Changeable elevator parameters are stored in the NVRAM memory
circuit which has a battery backup lifetime 10 years
– The new (replaced) LCECPU parameters and settings stored in
NVRAM must be checked and modified to match the settings from the
old board
SETTINGS AND The factory settings are basic defaults and the field settings are for fine tun-
PARAMETERS
ing on site. The field settings (parameters) can be preset with the user in-
terface in LCE. Also diagnostics data is stored in the NVRAM memory.
When you make parameter changes, mark them also in the parameter table
included in the elevator documentation!

KDH drive panel
What maintenance actions can I do to the KDH drive?
SUMMARY Recommendation is that the replacements of power components are done

at the factory or local ABB workshop. But in some special cases the power
components of the drive can be replaced on site.
1037864.wmf
KEY POINTS – Only specially trained and experienced maintenance person is allowed
to work with the KDH drive panel
– A faulty module is sent to a factory for an investigation and repair
– The power components in the KDH module are recommended to be
replaced at the factory or local ABB workshop
11.65.013)
SAFETY PRECAUTIONS Inverter drives usually remain energized for about 5 minutes after the power
WITH INVERTER
DRIVE!
has been disconnected. DO NOT work on the drive, hoisting motor or brak-
ing resistors until you have verified that this energy has been discharged.
Test equipment must be set to the 1000 V range. The test equipment must
be checked before and after the test to ensure that it functions correctly.

CONTACT KDH drive panels are supplied with contact protection shields. Remove the
PROTECTION SHIELDS
shields only when it is necessary for maintenance work. Be careful not to
damage the shields and see that the shields remain in original shape. Re-
connect the shields immediately after the maintenance work.
Forced Air In Forced Air In
Contact protection
shields
1 1 L1 3 L2 5 L3
OESA 250 D3
2 T1 4 T2 6 T3
1026655.wmf
IDENTIFICATION OF There are several KDH drive types that can be used in KONE MiniSpace™
DRIVE PANEL
with KDH drive elevator. (KDH100,150, 200 and 300)
The type and size of KDH drive panel can be verified from the type plate.

MX machinery
When the mechanical brake should be adjusted?
SUMMARY MX-machines are equipped with the two direct acting independent brakes.
These mechanical brakes need adjustment if the air gap is too big or too
small.
Brakes
1037865.wmf
KEY POINTS – The mechanical brakes need to be adjusted when the air gap is:
• less than 0.05 mm or more than 0.25 mm (MX32 and MX40)
• not the same at the brake line ends
Refer-to: Brake MX32 & MX40 (AM-04.08.024)
BRAKE AIR GAP If the brake air gap is too big the brakes can make a “banging” noise when
the elevator stops.
SAFETY PRECAUTIONS MX32 and MX40 are gearless machines and not equipped with dynamic
WITH MX MACHINE
braking. The counterweight must be lowered onto the buffer before working
with the brakes.
IDENTIFICATION OF There are two MX machine types that can be used in KONE MiniSpace™
MX MACHINE
with KDH drive elevator. (MX32 or MX40).
The type of MX machine can be verified from the type plate.

KSS signalisation
How do I replace a signalisation device?
SUMMARY Signalling devices like push buttons, floor indicators and displays are sur-
face- or flush mounted and fixed to the door frame or COP.
Hall lantern and display Thinline hall lantern
Landing call stations Button on door frame
1037802.wmf
KEY POINTS – Cover plates are opened with a screwdriver

– If a device is broken, the whole unit must be replaced
– Floor indication signs are changeable with the user interface
ADJUSTMENT OF Volume adjustment (audible feedback) of button buzzers and gong volumes
AUDIBLE FEEDBACK
are adjusted with the LCE user interface. (Menu 7 and submenus 80 to 83)
– 7_80, button buzzer volume
– 7_81, button buzzer volume at main floor
– 7_82, Gong volume
– 7_83, Gong volume at main floor

KSS COP The KSS COP panel is opened by lifting the panel to up direction. (Some
fixing screws and cover plates must be removed before lifting). To help lift-
ing use COP opening tool. (If possible to use.)
COP
COP Display
Multiboard
(F2KMUL)
Buttons
Emergency light
1037803.wmf
COP
COP Opening Tool
1037804.wmf

