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1K views453 pages

AM-01.01.084 Main En.d.1

Uploaded by

Michael Crane

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KONE 3000S/X MiniSpace™ and KONE EcoDom® 3000/5000

Installation Instruction

KONE 3000S/X MINISPACE™ AND KONE ECODOM® 3000/5000

KONE
Installation
©
AM-01.01.084
All
(D)
2005
rights
2010-05-31
3000S/X
KONE MiniSpace™ and KONE EcoDom® 3000/5000 Installation Instruction
reserved
Instruction
Corporation

SCAFFOLDLESS INSTALLATION

© 2005 KONE Corporation 1 (453) AM-01.01.084

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 © 2005 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.

© 2005 KONE Corporation 2 (453) AM-01.01.084

LIST OF CONTENTS

1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.2 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 General safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Installation method safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Recommended working postures and ergonomic methods . . . . . . . . . . . . . . . . . . . 20
2.4 Danger and personal protection signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Special precautions to limit injury in the event of a fall . . . . . . . . . . . . . . . . . . . . . . . 22
3 SITE REQUIREMENTS AND TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 UNLOADING AND DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Off-loading and distributing materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 PLUMBING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1 Placing the plumbing template (single elevator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2 Plumbing (single elevator from finished machine room or temporary deck) . . . . . . 43
5.3 Filling in plumbing table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.4 Plumbing groups of lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.5 Dividing beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6 HOIST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.1 Lists of hoist equipment parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.2 Selecting correct Tirak hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.3 Safety checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.4 Hanging the hoist from a beam in the ceiling (option A) . . . . . . . . . . . . . . . . . . . . . . 58
6.5 Hanging the hoist from a beam on the floor (option B) . . . . . . . . . . . . . . . . . . . . . . . 60
6.6 Overspeed governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.7 Testing the hoist equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7 FIRST GUIDE RAILS AND PIT EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.1 Preparations for guide rails and pit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.2 Installing guide rail brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.3 Lifting the first guide rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.4 Bracket combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.5 The first two rings of guide rail brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.6 Fixing the first guide rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.7 Guide rail alignment at the guide rail bracket level . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.8 Checking the car guide rail parallelity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.9 Installing and Aligning the first counterweight guide rails . . . . . . . . . . . . . . . . . . . . . 79
7.10 Buffers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.11 OL35 overspeed governor tension weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

© 2005 KONE Corporation 3 (453) AM-01.01.084

7.12 OL100 overspeed governor tension weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7.13 Installing counterweight frame on buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.14 Filling counterweight with 40 % of filler weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8 CAR INSTALLATION, EURECA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.1 Assembling upright and bottom beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.2 Second upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.3 Car safety gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.4 Car floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
8.5 Fixing the automatic safety gear trigger rope to the safety gear linkage. . . . . . . . . 102
8.6 Car walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.7 Glass walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
8.8 Top beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
8.9 Balustrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
8.10 Car roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
8.11 Kick plates and finalising the balustrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
9 CAR INSTALLATION, MCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
9.1 Preparations for bottom beam installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
9.2 How to use guide clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
9.3 Installing car sling CF10UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
9.4 Installing car sling CFE10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
9.5 Installing car sling CF10TD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
9.6 Installing car floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
9.7 Positioning car floor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
9.8 Wall panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
9.9 Car roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
9.10 Top beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
9.11 Upper isolations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
9.12 Car front installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
9.13 Balustrade and skirtings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
9.14 Lifting pockets and guide rail securing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10 THIRD RING OF GUIDE RAIL BRACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
10.1 For SMiniSpace with side counterweight and XMiniSpace . . . . . . . . . . . . . . . . . . . 158
10.2 For SMiniSpace with rear counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
10.3 Aligning guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
11 HOIST ATTACHMENT, EURECA CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
12 HOIST ATTACHMENT, MCD CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
13 GUIDE RAIL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
13.1 Second ring of guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
13.2 Installation and use of automatic safety gear trigger . . . . . . . . . . . . . . . . . . . . . . . . 171
13.3 Fixings under the Eureca car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
13.4 Fixings under the MCD car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

© 2005 KONE Corporation 4 (453) AM-01.01.084

13.5 Guide rail clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

13.6 Intermediate guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
13.7 Topmost guide rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
13.8 Checking guide rail installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
13.9 Bottom pulley beam and travelling cable hanger, Eureca car . . . . . . . . . . . . . . . . . 186
13.10 Preparing the machine and the car for transportation . . . . . . . . . . . . . . . . . . . . . . . 188
13.11 Transporting machine to the topmost floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
14 MACHINE ROOM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
14.1 Transporting machine and control panel to machine room . . . . . . . . . . . . . . . . . . . 192
14.2 Marking up machine room component positions on machine room floor . . . . . . . . 193
14.3 Fixing machine for K3000S MiniSpace™ (side counterweight). . . . . . . . . . . . . . . . 194
14.4 Fixing machine for K3000S MiniSpace™ (rear counterweight) . . . . . . . . . . . . . . . . 195
14.5 Fixing machine for K3000X MiniSpace™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
14.6 Plumbing machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
14.7 Fixing rope anchorages and overspeed governor. . . . . . . . . . . . . . . . . . . . . . . . . . 201
14.7.3 Installing the governor rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
14.7.4 Installing the rope anchorages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
14.8 Fixing control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
14.9 Closing machine room holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
14.10 Sticking adhesive tape (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
15 BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
15.1 Fixing the brake release cable to the brake release lever . . . . . . . . . . . . . . . . . . . . 212
15.2 Installing the brake release cable to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . 212
15.3 Main construction of the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
15.4 Checking the stroke of the brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
15.5 Adjusting the stroke of the brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
15.6 Closing the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
15.7 Adjusting the manual brake release device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
15.8 Checking the operation of the manual brake control. . . . . . . . . . . . . . . . . . . . . . . . 218
15.9 Checking after the brake is adjusted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
16 LANDING DOOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
17 CAR SILL AND FRONT WALLS INSTALLATION, EURECA CAR . . . . . . . . . . . . . . . . . . 220
17.1 Car sill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
17.2 Car front walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
17.3 Completing the car front installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
18 CAR SILL FRONT WALLS INSTALLATION, MCD CAR . . . . . . . . . . . . . . . . . . . . . . . . . . 226
19 CAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
20 MACHINE ROOM ELECTRIFICATION V3F16L DRIVE ELEVATORS . . . . . . . . . . . . . . . 228
20.1 V3F16L control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
20.2 Installing main switch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
20.3 Connections at the controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

© 2005 KONE Corporation 5 (453) AM-01.01.084

20.4 Connections at the main switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

20.5 Routing and connecting the machine cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
20.6 Overspeed governor wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
20.7 Connecting travelling cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
21 MACHINE ROOM ELECTRIFICATION V3F25S DRIVE ELEVATORS . . . . . . . . . . . . . . . 239
21.1 V3F25S control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
21.2 Installing main switch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
21.3 Connections at the controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
21.4 Connections at the main switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
21.5 Routing and connecting the machine cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
21.6 Overspeed governor wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
21.7 Connecting travelling cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
22 KDL32 CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
23 KDL16 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
23.1 KDL16L drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
23.2 KDL16R drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
23.3 Control cabinet with KDL16 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
24 ELEVATOR SHAFT ELECTRIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
24.1 Travelling cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
24.2 Support channels and trunkings for group elevators. . . . . . . . . . . . . . . . . . . . . . . . 262
24.3 Trunking and elevator shaft wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
24.4 (OSS) out of service switch and (OSI) out of service indication at landing . . . . . . . 268
24.5 (PRL) priority landing call cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
24.6 (FRD) fireman’s drive switch cables from landings . . . . . . . . . . . . . . . . . . . . . . . . . 269
24.7 Optional devices in the machine room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
24.8 Installation in the pit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
25 SIGNALLING DEVICES AT LANDINGS (KDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
26 CAR ELECTRIFICATION, EURECA CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
26.1 Install the magnet switches on top of the car roof . . . . . . . . . . . . . . . . . . . . . . . . . . 272
26.2 Installing the car top connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
26.3 Install the electrification on the car roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
26.4 Connect into the car top connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
26.5 Install the provision for lift announcer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
26.6 Install the intercom socket on the car roof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
26.7 Connectors on LCECCB board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
26.8 Curtain of light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
26.9 Routing the cables of the curtain of light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
26.10 Install the ramps and magnets (driving up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
26.11 Wiring of door operator and curtain of light (or photo cell) . . . . . . . . . . . . . . . . . . . 286
26.12 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

© 2005 KONE Corporation 6 (453) AM-01.01.084

27 CAR ELECTRIFICATION, MCD CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

27.1 Installation under the car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
27.2 Car operating panel installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
27.3 Magnet switches, oscillators and final limit switch on the car roof . . . . . . . . . . . . . 290
27.4 Connections in the car top connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
27.5 Final adjustment of magnets, oscillator vanes and final limit switch ramps. . . . . . . 294
28 INITIAL COMMISSIONING OF THE MACHINE (WITHOUT ROPES), V3F25S . . . . . . . . 295
28.1 Health and safety at work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
28.2 Check list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
28.3 Connecting supply cable(s) from building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
28.4 Tests and checks when driving the motor for the first time with RDF . . . . . . . . . . . 297
28.5 Motor first drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
28.6 Tests and checks when driving the motor for the first time on inspection drive. . . . 298
29 INITIAL COMMISSIONING OF THE MACHINE (WITHOUT ROPES), KDL16 . . . . . . . . . 300
30 INITIAL COMMISSIONING OF THE MACHINE (WITHOUT ROPES), KDL32 . . . . . . . . . 301
31 ROPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
31.1 Roping principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
31.2 Preparations in the machine room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
31.3 Attaching the compensation chain under the Eureca car (optional) . . . . . . . . . . . . 304
31.4 Roping for SMiniSpace with side counterweight and XMiniSpace . . . . . . . . . . . . . 305
31.5 Roping for SMiniSpace with rear counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
31.6 Lifting the counterweight frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
31.7 Shortening the ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
31.8 Attaching the compensation chain to the counterweight . . . . . . . . . . . . . . . . . . . . . 314
31.9 Finalising the roping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
31.10 Slack rope switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
32 CAR INTERIOR INSTALLATION, EURECA CAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
32.1 Ceiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
32.2 Mirror and handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
32.3 Skirting installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
32.4 Handicap seat and the top beam cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
33 CAR INTERIOR INSTALLATION, MCD CAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
34 CHECKING MACHINE BRAKE AND REMOVING HOIST. . . . . . . . . . . . . . . . . . . . . . . . . 325
34.1 Checking the machine brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
34.2 Dismantling the hoist from the car. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
34.3 Changing the temporary installation time overspeed governor to final one (OL100) 327
35 BALANCING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
35.1 Balancing the MCD car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
35.2 Adding extra weights to MCD car sling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
35.3 Balancing car and counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
35.4 Counterweight screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
35.5 Finalising the travelling cable installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