CONFIGURATION OF Buttons and switches on KSS COP panel are connected to the F2KMUL
BUTTONS AND
SWITCHES ON KSS
board via a communication lines. Each button or switch connected to these
COP PANEL lines have their own ID-number. Therefore, when a button or switch con-
nected to the information line is replaced, the new button or switch must be
configurated to have the same ID-number as the broken button or switch
had.
After replacement of the F2KMUL board the new board is configurated au-
tomatically after the power is switched on. Basically, the new empty board
reads the ID-numbers from the buttons and switches connected to the infor-
mation lines and saves the data into the F2KMUL boards memory. (Into the
configuration table).
(TC04818W21-EN)
IS IT POSSIBLE TO Yes, but it is not recommended. If using already configurated F2KMUL

USE AN OLD F2KMUL
BOARD TAKEN FROM
board, the configuration table stored in the board may be incorrect. In fact
ANOTHER COP? the elevator may function correctly and the problems may not arise until the
broken button or switch is replaced from the COP -panel. Therefore a used
board including an already generated configuration table must be always
reset before taking it to use.
Refer-to: Maintenance of KSS range signalisation (AS-12.20.004)
F2KMUL board
1010387-1.wmf

CONFIGURATION The configuration switch is a service tool for special cases. If there is a need
SWITCH
for manual re-configuration of button or F2KMUL board, the configuration
switch is needed. Basic function of configuration switch is to reset the cur-
rent settings from the F2KMUL board.
Connection principle of the configuration switch
COP-panel
F2KMUL board
Communication line
(flat cable)
J6
PCB-board
J1
Configuration switch
1037807.wmf

AMD door system
What are the main aspects of AMD door maintenance?
SUMMARY The corrective action for a safety item must be carried out immediately.
Some actions should be performed later and some periodically (for exam-
ple, after a certain number of door operations).
1037866.wmf
KEY POINTS – Always ensure your safety with extra safety precautions
– Corrective action for a safety item must be carried out immediately
– Doors should be clean, functionally correct and acceptable to the cus-
tomer, properly lubricated and safe
KONE QUALITY HAND Some of the corrective actions in the instruction are mainly targeted on cor-
OVER STANDARD
recting an insufficient installation. These will be avoided by running the V1/
V2 hand over procedure according to the KONE quality hand over standard.
Refer-to:Maintenance instruction for AMD doors (AS-03.12.036)
(TC04818W21-EN)

Safety at AMD door maintenance
How to ensure the working safety?
SUMMARY All the safety rules and instructions concerning general working with eleva-
tor should be followed. Also the safety items described on maintenance in-
structions of AMD doors must be followed.
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KEY POINTS – Take extra care when working on the car roof
– Be especially aware of open landing doors. Landing doors should be
closed if the car is not on the landing
– Ensure that the door safety chain circuits are operative at all times dur-
ing maintenance work
– Be familiar with safety items described on AMD door maintenance
instructions
PERSONAL SAFETY Use tools and implements for your personal protection like safety gloves,
overall, safety shoes, safety helmet, safety goggles and safety harness as
required.

WORKING ON THE CAR Key issues when working on the car roof and in the shaft:
TOP AND IN THE
SHAFT – Pay attention to the clearance between the landing door and the car
door operator when you are driving the elevator on the car top
– Do not support yourself by holding the operator
– When you are working in the shaft pit and the elevator needs to be
driven down, pay attention to the long toe guard
– Do not leave the landing door open. After closing it, always check that
the door is locked
WORKING WITH THE Key issues when working with the door operator:
DOOR OPERATOR
– In normal cases, perform all service operations from the landing level
– In special cases - where there is no other way and you must check and
adjust the operator from the car roof - take extra care about safety pre-
cautions:
• Always keep the elevator on service drive
• Keep the safety chain open by using two different safety devices

Exercises
EXERCISE 11.1 What components are sensitive for electrostatic discharges?
EXERCISE 11.2 Why should you take the EPROM from an old board and use it in the new
board?
EXERCISE 11.3 What preparations you must do before replacing the LCECPU board?

EXERCISE 11.4 How can you be sure before opening the drive panel that there are no volt-
age in the capacitors?
Refer-to: Repair instruction for KDH drive systems (AS-11.65.013)
EXERCISE 11.5 Describe a correct brake adjustment and how to check the adjustment.

EXERCISE 11.6 How do you check that the braking torque of the mechanical brake is high
enough?
EXERCISE 11.7 The 4th floor call button on KSS COP panel is broken. The button is re-
placed and it must be configurated. Describe how the configuration is
made?
After configuration, you noticed that by pressing the 4th floor button the car
ends up to the 5th floor, why? Describe also what are your actions to correct
the problem?
EXERCISE 11.8 How can you ensure your working safety if you must adjust the closing force
potentiometer from the car roof? (B-side door only on the bottom floor.)

EXERCISE 11.9 When you are working on the car top, what safety items you pay attention
to concerning the door?
EXERCISE 11.10 List five of the most common reasons for noise and explain how to eliminate
the noise.
Refer-to:Maintenance instruction for AMD doors (AS-03.12.036).
EXERCISE 11.11 Explain how you can change the hanger rollers of the AMDL2 Railing 1 slow
door panel.

Commissioning
12. Commissioning
1037868.wmf
A correct commissioning sequence is essential to avoid damage and en-

sure safe working practice.
In maintenance work the commissioning procedure can be different as with
the new elevator.
Some of the component replacement or maintenance instructions include
the commissioning procedures after replacement or maintenance.
Commissioning for a new elevator is described in the KONE MiniSpace™
with KDH drive PT 1.6 Installation (AM-01.01.069) and MiniSpace™ 1.6
with KDH drive commissioning and safety inspection (AM-11.65.023) in-
structions.

Commissioning
Commissioning procedure
What is the commissioning procedure after replacement

of the elevator component?
SUMMARY Always before switching the power ON for the first time after corrective
maintenance ensure that all doors are closed and nobody is working in
the shaft.
NORMAL
270
ON
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KEY POINTS – Before switching the power on check that the doors are closed and
nobody is working in the shaft
– and check that the car and CWT are free to move
– and check that the RDF switch (270) is turned ON position
– and check that the inspection drive is in NORMAL position
– Refer to the component instruction or elevator installation instruction
RDF MODE When the elevator is in RDF mode it will not start automatically after the
power is switched on. Notice also that the RDF mode over connects the final
limit switch, safety gear switch and overspeed governor.
When all checks are performed switch the power on from main switch 220.

Commissioning
COMMISSIONING OF THE MAIN STEPS OF NEW ELEVATOR COMMISSIONING PROCE-

NEW ELEVATOR WITH
KDH DRIVE
DURE (WITH KDH DRIVE)
1) INITIAL COMMISSIONING WITHOUT ROPES
– Removing ETSL supervision from the safety chain
– Preparations (before switching the power ON)
– Switching power ON to the LCE controller
– Switching power ON to the KDH drive
– Setting the LCE parameters
– Drive settings before motor setup
– Checking the motor encoder and resolver polarity
– Motor setup for KDH Drive
– Checking the speed value
– Finalising the initial commissioning
– Continue installation according to the elevator level installation instruc-
tions
2) COMMISSIONING FOR THE INSPECTION DRIVE (AFTER ROPING)
– Preparations
– Checkings before commissioning for inspection drive
– Switching the power ON
– Checking the safety chain operation using RDF
– Tests and checks when driving the motor for the first time on inspection
drive
– Continue installation according to the elevator level installation instruc-
tions
3) PREPARATIONS FOR COMMISSIONING FOR RATED SPEED
– Prerequisites
– Removing over connections
– Checking the operation of HIPO-M-A and elevator shaft switches
– Setting pulley diameter of the car encoder and checking the polarity