© 2005 KONE Corporation 7 (453) AM-01.01.084

36 COMMISSIONING, V3F16L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

36.1 Health and safety at work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
36.2 Commissioning with construction-time power supply . . . . . . . . . . . . . . . . . . . . . . . 337
36.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
36.4 Temporary adjustment of the load weighing device . . . . . . . . . . . . . . . . . . . . . . . . 343
36.5 Driving the elevator for the first time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
36.6 Adjusting the load weighing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
36.7 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
37 COMMISSIONING OF THE MACHINE AFTER ROPING, V3F25S . . . . . . . . . . . . . . . . . . 348
37.1 Checks before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
37.2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
37.3 Emergency light battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
37.4 LON protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
37.5 Drive commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
37.6 Levelling accuracy setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
37.7 External options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
37.8 Group connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
38 COMMISSIONING OF THE ROPING, KDL16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
39 COMMISSIONING OF THE ROPING, KDL32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
40 FINAL STEPS OF COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
40.1 Balancing the empty car and counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
40.2 Adding filler weights to the counterweight to correspond to 50 % of rated load . . . 356
41 COMMISSIONING OF THE CAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
42 SAFETY INSPECTION, V3F16L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
42.1 Standards and rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
42.2 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
42.3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
42.4 Visual check (Annex D1.c and d, Annex D2.a, b and c) . . . . . . . . . . . . . . . . . . . . . 359
42.5 Measuring insulation resistance of the main supply (Annex D2.f). . . . . . . . . . . . . . 360
42.6 Measuring insulation resistance of the safety chain (Annex D2.f). . . . . . . . . . . . . . 360
42.7 Short circuit test (Annex D2.f) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
42.8 Checking the running clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
42.9 Checking the car and counterweight balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
42.10 Readjusting GAIN setting of the load weighing device in the middle of the shaft . . 362
42.11 Speed measurement (Annex D2.e and h3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
42.12 Checking levelling accuracy (±5 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
42.13 Readjusting OFFSET setting of the load weighing device . . . . . . . . . . . . . . . . . . . 364
42.14 Upper limit switch check (Annex D2.g) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
42.15 Traction test with empty car (Annex D2.h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
42.16 Thermistor test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
42.17 Drive time supervision test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

© 2005 KONE Corporation 8 (453) AM-01.01.084

42.18 Lower limit switch check (Annex D2.g) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

42.19 Motor current measurement (Annex D2.e and h3) (V3F16L) . . . . . . . . . . . . . . . . . 367
42.20 Preparations for combined traction test and braking test with 125 % load (Annex D.d and
h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
42.21 Combined traction test and braking test with 125% load (Annex D.d and h) . . . . . 370
42.22 Preparations for car safety gear test (Annex D2.j) . . . . . . . . . . . . . . . . . . . . . . . . . 370
42.23 Car safety gear test (Annex D2.j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
42.24 Re-setting the elevator after car safety gear test . . . . . . . . . . . . . . . . . . . . . . . . . . 372
42.25 Readjusting the load weighing device setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
42.26 Test of alarm devices (Annex D2.m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
42.27 Counterweight safety gear test (Annex D2.k) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
42.28 One-sided braking test with rated load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
42.29 Car overspeed governor test (Annex D2.i and n) . . . . . . . . . . . . . . . . . . . . . . . . . . 377
43 SAFETY INSPECTION, V3F25S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
44 SAFETY INSPECTION, KDL16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
45 SAFETY INSPECTION, KDL32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
46 HANDOVER AFTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
47 APPROVALS AND VERSION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
APPENDIX A. Fuses and LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
APPENDIX B. Electrification panels, introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
APPENDIX C. Trouble-shooting instruction/vertical vibrations for MX10 elevators with V3F18 or
V3F25 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
APPENDIX D. Quality check forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
APPENDIX E. Roping (rise > 120 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422

© 2005 KONE Corporation 9 (453) AM-01.01.084

1 GENERAL

The installation method described in this instruction is designed to ensure an efficient,

trouble-free installation, whilst maintaining safe working practices.
This is a general instruction which can be used for KONE 3000S/3000X MiniSpace™ and
KONE EcoDom® 3000/5000 elevators (MX10 machine, V3F16L/V3F25S drive, rated speed
1.0..2.0 m/s, maximum travel height 120 m).
Some of the components may differ from those that are described in this instruction. In these
cases refer to the delivery documents or component level AM instructions.
Follow this instruction. If it is necessary to deviate from the method a carefully designed, risk
assessed, method statement must first be obtained from your front line management.
To ensure trouble-free and effective installation the following are mandatory.

Requirement Note
The site must be 100 % ready. See INSTALLATION PREREQUISITES on
page 20.
Transport routes on site must be defined
and agreed as close as possible to the
elevator shaft.
Elevator shaft tolerances must be checked
by the project engineer.
Delivery must be complete and on site.
Installation start date must be agreed with
the customer.
A locking off system for main electric supply Refer to AM-01.03.002 Take 5.
isolator, or other system (for example fuse
removal, locking and tagging system, etc.
when applicable), must be agreed with main
contractor before installation commences.
Installation tools must be available on site. Refer to chapter Installation tools.
Recommended hand tools must be Refer to chapter Hand tools
available. (recommended)
Personal safety equipment must be
available.
Lockable machine room door in place.

© 2005 KONE Corporation 10 (453) AM-01.01.084

1.1 Related documents

Safety and product related information is contained in the following documents.

It is mandatory to follow the AM safety instructions and safety related information included in
the Tirak manual.

Component Document Document ID

Fall prevention systems Safety instruction AM-01.03.001
Take 5, Electrical safety Safety instruction AM-01.03.002
Using Tirak hoist for man Safety instruction AM-01.03.003
riding purposes
- Rescue instruction AS-01.01.030
Tirak X750 hoist Tirak manual -
Tirak X1000 hoist Tirak manual -
Tirak X2000 hoist Tirak manual -
Installation clamp 654068 Installation instruction AM-09.04.006
Safety gear SGB01, Installation instruction AM-07.04.015
SGB02, SGB03 (car)
Safety gear SGB08 (car) Installation instruction AM-07.04.024
MX10 machine Brake adjustment AM-04.08.021
Augusta landing door Installation instruction AM-03.12.047
AMDL landing door, Installation instruction AM-03.12.066
design 2 packages
AMD car door Installation instruction AM-03.12.067
Drive 1 electrification Electrical installation, commissioning AM-03.35.022
(AMD door) and troubleshooting instruction
Drive 1.5 electrification Electrical installation, commissioning AM-03.35.024
(AMD door) and troubleshooting instruction
Curtain of light Installation instruction AM-03.17.011
(delivered with the curtain of light)
Eureca car cladding panels Installation instruction AM-06.01.007
Counterweight CWF10 Installation instruction AM-08.01.008
cladding panels
KONE Polaris destination Installation instruction AM-12.20.010
control system
EBD-E, emergency battery Installation instruction AM-13.30.008
drive
Kone remote monitoring Installation instruction AM-13.25.007
Shaft vanes Shaft vane diagrams -
(delivered to the local front line office)

© 2005 KONE Corporation 11 (453) AM-01.01.084

Component Document Document ID

KDL16L drive Machine-room-less elevators AM-11.65.031
commissioning with KDL16L drive
and safety inspection
KDL16R drive MaxiSpace™ elevators AM-11.65.032
commissioning with KDL16R drive
and safety inspection
KDL32 drive MiniSpace™ and KONE 3000S/X AM-11.65.029
MiniSpace™ commissioning with
KDL32 drive and safety inspection
Wiring Wiring diagrams -
(delivered to the local front line office)
Drive V3F25S Parameter table 870043
Drive Commissioning and safety inspection AM-11.65.024
instruction for drive system V3F25S
Drive V3F16L drive parameters 784393
Drive V3F16L drive fault codes 804611
LCE LCE fault codes 813138
LCE LCE user interface menu 813131
KDS signalling devices Installation Instruction AM-12.20.007-CHN
AM-12.20.008-CHN
AM-12.20.009-CHN

Product related maintenance instructions and spare parts lists:

Component Document Document ID

AMD car door and landing Maintenance instruction AS-03.12.036
doors Spare parts, landing door AR-03.12.076
Spare parts, car door AR-03.12.037
EuReCa car 2.0 Maintenance instruction AS-06.06.006
Spare parts manual AR-06.06.003
MX10 machine Rope replacement AS-09.03.003
Spare parts manual AR-04.06.002
MX14 machine Installation instruction AM-04.05.054
LCE electrification Maintenance instruction AS-10.22.006
Spare parts manual AR-10.22.006
V3F16L drive system Maintenance instruction AS-11.65.009
Spare parts manual AR-10.22.008
V3F25S drive system Maintenance instruction AS-11.65.001
Spare parts manual AR-11.65.008

© 2005 KONE Corporation 12 (453) AM-01.01.084

1.2 Abbreviations

1.2.1 General
C

D B

A 1007039.wmf

Abbreviation Term Unit Definition

FFL finished floor level
CL central line
DBG distance between
guide rails
A marking of entrance usually main door
e.g. A-door/side
B marking of entrance
e.g. B-door/side
C marking of entrance opposite main door
e.g. C-door/side
D marking of entrance
e.g. D-door/side

1.2.2 Elevator shaft and car

Abbreviation Term Unit Definition

elevator shaft
SH headroom height mm the vertical distance between the finished
floor at the highest level served and the
roof of the elevator shaft
PH pit depth mm that part of the elevator shaft located
under the lowest landing level served by
the elevator
WW elevator shaft width mm the horizontal distance between the inner
surfaces of the elevator shaft walls
measured parallel to the car width

© 2005 KONE Corporation 13 (453) AM-01.01.084

Abbreviation Term Unit Definition

WD elevator shaft depth mm the horizontal distance between the inner
surfaces of the elevator shaft walls
measured parallel to the car depth
H travel height mm sum of interfloor distances
HF floor to floor mm usually given as a minimum
distance
car
CH car clear height mm
BB car clear width mm
DD car clear depth mm
NE toe guard height mm car and landing door sills

Elevator shaft vertical dimensions

Frame doors Front doors

HA HB HB

SH
SH

HH
CH

HB
HA
H

H
HF
HF
HR

HH
PH

1018229.wmf 1018231.wmf

© 2005 KONE Corporation 14 (453) AM-01.01.084

1.2.3 Landing door

Elevator shaft horizontal dimensions

1007042.wmf

Topmost floor

Abbreviation Term Unit Definition

FW front wall width mm
FW1 front wall width mm
FW2 front wall width mm
FD front wall depth mm
LR door raw opening mm LR=WW-2*FW or WW-(FW+FW1)
width
HR door raw opening mm
height
LL door clear opening mm
width
HH door clear opening mm
height

© 2005 KONE Corporation 15 (453) AM-01.01.084

1.2.4 Machine room

NOTE! Some of the details on this page may differ from your local solutions. Refer to the
layout drawings.

MD
MH

FFL

1038381.wmf

Abbreviation Term Unit Definition

M/R machine room
MH machine room height mm clear height under the beam or hook
MW machine room width mm
MD machine room depth mm

© 2005 KONE Corporation 16 (453) AM-01.01.084

2 SAFETY

2.1 General safety precautions

Safety precautions Note

Follow your national lift codes and other In case of conflict between the Code and
safety related regulations. the present commissioning instructions, rely
on your Code.
The local safety codes and rules must be Refer to your local procedures for the type
obeyed at all times! of entrance protection required.
Follow the method described in this Warning signs highlight possible hazards.
instruction. (See page 21.)
Follow this instruction. Do not skip any step,
otherwise there may be a potentially
dangerous situation which you have not
considered.
ENSURE THAT ELECTRICAL
EQUIPMENT AND CONDUCTORS ARE
SAFELY DE-ENERGISED BEFORE
WORKING ON THEM.
Refer to AM-01.03.002 "Take 5 Electrical Safety When Working on Elevators".

The following 5 steps must be taken in the specified order unless there are essential
reasons for doing otherwise.

Take 5 steps to ensure electrical safety:

1. Disconnect the power supply completely.
2. Secure it against re-connection.
3. Verify that the installation is de-energised.
4. Check requirements for earthing in special circumstances. (This operation may only
be carried out by qualified personnel in co-operation with the person responsible for
the building electrification who must ensure that the technique can be safely
employed in this situation.)
5. Provide protection against adjacent live parts.
A locking off system for main electric supply
isolator or other system (for example fuse
removal, locking and tagging system, etc.)
must be agreed with main contractor before
installation commences.

© 2005 KONE Corporation 17 (453) AM-01.01.084

All rights reserved (D) 2010-05-31
K O N E 300 0S /X M i n i S p a c e™ an d K O N E E c o D o m ® 3000/5000
Installation Instruction

Safety precautions Note

Do not connect or disconnect any
connectors when the power is ON.

Personal safety equipment must be Refer to the list of Personal safety items on
available and used as required. page 19.
The rust protection must be removed from Refer to specific safety notes.
the rails. Otherwise, the safety gear will not
operate correctly.
NEVER WORK UNDER A SUSPENDED
LOAD OR AT DIFFERENT LEVELS AT
THE SAME ELEVATOR SHAFT!

Ensure that the lifting equipment is correctly

rated for the task and in good condition.
Always use the hoist in accordance with Additional safeguards ensure that there is
your local regulations! no unwanted movement of the car due to
Refer to AM-01.03.003 Take 2 - safe hoist control or other failure.
working when using Tirak hoists for man
riding purposes.
Take care handling the waste in accordance
with the local regulations.
Follow your local procedures for hot works.

2.2 Installation method safety

Special feature Note

The car is used as the working platform. Do not drive on the car roof until the
balustrade is fitted and the safety gear is
connected.
The installation hoist is positioned on the The installation hoist is used to move the
car roof and an additional securing rope is car during the initial stages of the
attached to the machinery lifting eye. installation.
The installation hoist is suspended from
lifting eye in top of the elevator shaft.
The elevator’s own overspeed governor Refer to AM-01.03.003 Take 2.
and safety gear are used during installation.
The automatic safety gear trigger is used to
engage the safety gear when required.

© 2005 KONE Corporation 18 (453) AM-01.01.084

Special feature Note

The parking chain is used to secure the car
to a car guide rail bracket whenever the
hoist hook is disconnected from the car.

P17000182.wmf

When working from the car roof you must At certain times the hoist hook is removed
always park the car using both the parking from the car whilst it is still used as a
chain and the safety gear before working platform. During these operations
disconnecting the hoist hook. the safety gear must be engaged and the
parking chain must be used.
Emergency descent from the car roof. If there is a power failure on site, it is always
possible to move the car to a lower landing
level using the brake release lever. For
emergency descent refer to the Tirak
handbook.
Guide rails are lifted using the car. Guide rails are fitted in the conventional
way using the sliding clamp to lift each rail.
The topmost guide rails are lifted using the
guide rail clamp.
When moving the car on manual brake
release, do not let it overspeed. (The
maximum recommended speed is 0.6 m/s.)
Do not leave the brake open. (Try to limit
the motor rotation to 1 second intervals.)

© 2005 KONE Corporation 19 (453) AM-01.01.084

2.3 Recommended working postures and ergonomic methods

These recommended working postures and ergonomic methods has been identified to
contribute a better workplace and your well-being.

Working height Working distance

Adjust height of working Adjust working
to enable your hands to distance to enable the
be within the vertical object to be within
area of chest and belt length of forearms.
buckle.

Lifting Carrying
Focus on the lift, even if 1. Keep the lifted
the lifted object is light! object as close to the
1. Go close to the lifted body as possible
object 2. Keep your back
2. Use your legs untwisted and straight
3. Keep your back
untwisted and straight
4. Keep both feet on the
same lane
Loading of transport
cart
Slide the component
onto the KONE
transport cart instead of
lifting it.

Moving heavy objects

without a handle
If the object doesn't
contain a handle, push/
slide the object instead
of pulling.

NOTE! If work is being carried out by kneeling, with bent back/legs or with hands elevated
above chest or object is further than length of forearms, ensure to limit time of
exposure and alternate the working postures. Make sure that the working area is un-
obstructed and not hindering you.

© 2005 KONE Corporation 20 (453) AM-01.01.084

2.4 Danger and personal protection signs

Danger signs
Danger Sign Danger Sign Danger Sign
Electric shock Risk of falling Magnetic field

Risk of fire Corrosion Entry

Dermatological prohibited
risk
General hazard Suspended Squeezing
warning load hazard

Safety gloves, overall, safety shoes with ankle protection, safety helmet, safety goggles, dust
mask, hearing protection and safety harness are provided for your personal protection. USE
THEM AS REQUIRED.

Personal protection signs

Mandatory Sign Mandatory Sign Mandatory Sign
Safety helmet Overall Dust mask

Hearing Safety shoes Safety gloves

protection with ankle Rubber gloves
protection
Fall prevention Safety goggles First aid kit
equipment

Tirak
mandatory
inspection

The words WARNING and CAUTION are used to highlight possible hazardous situations to
persons or equipment as follows:

WARNING This is to warn about serious safety hazards.

CAUTION This is to warn about damage to equipment which may also involve
a safety hazard.

© 2005 KONE Corporation 21 (453) AM-01.01.084

2.5 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 whenever there is a risk of
injury from a fall. Refer to AM-01.03.001.
It is recommended that you attach the harness to a fixing point at least 1.8 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 risks from possibly dangerous striking points such as guide rail
brackets.)
If you are likely to fall down the side of the car or scaffolding platform level 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 cannot be any unwanted movement of the elevator car.
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.
Do not share life lines.
Be aware of the effect of the lifeline stretch.

a1184b4.wmf

© 2005 KONE Corporation 22 (453) AM-01.01.084

3 SITE REQUIREMENTS AND TOOLS

3.1 Site requirements

The site inspection should take place at least one week before the installation is scheduled to
start.
NOTE! Whenever possible the machine and control panel should be lifted into the machine
room before the roof is erected. If that is not possible, lift machine and control panel
up in the elevator shaft and place on the topmost landing before any other work
commences.
The following things must be ready before starting the installation:
NOTE! Items 1 to 5 are the 5 top absolute standards in site. Only if these prerequisites are in
place, we can do our job safely, fast and without interruption and keep to construction
schedule.

Item Requirement Note

1 Elevator shaft is clean, dry and painted
before the installation work starts.
2 Proper three-phase and one-phase
power supplies are in place.
3 Storage place is provided on the ground Manual transportation of material should
floor close to the shaft and access ways be done within 20 metres or close range
to the shaft are clear. from the elevator shaft.
Clear, unobstructed access routes,
handling procedures and methods, for
long or bulky items, (guide rails, car
components, doors and so on), must be
defined prior to delivery.
4 Shaft opening and recesses are
constructed as per KONE layout
drawings. A
5 Lifting hooks and ventilation ducts are in
place.
NOTE! Lifting eye must be positioned
in the machine room ceiling
according to the layout drawing
and marked with the safe
working load.

1039114.wmf

© 2005 KONE Corporation 23 (453) AM-01.01.084

Item Requirement Note

6 Adequate lighting must be temporary or Where required, the elevator shaft
permanent positioned for the elevator lighting can be lowered from the top floor
according to the layout drawing. and temporarily secured to the plumbing
jig supports.
7 Finished floor marks must be on each
landing.
8 Elevator pit must be waterproofed. The elevator shaft must be watertight.
9 For group elevators setting out grid lines
must be marked on the lowest common
floor area.
10 C-inserts (if used) must be correctly
positioned and cleaned.
11 Landings must be protected with
coverings according to the local safety
codes and regulations.

Fit temporary barriers wherever

temporary protection is removed or
landing doors must remain open.
1100

It is recommended that entrance

protection is imperforate.
530
100

a1196d5.wmf

12 Suitable life line and fitments in position,

attached to the centre lifting eye.
13 Suitable provision for disposal of waste According to the local requirements.
materials must be available.