Commissioning
4) COMMISSIONING FOR RATED SPEED

– Speed check
– Checking the mechanical installation
– ETSL setup
– Set up load weighing device
– Fine adjustment of the LWD operation
– LON download
– Loading NTS parameters
– Removing NTS overconnection
– Resetting existing virtual floor setup
– Elevator shaft and NTS setup
– Express zone (EZO) and virtual floor setup
– Increasing the elevator speed up to rated speed
– ETSL switch testing, bottom and top
– Resetting the LCE parameters

Commissioning
Exercises
EXERCISE 12.1 Motor resolver or encoder has been replaced. What is the commissioning
procedure?
Refer-to:Repair instruction for KDH drive systems (AS-11.65.013)

Commissioning
EXERCISE 12.2 Why is it important that the load weighing device is correctly adjusted? De-
scribe also the adjustment made with the user interface.
(TC04818W21-EN)

Commissioning
EXERCISE 12.3 Describe how the setup drive is started and what the elevator performs dur-
ing it.
(TC04818W21-EN) and Site reference card.

Troubleshooting
13. Troubleshooting
1037870.wmf
The user interface and the LCE fault code table are the main tools in fault
finding. You can also investigate faults in the control and drive systems with
the same interface. The display shows the current fault codes. The fault his-
tory is also available in the fault log menu “E” and “d”.

Troubleshooting
Locating a fault
How do I begin a fault finding?
SUMMARY Usually the locating of fault begins by opening the control panel door and
having a look of possible fault codes and LED indications.
1037854.wmf
KEY POINTS – User interface and the LCE fault code table are the main tools
– User interface LEDs give direct information
– LCE control uses basically the same fault codes as the TMS600
LEDS ON LCE USER LEDs on the user interface give information about the current status of the
INTERFACE
elevator. It is essential for the troubleshooter to investigate possible faults
and to learn the meanings of the LEDs in different situations. The speed
LEDs show the correct start sequence, beginning with “safety input” and
ending with “speed >0.1m/s”.
FAULT CODES LCE control uses basically the same fault codes as the TMS600. The cur-
rent fault code blinks on the display and the last 50 faults can be found in
the fault history of the fault log (Menu “E”). If you are not familiar with the
fault codes, you will find them in site reference card.

Troubleshooting
USEFUL DOCUMENTS The following instruction include useful information on troubleshooting:

IN FAULT FINDING
• KONE MiniSpace™ 1.6 with KDH drive Technology book
(TC04818W21-EN)
• Site reference card
• Troubleshooting instruction for AMD drive 2 (AM-03.35.020)
• Installation instruction (AM-01.01.069)
• Field reference guide for fault finding of KONE MiniSpace™ LCE (AS-
10.22.004)

Troubleshooting
Exercises
EXERCISE 13.1 Fill in the missing information.

(TC04818W21-EN)
Name of the LED Current situation Status

Contactor 201:1 has stuck
Rescue drive ON
Alarm button Emergency alarm button pushed in

car
Photocell OFF
Car door contact is open OFF
77:U ON
Shaft door contact Shaft door is open
Inhibit landing calls Landing calls are operating
Open door command Open command not given
Main contactor OFF
EXERCISE 13.2 You receive a message from the customer that the 2nd floor landing door
does not reopen when entering to the car. On the way to the site you are
preparing to check possible fault cause devices, what are these.
Refer-to: Advanced modular door, drive 1.5 car door operator electronic
(AM-03.35.024).
EXERCISE 13.3 A fault code “11 01” is displayed on the user interface. All the fuses and
power supply are OK. What are your actions?
Refer-to:Site reference card.

Glossary
Glossary
A-side Front side.