© 2005 KONE Corporation 24 (453) AM-01.01.084

3.2 Tools

3.2.1 Installation tools

MonoSpace® tool box

1007065-1.wmf

© 2005 KONE Corporation 25 (453) AM-01.01.084

MonoSpace® tool box

O 40 mm

1010241.wmf

© 2005 KONE Corporation 26 (453) AM-01.01.084

Extension 1 installation tool box

1018253.wmf

© 2005 KONE Corporation 27 (453) AM-01.01.084

Extension 2 installation tool box

1018261.wmf

© 2005 KONE Corporation 28 (453) AM-01.01.084

MonoSpace® tools
Pcs. Tool Figure
Automatic safety gear trigger
1 Drawing number: 803140G01
Brake wire rope bracket
1 Drawing number: 803144G01
Brake wire rope
1 Drawing number: 772277G01
1007069.wmf

1 Rope fixing plate

Drawing number: 803146

1027222.wmf

1 Parking chain 2 m, 1500 kg

1007070.wmf

2 Plumbing supports (pit)

Drawing number: 716177G01

1007072.wmf

1 Counterweight guide rail alignment

tool
Drawing number: 716180G01

1007074.wmf

1 Counterweight guide rail positioning

tool
Drawing number: 716175G01

1007075.wmf

4 Eyebolts for car 4 x M12 (male)

1 Eyeloop for car 1 x M10 (female) +
M10 T-bolt
Drawing number: 266824 1007077.wmf

© 2005 KONE Corporation 29 (453) AM-01.01.084

MonoSpace® tools
Pcs. Tool Figure
Hoisting chains:
1 Extension chain 1.5 m, 500 kg
Drawing number: 266827
1 Shortenable chain 2 x 1.5 m, 500 kg
Drawing number: 266826
1 Car/door installation chain 2 x 0.5 m, 1007078.wmf
500 kg
Drawing number: 266825
1 Guide rail lifting clamp for guide rails
T82-T89
Drawing number: 716165G01

1007079.wmf

2 Shackle 13 mm tap, 1500 kg

Drawing number: 754257H02

1007081.wmf

1 Shackle for car roof rope reeler

securing, 8 mm tap, 500 kg
Drawing number: 754257H03
1007082.wmf

1 Rope grip for rope reeler securing,

9 mm or 14 mm
For correct type see drawing number:
754257H01 1007083.wmf

1 Hoist test bracket

Maximum load 2000 kg
Drawing number: 716157G01

1007084.wmf

© 2005 KONE Corporation 30 (453) AM-01.01.084

Extension tools
Pcs. Tool Figure
1 Extension for counterweight guide rail
alignment tool
Drawing number: 763082G01

P17000183.wmf

1 Hoist test bracket

Maximum load 4000 kg
Drawing number: 762395G01

1011800.wmf

2 Guide rail clamps

Drawing number: 654068

1011810.wmf

2 CFE-sling adapter
Used together with guide rail clamps
for CFE-10 sling.
Drawing number: 856699

1 Rope cutter

1018279.wmf

2 Plumbing supports (pit)

Drawing number: 716177G01

1007072.wmf

© 2005 KONE Corporation 31 (453) AM-01.01.084

Extension tools
Pcs. Tool Figure
2 Rope grips

P17000192.wmf

1 Car parking chain 2 m, 2500 kg

1007070.wmf

1 Hoist testing chain 2 m, 4000 kg

1011819.wmf

1 Tirak hoist suspension beam

Length = WD, elevator shaft depth

For use of suspension beam see

layout drawings.

1039259.wmf

2 Guide rail securing to car roof

Drawing number: 773444G01

2 Guide rail lifting pocket

Drawing number: 762396G01
P17000195.wmf

2 Shackle
Maximum load: 1000 kg
Size: D=10, d=11, a=16, C=36
Order number of Bjornsteel: G4161-1T

1011817.wmf

2 Roping tool for working platform

Drawing number: 851510G01

1018299.wmf

© 2005 KONE Corporation 32 (453) AM-01.01.084

Other installation tools

Pcs. Tool Figure
1 Installation hoist, Tirak X series 750 kg
capacity + pulleys.
(Optional)

See hoist equipment parts on page 50.

1007086.wmf

1 Installation hoist, Tirak X series

1000 kg capacity + pulleys.
(Optional)

See hoist equipment parts on page 52.

1018293.wmf

1 Installation hoist, Tirak X series

2000 kg capacity + pulleys.
(Optional)

See hoist equipment parts on page 54.

1011796.wmf

1 Test plate, separately ordered by front

line.

1010613.wmf

1 Manual chain hoist, capacity 500 kg.

Height from hanging hook to lifting

hook maximum 270 mm (when the 1007087.wmf
lifting hook is fully raised).
Lifting and manoeuvring chain length
5.0 metres.
1 Material hoist
Supplied locally
For lowering suspension rope from
machine room in high travels.
4 G clamp

1007097.wmf

© 2005 KONE Corporation 33 (453) AM-01.01.084

Other installation tools

Pcs. Tool Figure
1 Site trolley
Drawing number: 834454

1007088.wmf

Work stool

1007089.wmf

1 set MX10 machine transporting wheels

Drawing number: 715802

1007090.wmf

2 Steel pit prop 80x80x6 mm, supplied

locally.
m m
000
2

1029362.wmf

1 Battery tool
Cable (Drawing number: 859326) and
9V battery (supplied locally)

Used with construction-time power

supply.

1039959-1.wmf

4 Guide blade aligner clamp

Type AMF-6800
Supplier: Björnsteel, Finland

1011798.wmf

1 Guide rail lifting clamp

Drawing number: 733160G01
(maximum load 500 kg)
for rails T82-T127
Drawing number: 736196G01
(maximum load 500 kg) 1011809.wmf

for rails T127-T140

© 2005 KONE Corporation 34 (453) AM-01.01.084

3.2.2 Tools delivered with the elevator

Pieces Tool Figure

1 Car guide blade aligner
Drawing number: 803400G01

1011821.wmf

1 Counterweight guide blade aligner

Drawing number: 803400G02

1011822.wmf

1 or Plumbing templates
more (In case of through-type car
additional templates are provided) *
Drawing number: 803134

*) Additional template for through-

type elevator

a1184a2.wmf

© 2005 KONE Corporation 35 (453) AM-01.01.084

3.2.3 Installation time equipment

Pcs. Tool Figure

1 Temporary overspeed governor
OL100 for installation time use (used if OL100
elevator rated speed is
≥ 1.75 m/s).
Tripping speed 0.98 m/s.

Use OL35 as an installation time

overspeed governor by using smaller
groove *).

*) OL35

1043111.wmf

3.2.4 Hand tools

Refer to KOS-000029 KONE hand tool sets for installation and maintenance purpose.

© 2005 KONE Corporation 36 (453) AM-01.01.084

4 UNLOADING AND DISTRIBUTION

Introduce yourself to the site agent. Familiarise yourself with the site facilities, the local rules,
safety requirements and site management procedures.
NOTE! For personal safety and to prevent any damage to the components.
• Keep the working areas clear and unobstructed.
• Never go under any suspended load.
• Use correct manual lifting techniques.
• Wear gloves.
• Always wear a helmet.
• Wear safety harness and fix it to an approved fixing point while working in areas where
there is risk of injury from a fall.
• Wear goggles and dust masks as necessary.
• Use hearing protection as necessary.

WARNING
When transporting the electrification panels use transportation
cart. They are both top heavy. Take extreme care when
maneuvering and transporting the control panels and MX
machinery. Ensure that the cart is moving over flat level ground!

4.1 Off-loading and distributing materials

Step Action Note

1 Off-load the material.
2 Check that the delivery is complete with Do not open the packages until you are
the material documentation. Complete ready to install the equipment.
the check form for return to factory.
3 Complete the site readiness audit form.
Return it to KONE projects engineer.
4 Position the tools and materials to It is important that the tools and
correct levels according to the following materials are positioned according to the
list before the installation commences. installation sequences to achieve and
maintain a controlled installation
environment throughout the installation.
Suitable arrangements must be made for
the safe transportation of materials to all
floors.

© 2005 KONE Corporation 37 (453) AM-01.01.084

A Machine room
• Control panel
• Overspeed governor and rope A
• Car and counterweight rope anchorages
• Installation beams (if applicable)

B Topmost landing
• Elevator shaft lighting (if applicable)
• Tirak hoist diverter pulley
• MonoSpace tool boxes B
• Extension 1 tool box

C Entrance / Storage area

• MX machine
• Alignment tools
• Guide rails, brackets and fish plates
• Counterweight and filler weights
• Landing doors to each landing
• Elevator shaft electrification
• Compensation chain (if applicable)
• Tirak hoist
• Car sling
• Car
• Car door and door operator
• Car operating panel
• Installation clamps
• Ropes
• Extension 2 tool box
• Working stool
C
• Automatic safety gear trigger
• Parking chain (Extension 1 tool box)
• Guide rail lifting clamp (MonoSpace tool
box)
1039115.wmf

© 2005 KONE Corporation 38 (453) AM-01.01.084

5 PLUMBING

5.1 Placing the plumbing template (single elevator)

Step Action Note

1 Open template.
2 Place the templates upside down on
the floor.

Rivet plates from the under side of

the template.
4x

1011829.wmf

3 Position the template to its approximate

position.
DBG 60

C/L

LL 1011830.wmf

4 Check the template dimensions in the layout drawing.

© 2005 KONE Corporation 39 (453) AM-01.01.084

Step Action Note

5 Through-type car (if applicable):
Assemble and place the second
template in position.

Fix the templates together using

screws.

Check the template dimensions in the

layout drawing.

1028956.wmf

1. Plumb line holes for landing doors

2. Alignment holes for A-side and C-side templates

© 2005 KONE Corporation 40 (453) AM-01.01.084

5.1.1 Lowering the plumb lines

Step Action Note

1 Lower all the plumb lines using the
outside holes Ø1.5 mm.
Use light weights.
2 For long travel or windy conditions
stabilize the weights using water
buckets.

1011831.wmf

3 Tie the plumb wire back using the

securing holes.

1 1

2 2

1011832.wmf

1. Plumb wire for car guide rail

2. Plumb wires for door

© 2005 KONE Corporation 41 (453) AM-01.01.084

For dimensions A and B refer to the layout drawings.

1 1

DIM mm
A
A B B

a1184a4.wmf
2 2
1. Plumb wires for car guide rail
2. Plumb wires for door

© 2005 KONE Corporation 42 (453) AM-01.01.084

5.2 Plumbing (single elevator from finished machine room or temporary

deck)

5.2.1 Plumbline checking

Step Action Note

1 Measure the lift well at each floor.
2 When it has been established that all sill entrances are correct. Secure the template
to the floor. Use expander nails for concrete (delivered with the template when fixing
to concrete) and wood screws for the wooden floors.
3 Locate and position the counterweight Distance between landing door sill and
template. Measure from the car its plumbing lines is 20 mm, in shaft
plumblines (refer to layout drawing). depth direction.
Secure the template to the floor.
4 Secure the plumb lines to the support
brackets in the pit.

Check the distance between the plumb +A

lines (A + DBG + A): DBG
A+
• Guide rail T75 - A is 40 mm. LL
• Guide rail T82 - A is 40 mm.
• Guide rail T89 - A is 40 mm.
• Guide rail T114 - A is 50 mm.
• Guide rail T125 - A is 50 mm.
• Guide rail T127 - A is 60 mm.
• Guide rail T140 - A is 70 mm.
• Guide rail TK5A - A is 17 mm.
• Guide rail HT60 - A is 26 mm. 1011834.wmf

© 2005 KONE Corporation 43 (453) AM-01.01.084

5.3 Filling in plumbing table

Step Action
1 Control the elevator shaft dimensions to ensure that the lift is installed in its
optimum position.
2 Refer to the layout drawing and fill the nominal dimensions in the table. Fill in the
other rows according to the measurements.
3 Keep the recorded measurements with other lift documentation.

Elevator number: Measured by: Date:

NOTE! *) Do not forget to measure the C-side and offset of the car and landing door centre
lines.

D C1 C2 B
D B

A1 A2
A3 A4

A5
A A6
8000840.wmf

© 2005 KONE Corporation 44 (453) AM-01.01.084

Pos. Measured (mm)

SH
H
PH
WW
WD

A1 A2 A3 A4 A5 A6 B D C1 C2 C3 C4 C5 C6
Nominal
dim.
Level
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

© 2005 KONE Corporation 45 (453) AM-01.01.084

5.4 Plumbing groups of lifts

Step Action Note

1 Ensure that all the front plumb lines of
the elevators are in line.

CL CL CL

1007143.wmf

2 Construct a line at right angles to the Work from a reliable reference point, (for
elevator shaft centre-lines as close as example the building grid lines).
possible to the front walls of the
elevator shafts.

1007144.wmf

3 Measure out from each centre-line and

mark the door clear opening width of
each opening on the reference line.
C C C
L L L

LL 1007145.wmf

© 2005 KONE Corporation 46 (453) AM-01.01.084

Step Action Note

4 Measure from each plumb line to the If all the measurements are equal the
respective mark on the grid line. plumb lines are in line and aligned to the
building grid.

1007146.wmf
=

=
5 Make your plumbing charts for each If it is necessary to move the template in
elevator as before. one elevator shaft all the templates must
be moved exactly the same amount.
6 For elevator shafts on opposite sides of The centre-line must come in the middle
a common lobby, check the plumb line of the plumb lines and measurements D
alignment of the adjacent elevators as must be equal.
before. Then measure across the lobby
between the plumb lines. (Distance D).

CL CL CL

= =
D
D

= = 1007147.wmf

© 2005 KONE Corporation 47 (453) AM-01.01.084

5.5 Dividing beams

WARNING
Always work with two cars at the same level to ensure work safety and sharing of the
work tasks.

Step Action Note

1 Measure and mark out the beam centre
line and height on the front and rear WARNING!Use safety harness.
walls of the elevator shaft. Refer to the
layout drawing.
2 Install the wall brackets, (drilled holes
and expanding bolts or C-inserts and T-
bolts). *) Use shim plates if necessary.
3 Check that the brackets are vertically
and horizontally level and in line and
level with each other.
4 Remove the upper bolts from the wall
brackets.

P04000185.wmf

5 Lift the beam into position using the Daily check the condition of the sling and
Tirak hoist and soft sling (canvas or discard it if it is defective.
nylon).

P04000186.wmf

© 2005 KONE Corporation 48 (453) AM-01.01.084

Step Action Note

6 Check for level and alignment. Measure
back from the plumb lines and from the
edges of the cars (when working on the
car roof).

1028589.wmf

© 2005 KONE Corporation 49 (453) AM-01.01.084

6 HOIST INSTALLATION

6.1 Lists of hoist equipment parts

6.1.1 Tirak X750

Pos. Item Greifzug’s component no.

1 Diverter pulley including the safety rope 33009
2 Electric hoist
3 Tension weight 57497
4 Manual rope reeler for maximum 60 m 30158
rope
5 Safety pin no. 2. 6 mm 12056
6 Electric supply extension cable for main 16537
power supply, 45 m, 5 x 1.5 mm2
7 Pendant controller
8 Extension cable for the pendant control
9 Car adapter for the hoist 53877
10 Car adapter for the hook 53887
11 Adapter axle 72415
12 Split pin 6.3 x 40 63496
13 Diverter pulley Ø160 mm 53997
14.1 Safety pin 5 x 32 mm for diverter pulley 63656
14.2 Safety pin no. 2. 6 mm 12056
15 Tension weight pulley Ø130 mm 20205
16 Tension spring (guide for rope from 8363
bottom of Tirak)

Suspension Minimum Tirak rope length

2:1 2 x elevator shaft height

© 2005 KONE Corporation 50 (453) AM-01.01.084

Tirak X750 with adapters for elevator installation (2:1 suspension)

7.
1.

8.
6.
2.

16. 12.

3.
9.
4.
11.
10.

P17000140-1.wmf

© 2005 KONE Corporation 51 (453) AM-01.01.084

6.1.2 Tirak X1000

Pos. Item
1 Diverter pulley, 2:1 pulley with swivel hook, MC2.0 W code
2 Electric hoist Tirak X1033 P,
Speed: 9/18 m/min (50 Hz), 35/70 ft/min (60 Hz)
*) Fixing bore Ø18 and shackle 2 t
3 Tension weight, 11 kg
4 Manual rope reeler for max. 100 m rope
5 Hoist anchorage kit
6 Electric supply extension cable for main power supply
7 Pendant controller
8 Extension cable for the pendant controller
9 Safety rope for diverter pulley, 3 m, with hook

Suspension Minimum Tirak rope length

2:1 2 x elevator shaft height

© 2005 KONE Corporation 52 (453) AM-01.01.084

Tirak X1000 with adapters for elevator installation (2:1 suspension)

2000kg
9
7
1
ø150
6 1000kg
309 7 315
ø10 60

67
8

585

370
297
49.5

40
292

*
195

. 11
..
.

.
.

185
5

1018312-2.wmf

© 2005 KONE Corporation 53 (453) AM-01.01.084

6.1.3 Tirak X2000 P

Pos. Item
1 2:1 diverter pulley with swivel hook (approx. 6 kg/13.5 lb)
2 Electric hoist (approx. 150 kg/330 lb)
Speed: 6/12 m/min (50 Hz) or 23/45 ft/min (60 Hz)
*) Fixing bore Ø30 for shackle 8.5 t
**) 4 x spacers to position the hoist and hook anchorage in sling
3 Tension weight (approx. 22.5 kg/50 lb)
4 Manual rope reeler with wire rope, Ø14 mm
(e.g. 60 m wire rope, approx. 55 kg/120 lb)
5 Hoist anchorage kit
6 Electric supply extension cable for main power supply
7 Pendant controller
8 Extension cable for the pendant controller
9 Safety rope for diverter pulley, 3 m, with hook

Suspension Minimum Tirak rope length

2:1 2 x elevator shaft height

© 2005 KONE Corporation 54 (453) AM-01.01.084

Tirak X2000 P with adapters for elevator installation (2:1 suspension)

4000 kg

9
1
7
6
14 483.5
8 132

400

2
216
1154

132
*

5
4000 kg
21.5
195

2000 kg
2000 kg

**
3 mm
50

1018318-2.wmf

© 2005 KONE Corporation 55 (453) AM-01.01.084

6.2 Selecting correct Tirak hoist

Verify that you have the correct hoisting application prior to installation. If in doubt about the
required hoist capacity and load to be hoisted contact you supervisor or local engineering
support function. You must never start installation unless all correct hoisting equipment are
available.

Step Action Note

1 Calculate the required Tirak hoist capacity in the following situations:
• Machine transportation using the car (G1):
G1 = Fmax + FT + MX - Q - n x door
• Roping (G2):
G2 = Fmax + FT + ropes - Q
• Guide rail installation (G3):
G3 = Fmax + FT + car guide rails + counterweight guide rails - Q - n x
door
G1, G2, G3 = load to be lifted with Tirak hoist (kg)
Fmax = mass to be gripped (kg), refer to the KONE intranet (EDMS), Component
Order Tool (COT), safety gear label or Elevator Supply Unit.
FT = weight of two fitters and tools (kg) = 250 kg
MX = weight of machine and package (kg): MX10 = 370 kg
Q = rated load of the elevator (kg), refer to the layout drawing
n = number of car doors ( )
door = weight of a car door (kg) = 130 kg
ropes = weight of hoist ropes (kg), see the following table
car guide rails = weight of 10 m of car guide rails:
T125 = 180 kg; T89 = 123 kg
counterweight guide rails = weight of 10 m of counterweight guide rails:
T82 = 86 kg; HT60 = 32 kg, T75-3/B = 86 kg, Tk5A = 49 kg
2 Select the Tirak hoist type and See the hoist capacity in the table on
suspension according to the biggest page 57.
load (G1, G2 or G3).
If the machine transportation to the
topmost floor is done using the site
crane, select the Tirak hoist type and
suspension according to the bigger load
(G2 or G3).

© 2005 KONE Corporation 56 (453) AM-01.01.084

Travel (m) Weight of hoist ropes (kg)

10 50
20 79
30 107
40 136
50 165
60 194
70 223
80 252
90 281
100 310

Hoist type Suspension Hoist capacity (kg)

Tirak X750 2:1 1500
Tirak X1000 2:1 2000
Tirak X2000 2:1 4000

6.3 Safety checks

Make the following safety checks.