A-door Front door.
AMD Advanced Modular Door. A series of auto-
matic doors for elevators, based on inter-
changeable components. Suitable for use
in most elevator applications.
AMD1 Center opening AMD door.
AMD2 Side opening AMD door.
Asynchronous motor The rotor is not following the electrical rota-
tion in the stator magnetic field, there is al-
ways slip.
B30 B-door zone switch
B-door Rear door.
Brake lever Mechanical brake releasing lever.
Car door operator A power operated device which opens and
closes the car doors. Automated landing
doors are opened/closed via a door cou-
pler.
C-side Rear side (In electrification drawings sec-
ond door is B- door).
CAN network Controller area network for group commu-
nication.
Car top connection box Connection box on the car roof where trav-
elling cables and car cables are connect-
ed.
Controller A device, or a group of devices, which
serves to control, in a predetermined man-
ner, the apparatus to which it is connected.
An elevator controller consists of drive and
control functions.
COP Car Operating Panel. The user interface
for passengers inside the elevator car. In-
cludes car call buttons, alarm button, door
open button etc.
Control panel Control panel contains the main parts of
the electrification system. (LCECPU40)
Design 1 Door design based to ADV doors.
Design 2 Door design based to ADZ doors.
Drive 1 DC-motor (in design 1 doors).
Drive 2 AC-synchronous motor (inverter drive).

Glossary
Drive panel Drive cabinet contains the KDH drive unit

which controls the machine.
Duplex Two elevators in group.
Dynamic braking Feature that helps controlling and limiting
car speed when opening release lever.
Used only in MonoSpace® type elevators.
KONE MiniSpace™ with
KDH drive New elevator concept by KONE.
EcoDisc® Axial synchronous motor.
EMI Electro-Magnetic Interference filter.
Encoder Pulse counter (pulse tachometer).
Frequency converter System which controls elevator drive by
regulating frequency and voltage.
Function mode Selected mode of the user interface for dif-
ferent operations.
Gain Adjustment of the linear angle of the LWD
amplifier.
Geared machinery Elevator machinery where the motor rota-
tion speed is reduced by mechanical gear
for the traction sheave.
Gearless machinery Elevator machinery where the traction
sheave is mounted directly to the motors
shaft.
Group control computer A separate PC that enhances the group
functions.
Integrated sling Car sling is integrated to the car without in-
sulation, also called a structural ring.
KSS signalisation New signalisation series for KONE eleva-
tors.
KCP931™ electrification Lift Controller and Electrification system in-
cluding controller, car and shaft electrifica-
tion.
LCECAN CAN network board for group communica-
tion.
LCECCBN2 Car connection board inside the car con-
nection box, the connection link between
the controller and car devices.
LCECPU Controller's computer board.
LCEFCB Floor control board. Connects 24V landing
devices to the serial network.
LCEGTW Gateway board to connect landing calls.
LED Light emitting diode.
LWD Load weighing device.

Glossary
Main switch unit A separate circuit breaker between the

main power supply and elevator electrifica-
tion.
Menu display A display which shows the commands and
settings of the elevator control system. It is
a part of the user interface.
MiniSpace™ KONE elevator concept with machine-
room.
MLB unit Modulated Line Bridge unit feeds energy
back to the network direction.
Nudging drive Elevator closes the door with low speed,
reopening is normally disabled.
OFL Open Force Limiter.
Prefabricated door The door is assembled at the factory as
ready-to-instal element.
Resolver A rotating device that is used to give accu-
rate information of the rotor position rela-
tive to the stator. It is used for calculating
the elevator car speed and position.
ReCall Drive Drive mode which gives the possibility to
move the elevator by using the push but-
tons. This by-passes part of the safety
chain.
RS485 Standard serial line for communication.
Segmented shaft network A type of shaft electrification used in mid
and high-rise buildings.
Setup drive An elevator drive mode in which the infor-
mation about the elevator well is stored
into controller memory. The information
contains for example: number of landings
and their positions, terminal floors and their
positions and slowdown monitoring devic-
es.
Synchronous motor The rotor is rotating with the same frequen-
cy and speed as which has the supply volt-
age to the stator field.
Test drive Drive mode of AMD when signal in terminal
"SD" is active. (Door will be driven only by
its own test drive buttons).
Triplex Three elevators in group.
User interface Communication link between KCP931™
system and user (Fitter, service man, trou-
ble shooter etc.).
V3F-inverter KONE drive system which controls eleva-
tor drive by regulating frequency and volt-
age.

Glossary
KDH drive KONE drive systems for KONE MiniS-

pace™ 1.6 with KDH drive elevator which
controls elevator drive by regulating fre-
quency and voltage.
VAC Volts, Alternating Current.
VDC Volts, Direct Current.
30 Door zone switch
61:N Positioning switch for downward direction
61:U Positioning switch for upward direction
77:S Bistable Synchronisation switch, used
when there is short floor to floor distance at
terminal floor.