Item Requirement Risk

Lifting equipment and Must be load marked, tested Falling loads.
suspension eyes. and in good condition
according to local
requirements.
Hoist and lifting equipment. Must be tested according to
local requirements.
Plugs and cables. Must be in good condition. Electric shock.
Emergency stop button and Must prevent movement of Uncontrolled movement of
limit switches (if applicable). hoist when contacts are hoist/car.
open.
Safety harnesses and Must be inspected and in Falling.
ropes. good condition. When used,
they must always be
securely attached to
approved fixing points.

© 2005 KONE Corporation 57 (453) AM-01.01.084

6.4 Hanging the hoist from a beam in the ceiling (option A)

Step Action Note

1 Transport Tirak rope, reel and pulley to
top floor.
2 From the machine-room drop a lifting
rope to the top floor.
3 Attach one end of a 5000 kg lifting
chain to the pulley hook.
4 Attach the other end of the lifting chain
to the lifting rope.
5 Place Tirak rope around the pulley.
6 Pull the pulley to the machine-room and Protect the edges of the hole against
secure it to a 4000 kg lifting beam. falling objects.
7 One fitter lowers the rope from the top NOTE! Take care that the rope does not
floor to the pit by feeding the rope by gather too much momentum.
hand, while another fitter fixes the rope
hook to the Tirak suspension bar.
8 Temporarily fix the Tirak rope to prevent
it from running through the pulley.
9 Uncoil rest of the Tirak rope from reeler
and feed down to pit.
10 Feed rope tail through Tirak.

© 2005 KONE Corporation 58 (453) AM-01.01.084

5 6

1
4

7
2

3 a1184a3.wmf

1. Suspension beam for lifting eyes

2. Plumbing template
3. Lowest landing
4. Chain, rated for 4000 kg load
5. Lifting trolley, supplied locally
6. Beam clamp, supplied locally
7. Chain, rated for 4000 kg load and timber packing
8. Suspension beam and safety rope of the pulley

Refer to your local engineering support function for exact method of suspending
hoists.

© 2005 KONE Corporation 59 (453) AM-01.01.084

6.5 Hanging the hoist from a beam on the floor (option B)

1039227.wmf

Step Action Note

1 Transport Tirak rope, reel and pulley to
top floor.
2 From the machine-room drop a lifting
rope to the top floor.
3 Lower the power supply cable (from the Allow an extra 3 metres of power supply
hole, that is for the main power supply) cable at the bottom landing to reach the
to the bottom landing. car roof later in the installation
sequence.

© 2005 KONE Corporation 60 (453) AM-01.01.084

Step Action Note

4 Connect the power supply to the hoist Be careful when unwinding the rope
and check the operation of the hoist from the rope reeler.
safety functions.
5 Attach one end of a 5000 kg lifting sling
to the pulley hook.
6 Attach the other end of the lifting sling
to the lifting rope.
7 Place Tirak rope around the pulley.
8 Pull the pulley to the machine-room Protect the edges of the hole against
falling objects.
9 Put a U-beam through the lifting sling.
Protect the sling from sharp corners
with wood.
Secure the beam to the floor.
When the floor is not load-bearing, fix
the U-beam to the support beams.
10 Clip the securing hook over the lifting
eye in the machine room.

1039228.wmf

11 One fitter lowers the rope from the top NOTE! Take care that the rope does not
floor to the pit by feeding the rope by gather too much momentum.
hand, while another fitter fixes the rope
hook to the Tirak suspension bar.
12 At the topmost landing, temporarily fix
the Tirak rope to prevent it from running
through the pulley.
13 Uncoil rest of the Tirak rope from reeler
and feed down to pit.
14 Feed rope tail through Tirak. If the hoist motor does not run, reverse
two phases in the plug by rotating the
phase changer in the plug housing.

P17000107.wmf

© 2005 KONE Corporation 61 (453) AM-01.01.084

6.6 Overspeed governor

WARNING
If rated speed of the elevator is ≥ 1.75 m/s use OL100
temporary overspeed governor for installation
time use.
Tripping speed 0.98 m/s.

WARNING
If the overspeed governor type is OL35 always
use the smaller groove *) during the *) OL35
installation.

1043111.wmf

Step Action Note

1 Fix the overspeed governor in place
according to the layout. Install the I-
beams first if needed.

OL100

OL35

1043095.wmf

2 Ensure that the tripping direction is

correct from arrow on governor.
3 Lower one end of the overspeed
governor rope down the pit.
4 Lower the other end of the overspeed
governor rope down the pit and secure
the rope ends.

© 2005 KONE Corporation 62 (453) AM-01.01.084

6.7 Testing the hoist equipment

If the lifting eye or suspension element for the Tirak diverter pulley has not been tested and
certified, perform and record the test. The test ensures that the hoist equipment will take the
maximum load hoisted during the installation.

WARNING
No one is allowed to be in the lift well during this test.

Step Action Note

1 Install the hoist test bracket on the lift *) Tirak X750 or Tirak X1000:
well wall on the guide rail side in the M12 bolts or Halfen screws
height of 1 - 1.4 metres from the pit
floor. **) Tirak X2000:
Expander bolts HSA-F M16x140, 4 pcs

*
1-1.4 m

** 1050137.wmf

© 2005 KONE Corporation 63 (453) AM-01.01.084

Step Action Note

2 Attach the dynamometer / test plate
(breaking strength 2000 kg or 4000 kg,
supplied locally) to the hoist test
bracket.
3 Shorten the parking chain to 300 mm.
4 Connect the car parking chain (capacity
1500 kg) to the dynamometer / test
plate.
In case of Tirak X1000 or Tirak X2000
use the hoist testing chain (capacity
4000 kg).
5 Step out of the pit.
6 Drive the hoist slowly upwards until the
hoist ropes are under tension.
Take up the tension smoothly. Any 1009536.wmf
sudden loadings may damage the
equipment.
7 Run continuously until the load limit of The hoist can now be used for material
the Tirak hoist is reached or the test transportation.
plate breaks. Do NOT use the hoist for man riding
Motor power supply is automatically until:
disconnected. Drive the hoist • The hoist and hook are correctly
downwards to reset it. secured to the car sling (See
section 9 Attaching hoist to car
sling on page 155).
• The overspeed governor is
connected to the safety gear.
• The ASGT is fitted and operating
1010613.wmf
correctly.

© 2005 KONE Corporation 64 (453) AM-01.01.084

7 FIRST GUIDE RAILS AND PIT EQUIPMENT

7.1 Preparations for guide rails and pit

WARNING
Do not work beneath suspended loads. Wear harness whenever there is risk of injury
from a fall. Ensure that there are no tripping hazards.

Step Action Note

1 Clean the guide rails and fish plates. Check that the guide rails are straight.
WARNING!The rust protection must be
removed from the rails. Otherwise the
safety gear will not operate correctly.
The working method necessitates
repeated engagement of the safety
gear and even safety gears designed
for oiled guide rails will not function
1009623.wmf under these conditions unless the
guides are clean.
1250 1250
CAUTION!The guide rails and fish
700-900

plates must be cleaned thoroughly.

WARNING!Work in a well ventilated
1010405.wmf area and follow the instructions
delivered with the cleaner.

© 2005 KONE Corporation 65 (453) AM-01.01.084

Step Action Note

2 Dress the guide rail joints.

1016904.wmf

3 Check that the guide rails are straight horizontally and vertically and that they are
not twisted.

1011864.wmf

4 Install the fish plates to the guide rails.

Tighten the bolts hand tight.

1038862.wmf

5 Clamp the alignment tool to a car guide Refer to the layout drawing.
rail. Adjust the DBG and check that the
tool is parallel to the guide.

1029426.wmf

1009625.wmf

6 Set the counterweight guide rail

positioning tool to correct length.
P17000201.wmf

© 2005 KONE Corporation 66 (453) AM-01.01.084

Step Action Note

7 Install clamps to the guide rail blade
aligners. Add shim plates for different
guide rail sizes:
• T140-1B = 2 shim plates
• T140-2B = 4 shim plates
• T140-3B = 4 shim plates

Remove rubber cover from guide blade

aligner clamp.
1030000.wmf

7.2 Installing guide rail brackets

7.2.1 Drilling holes to wall for guide rail brackets

Step Action Note

1 Place the first 2 rings of guide rail
brackets on the pit floor.
2 Transfer the plumb wire position to the Measure from plumb wire to both side
wall using a square. wall and front wall. This measurement is
used later to reposition the plumb wires.
3 Mark out the height of the plumbing
support and guide rail brackets.
Extend the marks (including the mark
for the rear counterweight bracket)
along the wall using spirit level.

1029433.wmf

4 Use the square mark and transfer it to Refer to the Table of drilling dimensions.
the drilling positions.

© 2005 KONE Corporation 67 (453) AM-01.01.084

Step Action Note

5 Drill the holes for the brackets.

1029434.wmf

Bracket data:
- drilling depth 75 mm
- hole diameter 19 mm
Assemble unpainted surfaces
against each other to increase
friction
After guide rail alignment paint
the unpainted surfaces
a1184a5.wmf

© 2005 KONE Corporation 68 (453) AM-01.01.084

7.2.2 Drilling dimensions for SMiniSpace with side counterweight and XMiniSpace

B1 B2

A1 A2

8000794.wmf

SMiniSpace with side counterweight

Car guide rail type A1 (mm) B1 (mm) A2 (mm) B2 (mm) C1 (mm)

T82 70.5 (a 199.5 (a 90.5 179.5 DBG+h1 (d+203
75.5 (b 204.5 (b
175.5 (c 304.5 (c
T89/T114 67 (a 203 (a 87 183 DBG+h1(d+203
72 (b 202 (b
172 (c 308 (c
a) Applicable for car bracket KM630382G01, KM630360G01 and KM741039G01.
b) Applicable for car bracket KM822260G01, KM775800G01, KM657583G01, KM657584G01 and
KM775801G01.
c) Applicable for car bracket with extension KM741027G01, KM741027G02, KM741103G01,
KM741120G01, KM741120G02, KM741120G03, KM741120G04, KM741120G05 and
KM741120G06.
d) h1: counterweight guide rail height. h1=62 for T75/T89; h1=60 for TK5A.

XMiniSpace

A1 (mm) B1 (mm) A2 (mm) B2 (mm) C1 (mm)

50 130 44 136 DBG+230.5

© 2005 KONE Corporation 69 (453) AM-01.01.084

7.2.3 Drilling dimensions for SMiniSpace with rear counterweight

C1 C1

B1 B1

A1 A1

8000795.wmf

Table of drilling dimensions for SMiniSpace with rear counterweight

A1 (mm) B1 (mm) C1 (a (mm)

72 (b 208 (a DBG/2-35 (d
172 (c 308 (b DBG/2+43 (e
a) Refer to layout drawing to locate the counterweight center line.
b) Applicable for car bracket KM657583G01, KM657584G01, KM657586G01 and
KM775800G01.
c) Applicable for car bracket with extension KM651389G01.
d) Only applicable for CWT bracket KM741022G01 and KM741022G04.
e) Only applicable for CWT bracket with extension KM777621G03 and KM777621G04.

© 2005 KONE Corporation 70 (453) AM-01.01.084

7.3 Lifting the first guide rails

Step Action Note

1 Tie the draw wire to the sliding clamp to
help pulling it back down the guide rail
when the hoist is lowered.
NOTE! Clamp type depends on guide
rail size.

1007158.wmf

2 Prepare to lift the guides in to the pit

using the sliding clamp, fish plates up.

1029436.wmf

3 If there is insufficient space in the pit to The rest of the guide rails can be
place all the guide rails at the side and positioned in the pit later when the car
rear of the car, start with the first 2 runs has been moved up the elevator shaft.
of guide rails only. Refer to the layout drawing.

© 2005 KONE Corporation 71 (453) AM-01.01.084

7.4 Bracket combinations

Combination guide rail brackets

70
5 ...3
20
1038971.wmf

90
0...3
23

a1184l.wmf

© 2005 KONE Corporation 72 (453) AM-01.01.084

Counterweight guide rail brackets

1038972.wmf

0
...30
5
11
a1184m.wmf

© 2005 KONE Corporation 73 (453) AM-01.01.084

Car guide rail brackets (single side)

10
0 ...1
8

0
0 ...8
5

1029442.wmf

45 65
≤2 ≤1

5
5 ≤8
≤ 12

1029443.wmf

© 2005 KONE Corporation 74 (453) AM-01.01.084

Car guide rail brackets (single side)

70 5
0...1 ...37
8 5
14
a1184k.wmf

7.5 The first two rings of guide rail brackets

Step Action Note

1 Fix the guide rail brackets to the wall. If Ensure that the combination side
needed fit shim plates. brackets are level in both planes.

Side counterweight Rear counterweight

1057179.wmf
8000850.wmf

© 2005 KONE Corporation 75 (453) AM-01.01.084

7.6 Fixing the first guide rails

Step Action Note

1 Lift the car guide rail. If oil cups are delivered, install them
now.
If clip on plastic trays and bottles are
delivered, they will be fitted later.
Refer to the delivery documents.

a1184a7.wmf

2 Position and fix the car guide rails to

the brackets.

© 2005 KONE Corporation 76 (453) AM-01.01.084

7.7 Guide rail alignment at the guide rail bracket level

Guide rail size A (mm)

T82 40
T89 40
T114 50

© 2005 KONE Corporation 77 (453) AM-01.01.084

Step Action Note

1 Clamp the car guide rail aligner between Ensure that there is no gap between
the guide rails at each bracket level. guide rail and clamping bolt.
Ensure that the aligner is level.
2 Align the guide rails according to the
plumb lines.
Verify the distance between guide rails
(DBG) with the car guide rail aligner.

7.8 Checking the car guide rail parallelity

Step Action Note

1 Place the rail aligner against the guide
rail blade.
2 Check the parallelity by referring to the
alignment tool surface using 300 mm
square.
3 Adjust the parallelity.
4 Tighten the bracket bolts.
5 Check the parallelity from opposite
side.
6 Tighten the bolts.
The guide rail is aligned when:
• The plumb wires align with the
notches of the alignment tools.
• DBG is correct. (Tolerance is
±0.5 mm)
• The guide rails are parallel with
rail aligner.

1011883.wmf

© 2005 KONE Corporation 78 (453) AM-01.01.084

7.9 Installing and Aligning the first counterweight guide rails

7.9.1 For SMiniSpace with side counterweight and XMiniSpace

Step Action Note

1 Fix and tighten the first counterweight
guide rail to the combination bracket.
2 Fix the rear counterweight guide rail to
the bracket using the clips.

1029472.wmf

3 Clamp the alignment tool in the middle Hold one side of the diagonal positioning
of the two counterweight guide rails (at stick against the rail and move the other
the same height with the bracket). end against the other rail up and down.
4 Align the counterweight guide rails with The other end should just touch the rail
the alignment tool and the diagonal face.
positioning stick.

1029473.wmf

5 Tighten the opposite counterweight

guide rail bracket.
6 Check DBG at bottom using alignment
tool.

© 2005 KONE Corporation 79 (453) AM-01.01.084

Step Action Note

7 Repeat the alignment at the second
guide rail fixing.

1029474-1.wmf

8 Re-check the alignment at the first

guide rail fixing position.
Re-align if necessary.

NOTE! For HT60 guide rails, refer to AM-02.03.003.

7.9.2 For SMiniSpace with rear counterweight

Step Action Note

1 Lift the first pair of counterweight guide
rails into position on the jack bolt using
lifting clamp and material hoist.

© 2005 KONE Corporation 80 (453) AM-01.01.084

Step Action Note

2 Envelop the first pair of guide rails with NOTE! For SMiniSpace with rear
the delivered brass plate before counterweight and travel length
installing them onto the brackets. more than 100 m, envelop the
NOTE!This step is only applicable for first pair of guide rails with the
SMiniSpace with rear counterweight delivered brass plate before
and travel length more than 100 m. installing them onto the
brackets.
NOTE! For Xminispace when car guide
rail is T82, travel is more than
60 m and load is 1000 kg, brass
plate is also used.

8000791.wmf

© 2005 KONE Corporation 81 (453) AM-01.01.084

Step Action Note

3 Fix and align the first counterweight
guide rails.
• Adjust alignment tool to correct
DBG-measure.
• Check cross-measure and
distance between guide rail lines.
• Check DBG-measure and
parallelity of guide rails with
alignment tool and fix the guide
rails.

G
DB

8000846.wmf

© 2005 KONE Corporation 82 (453) AM-01.01.084

7.10 Buffers

NOTE! Polyurethane buffers are used when the elevator rated speed is 1.0 m/s.
Oil buffers are used when the elevator rated speed is more than 1.0 m/s.

Step Action Note

1 Lift the buffers into the pit using the Refer to the layout drawing.
hoist.
2 Install the buffers:
• Mark the centre line of DBG.
• Position the base.
• Fit the buffer.
• Check level and shim if
necessary.
CAUTION! Check the oil level using
dipstick or oil level indicator. Add oil if
necessary. Use oil resistant gloves
and avoid contact with skin. Make
sure not to exceed the maximum oil
level indicated on the dipstick or oil
level indicator.

1007174.wmf

1043068.wmf 1054rrr.wmf

© 2005 KONE Corporation 83 (453) AM-01.01.084

Step Action Note

3 If polyurethane buffers, detach two The timber pieces can prevent the buffer
timber pieces from the guide rail crate from deforming when the counterweight
and place them beside the buffer. frame is installed over the buffer.

Remove the two timber pieces after

roping.

1027337-1.wmf

7.11 OL35 overspeed governor tension weight

Step Action Note

1 Install the overspeed governor tension Refer to the layout drawing.
weight.
2 Fit the overspeed governor rope around
the tension weight and secure it with
cable ties.

© 2005 KONE Corporation 84 (453) AM-01.01.084

7.12 OL100 overspeed governor tension weight

Step Action Note

1 Transport the overspeed governor Use site trolley.
tension weight to the access landing.
2 Lower the overspeed governor tension Wear harness if there is a risk of falling
weight in position to the pit using Tirak more than 1.8 m.
hoist.
Refer to AM-05.06.006.

Ensure that there are no tripping

hazards.
3 Fasten the fixings (1) to the tension
weight guides (2) and install then the
tension weight guides to the guide rail.
The lower fixing must be X mm above
the pit floor level (see table and figure).

OL100 OL120
H X min H X min
970 220 1150 220
1290 540 1470 540
1690 940 1870 940

1057501.wmf

4 Lower the tension weight frame (3) to

the tension weight guides (it can also be
installed directly to the tension weight
guides, if the guides are partially
detached).
5 Support the tension weight frame.
6 Fit the overspeed governor rope around
the tension weight pulley. Fix the rope
ends to the rope fixing.
7 Remove the supports and lower the
tension weight on the rope.
8 Place and secure filler blocks into the During installation store the unused
tension weight. weights in a secure place so that they
NOTE! During installation phase fit only are not misplaced. Label them, if
needed.
one weight.

© 2005 KONE Corporation 85 (453) AM-01.01.084

Step Action Note

9 Check that switch contact (4) is 250 mm
below the upper guard of the contact
cam (5).
10 Operational distance of the switch must

250
be 3 mm.
3mm

5
1011908.wmf

7.13 Installing counterweight frame on buffer

Step Action Note

1 Install counterweight guide shoes on
the combination bracket side. Loosen
the front plate screw joints of the
diverter pulley plate. (This is removed
during roping and it is easier to loosen
the screws now.)

If counterweight safety gear, refer to

AM-08.07.002.
2 Fit hoist chain through pulley.

1029497-1.wmf

© 2005 KONE Corporation 86 (453) AM-01.01.084

Step Action Note

3 Lift counterweight frame into the pit.
Manoeuvre it between the
counterweight guide rails and push the
guide shoes over guide rail.

1007168.wmf

4 Lower the frame onto the oil buffer or

timber pieces. 1029499.wmf

5 Fix the oil lubricator brackets and upper

and lower guide shoes.

1017991.wmf

6 Shim the guide shoes to achieve 1 mm

clearance on both sides.

© 2005 KONE Corporation 87 (453) AM-01.01.084

Step Action Note

7 Fix the oil lubricators.

1029501.wmf

The skewed counterweight frame (MX10):

1007166.wmf

1. The side facing combination bracket for side counterweight installation

8000325(2008-08)

1. The side facing D wall for rear counterweight installation

Refer to layout drawing for more information.

© 2005 KONE Corporation 88 (453) AM-01.01.084

7.14 Filling counterweight with 40 % of filler weights

NOTE! Install first cast iron filler weights and then the concrete filler weights.