Index
Index
Numerics
4-floor cable ................................................................... 27
5 steps to ensure electrical safety ................................. 17
A
ABB drive panel ......................................................... 9, 21
Air gap ........................................................................... 82
AMD ............................................................................... 87
AMD doors ................................................................. 8, 64
AMDC ............................................................................ 64
AMDL ............................................................................. 64
B
B-door ............................................................................ 27
Button buses .................................................................. 47
C
CAN ............................................................................... 53
Car operating panel ....................................................... 42
Commissioning .............................................................. 94
Commissioning ........................................................ 94, 95
Configuration switch ...................................................... 86
COP ................................................................... 42, 46, 83
CWT ............................................................................... 95
D
DCBH module .......................................................... 18, 19
Drive 2 ........................................................................... 64
E
Electrostatic discharge ................................................... 78
Elevator controller .......................................................... 18
EPROM .......................................................................... 79
ESD ............................................................................... 78
ESDS ............................................................................. 78
F
F2KMUL ........................................... 42, 43, 46, 47, 48, 85
G
Group control computer ........................................... 54, 58

Index
I
Intelligent button ...................................................... 36, 85
INU ................................................................................. 21
INverter motor control Unit (INU) ................................... 21
Inverter Supply Unit (ISU) .............................................. 22
ISU ................................................................................. 21
K
KCP931™ ...................................................................... 12
KDH ................................................................................. 9
KDH drive panel ............................................................. 80
KDH drive system ............................................................ 8
KGC ............................................................................... 58
KNXRIF .......................................................................... 46
KONE EcoDisc® .............................................................. 8
KONE EcoDisc® machine ............................................... 8
KONE EDMS intranet .............................................. 69, 76
KONE environment policy .............................................. 74
KONE Quality Maintenance ........................................... 67
KONE Service Center .................................................... 48
KoneXion KX99 ............................................................. 48
KRMRIF ......................................................................... 48
KSS ................................................................................ 36
KSS COP panel ............................................................. 84
KSS signalisation ............................................................. 8
KSS signalisation system .............................................. 36
KSS signalsation ............................................................ 42
L
LCE electrification for KCP931™ ..................................... 8
LCE fault code ............................................................. 101
LCE fault code table .................................................... 101
LCE software ................................................................. 79
LCE User Interface ........................................................ 61
LCE user interface ......................................................... 61
LCEADJ ......................................................................... 48
LCEADON ..................................................................... 28
LCECAN ........................................................................ 57
LCECCB ............................................................ 43, 46, 48
LCECCBN ...................................................................... 43
LCECCBN2 .............................................................. 42, 43
LCECPU ...................................................... 32, 34, 57, 79
LCECPU40 .................................................................... 13
LCEFCB ................................................................... 30, 32
LCEFOB .................................................................. 30, 34
LCEGTW ....................................................................... 56
LCEGTWO ......................................................... 31, 53, 56
LCEKNX ........................................................................ 48
LCEOPT ........................................................................ 30

Index
LCEREC ........................................................................ 31
LCEVOI .......................................................................... 48
LON ............................................................. 32, 34, 53, 56
LON network ............................................................ 53, 56
M
MCD car ........................................................................... 8
Mechanical brake ........................................................... 82
MX18 ............................................................................... 8
MX32 ............................................................................... 8
MX-machine ................................................................... 82
N
NVRAM .......................................................................... 79
R
RDF ............................................................................... 95
RDF switch .................................................................... 95
Roll call .......................................................................... 55
S
Segmented shaft network .............................................. 12
SEP ................................................................................ 79
T
Termination resistor ....................................................... 29
Traffic supervision display ............................................. 20
Travelling ....................................................................... 43
Trunking ......................................................................... 27
Y
Y-cable ........................................................................... 27

Version history
Version history
Compiled by: Technical Editor / Tapio Kiivanen

Checked by: KEE SEB Maintainability Manager / Seppo Valliovuo
Approved by: Manager of Training Center / Lauri Kinnunen
Issue Date Description of change Ref CR Approved by
(-) 2005-10-06 First issue. Lauri Kinnunen

Version history
KONE Corporation
Training Center
P.O.Box 679
FIN-05801 Hyvinkää, Finland
Tel. +358 204 75 2048
Fax. +358 204 75 2090

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Maintenance Learning Guide

Copyright © 2005 KONE Corporation

Copyright © 2005 KONE Corporation 2 (113) TC06818W23-EN / Issue: -

How to use this training package ........................................................ 5

Copyright © 2005 KONE Corporation 3 (113) TC06818W23-EN / Issue: -

KSS signalisation .................................................................... 83

Copyright © 2005 KONE Corporation 4 (113) TC06818W23-EN / Issue: -

How to use this training package

PURPOSE OF This training package provides a quick overview of maintenance tasks in

Copyright © 2005 KONE Corporation 5 (113) TC06818W23-EN / Issue: -

• Site reference guide for KCP931™ and KDH (AS-10.80.001)

Copyright © 2005 KONE Corporation 6 (113) TC06818W23-EN / Issue: -

The Maintenance Learning Guide workbook has been designed by the

Copyright © 2005 KONE Corporation 7 (113) TC06818W23-EN / Issue: -

2. KONE MiniSpace™ 1.6 with KDH drive

– KONE EcoDisc® machine (MX32 or MX40)

Copyright © 2005 KONE Corporation 8 (113) TC06818W23-EN / Issue: -

What kind of new features does KONE MiniSpace™ with

KEY POINTS – Higher speed up to 6.0 m/s with a load 2050 kg

Copyright © 2005 KONE Corporation 9 (113) TC06818W23-EN / Issue: -

Copyright © 2005 KONE Corporation 10 (113) TC06818W23-EN / Issue: -

3. LCE electrification in general

Copyright © 2005 KONE Corporation 11 (113) TC06818W23-EN / Issue: -

LCE electrification for KCP931™

Main switch unit

Copyright © 2005 KONE Corporation 12 (113) TC06818W23-EN / Issue: -

KONE MiniSpace™1.6 with KDH drive

Control panel for KCP931™

KDH drive panel

Machine room electrification

Copyright © 2005 KONE Corporation 13 (113) TC06818W23-EN / Issue: -

EXERCISE 3.1 Identify the LCE components.

Copyright © 2005 KONE Corporation 14 (113) TC06818W23-EN / Issue: -

4. Machine room electrification

Copyright © 2005 KONE Corporation 15 (113) TC06818W23-EN / Issue: -

Main switch boxes

Where are the supply switches for elevator?

Copyright © 2005 KONE Corporation 16 (113) TC06818W23-EN / Issue: -

5 steps to ensure electrical safety:

Copyright © 2005 KONE Corporation 17 (113) TC06818W23-EN / Issue: -

What components does the control panel include?

STOP switch Switch

KEY POINTS – Control panel includes elevator controller

Copyright © 2005 KONE Corporation 18 (113) TC06818W23-EN / Issue: -

Copyright © 2005 KONE Corporation 19 (113) TC06818W23-EN / Issue: -

Machine room Supervision room

Traffic supervision display

Copyright © 2005 KONE Corporation 20 (113) TC06818W23-EN / Issue: -

KDH drive panel

What components does the drive panel include?

Line bridge (ISU)

Copyright © 2005 KONE Corporation 21 (113) TC06818W23-EN / Issue: -

Copyright © 2005 KONE Corporation 22 (113) TC06818W23-EN / Issue: -

What are the special requirements for machine cabling?

Copyright © 2005 KONE Corporation 23 (113) TC06818W23-EN / Issue: -

EXERCISE 4.1 Name the machine room components.

Copyright © 2005 KONE Corporation 24 (113) TC06818W23-EN / Issue: -

EXERCISE 4.4 What is an ISU unit?

Copyright © 2005 KONE Corporation 25 (113) TC06818W23-EN / Issue: -

Copyright © 2005 KONE Corporation 26 (113) TC06818W23-EN / Issue: -

Landing door safety chain