Step Action Note

1 Add filler weights until 40 % of the
delivered weights are installed.

40%

1025249.wmf

WARNING! Do not install more than

40 % of the weights delivered for the a1184a.wmf
counterweight frame. The car must
remain heavier than the
counterweight until final balancing.
2 *) Fix counterweight retaining
clamps.
WARNING! Clamps MUST be fitted
before the counterweight can be
allowed to be moved.

1039704.wmf

© 2005 KONE Corporation 89 (453) AM-01.01.084

8 CAR INSTALLATION, EURECA

8.1 Assembling upright and bottom beam

Step Action Note

1 Fix the switch fixing plate to the upright.
(The bigger switch fixing plate will be on
the opposite side of the machine.)

1007184.wmf

2 Attach the chain (2 x 0.5 m) to the holes Use the hoist for lifting.
of the triangular plates. Attach the hoist
chain to the 0.5 m chain.
3 Place the upright to horizontal position
to correct working height.
Place the lower part of the upright on
the working stool.

1007185.wmf

4 Install the ballast weights (if delivered) Secure the ballast weight very tight to
to the uprights on the landing using two the upright by hammering the plate ends
G-clamps. Install the ballast weights to the opposite sides.
according to the following tables. The two lowest plate ends must be bent
NOTE!Install the ballast weights to the in the safety gear direction to allow car
floor installation.
bottom beam after it is assembled
between the car guide rails.

1007186.wmf

© 2005 KONE Corporation 90 (453) AM-01.01.084

Elevators with rated speed 0.63 m/s or 1.0 m/s

Number Uprights Bottom beam Figure
of ballast Left Right Rear Front
weights beam beam
1 0 0 1 0 The picture below represents a case
2 0 0 2 0 when 31 ballast weights are installed.
3 0 0 3 0
4 0 0 4 0
5 1 1 3 0
6 1 1 4 0
7 2 2 3 0
8 2 2 4 0
9 3 3 3 0
10 3 3 4 0 2
11 4 4 3 0
12 4 4 4 0
13 5 5 3 0
14 5 5 4 0
15 6 6 3 0 1
16 6 6 4 0
17 7 7 3 0
18 7 7 4 0 1
19 8 8 3 0
20 8 8 4 0 2
21 9 9 3 0 1007187.wmf

22 9 9 4 0
23 10 10 3 0
24 10 10 4 0 1. Right upright
25 10 10 5 0 2. Left upright
26 10 10 6 0 3. Bottom beam (front beam)
27 10 10 7 0 4. Bottom beam (rear beam)
28 10 10 8 0
29 10 10 9 0
30 10 10 9 1
31 10 10 9 2
32 10 10 9 3
33 10 10 9 4
34 10 10 9 5
35 10 10 9 6

© 2005 KONE Corporation 91 (453) AM-01.01.084

Elevators with rated speed 1.6 m/s

Number Uprights Bottom beam Car top Figure
of ballast Left Right Rear Front balustr
weights beam beam ade
1 0 0 1 0 0 The picture below
2 0 0 2 0 0 represents a case when 33
3 0 0 3 0 0 ballast weights are
installed.
4 0 0 4 0 0
5 1 1 3 0 0
6 1 1 4 0 0
7 2 2 3 0 0
8 2 2 4 0 0
9 3 3 3 0 0 5
10 3 3 4 0 0
11 4 4 3 0 0
12 4 4 4 0 0
13 5 5 3 0 0
14 5 5 4 0 0 1
15 6 6 3 0 0 2
16 6 6 4 0 0 4
17 7 7 3 0 0
18 7 7 4 0 0
19 8 8 3 0 0
3
20 8 8 4 0 0
21 9 9 3 0 0
22 9 9 4 0 0 3
23 10 10 3 0 0
24 10 10 4 0 0 4
25 10 10 5 0 0 1009343.wmf

26 10 10 6 0 0
1. Right upright
27 10 10 6 1 0
2. Left upright
28 10 10 6 2 0
3. Bottom beam
29 10 10 6 3 0 (front beam)
30 10 10 6 4 0
4. Bottom beam
31 10 10 6 4 1 (rear beam)
32 10 10 6 4 2 5. Car top
33 10 10 6 4 3 balustrade
34 10 10 6 4 4
35 10 10 6 4 5
36 10 10 6 4 6
37 10 10 6 4 7
38 10 10 6 4 8

© 2005 KONE Corporation 92 (453) AM-01.01.084

Step Action Note

5 Place the bottom beam horizontally on
the upright so that the wider part will be
on the pulley side.

Uprights for wide cars:

Ensure that the slot in the upright is at
the rear side.

M12
SGB01

1007188.wmf

upright2.wmf

6 Remove the safety gear adjustment

bolt M8.

M8
1007189.wmf

7 Lift the bottom beam into vertical position.

(SGB01: Remove the axle. Keep the block in position. Fit the axle through block.
Lock the axle with split pins.)
Fit the bottom beam to the upright with 4 pcs M12 bolts. Do not tighten the bolts
finally.

© 2005 KONE Corporation 93 (453) AM-01.01.084

Step Action Note

8 Adjust the horizontal and vertical Bottom beam must be flush with the
angles between the bottom beam and upright.
the upright using a big square,
minimum 400 mm long. Finally tighten
the M12 bolts.

1007190.wmf

9 Refit the safety gear adjustment bolt The final alignment will be done later.
M8. Ensure that the car guide shoe and
the safety gear are aligned.
10 Move the chain to the centre holes of
the upright.
11 Lift the upright and the bottom beam
into the elevator shaft.
Ensure that the safety gear linkage is
facing the back of the elevator shaft.
12 Insert the side without the upright
between the guide rails first.

1051598.wmf

© 2005 KONE Corporation 94 (453) AM-01.01.084

Step Action Note

13 Push the upright against the guide rail
and centralize the safety gear block.
14 Fix three heavy duty cable ties around
the upright and guide rail above the
bracket to keep the upright close to the
guide rail.
NOTE! Do not stand on the bottom
beam.

1051599.wmf

© 2005 KONE Corporation 95 (453) AM-01.01.084

8.2 Second upright

Step Action Note

1 Remove the safety gear adjustment
bolt M8 from the second upright.
2 Lift the upright to position. Fix the
upright to the bottom beam with 4 pcs
M12 bolts. Do not tighten the bolts
finally.
3 Fix 4 pcs M12 bolts on the lower part of
the upright to secure the safety gear
plate support to the uprights.
4 Fix three heavy duty cable ties around
the upright and guide rail above the
bracket to keep the upright close to the
guide rail.
5 SGB01: Secure the safety gear block
with the axle.

M12

a1184b.wmf

© 2005 KONE Corporation 96 (453) AM-01.01.084

Step Action Note

6 Move the chain to the first installed
upright.
Raise or lower the first installed upright
to level the bottom beam so that there
will be 90° angle between the bottom
beam and the second installed upright.

1051601.wmf

7 Adjust the horizontal and vertical Bottom beam must be flush with the
angles between the bottom beam and upright.
the second upright. Finally tighten the
M12 bolts.
=
=

1007195.wmf

8 Refit the safety gear adjustment bolt

M8. Ensure that the car guide shoe and
the safety gear are aligned.

© 2005 KONE Corporation 97 (453) AM-01.01.084

8.3 Car safety gear

Step Action Note

1 Fix the horizontal safety gear levers to If there is not enough space between the
the vertical ones. Levers are delivered side wall and the upright, pull the vertical
with the car floor assembly. lever towards the back of the elevator
2 Fix the safety gear springs to the shaft. Then fix the horizontal lever to it
respective holes on both safety gear and turn the vertical lever back into
linkages. upright position.
SGB01/SGB05/AQ11: Fix the split pin
to the hole on the upright and open the
ends.

1007196.wmf
1009348.wmf

© 2005 KONE Corporation 98 (453) AM-01.01.084

Step Action Note

3 SGB08: Adjust the gap between the
3mm
guide rail and safety gear to 3 mm on 3mm
the opposite side to the overspeed
governor.
Use the keeper plate of the single guide
rail bracket as a gauge for the gap.

1007197.wmf

SGB01/SGB05/AQ11: Screw in the Ensure that the spring (5) is aligned with
screw (1) so that the distance between the bolt (2) Do not remove the seal (6).
the counter wedge (4) and the guide rail Do not adjust using the screw (7).
becomes 2 mm.
Screw in the bolt (2) to completely
compress the spring (5). Slacken the 5
bolt (2) 4.5 turns and then lock the 3
setting with the locking nut (3). 2

1009352.wmf

4 Fix the overspeed governor rope to the

anchorage plate.

m
0m
10
m
0m
10

1009488.wmf

5 Attach the anchorage plate to the 1007198-3.wmf

safety gear linkage.
6 Turn the safety gear levers down so
that they do not prevent the car floor
installation.
WARNING! Ensure that the rope loop
cannot catch on obstacles in the
elevator shaft and is clear of car sling
components.
1009358-3.wmf

© 2005 KONE Corporation 99 (453) AM-01.01.084

8.4 Car floor

Step Action Note

1 Fix the floor supports to the rear side of
the bottom beam.
60mm

1007199.wmf

2 Fix two M6 bolts to the car floor in the

front of the upright position. (These
bolts will be used for positioning the car
floor against the uprights when lowering
the floor onto the bottom beam.)

Fix two M12 bolts to the car floor. M12

These bolts will be used to fix the car M6
floor to the supports.
1009363.wmf

3 Transport the car floor using the site

trolley to the elevator shaft.

1007200.wmf

© 2005 KONE Corporation 100 (453) AM-01.01.084

Step Action Note

4 Use M12 bolts to fix angle iron of the
counterweight guide rail brackets to the
car floor.

Fix M12 eye bolts to the L-brackets.

5 Lift the car floor into the elevator shaft
using the parking chain and 1.5 m
extension chain.
WARNING! Do not go into the pit when
the car floor is being lifted into
position.
6 Turn the floor to horizontal position.
7 Push the M6 guiding bolts against the
uprights.

a1184c.wmf

8 Lower the floor onto the bottom beam.

Pull the floor towards the front wall to
engage the two M12 bolts to the floor
supports.
1

1007202.wmf

9 Ensure that the floor has fixed to the WARNING! If necessary, step only
supports by pushing the front of the car between the uprights, not on the front/
floor down. rear edge of the floor.
10 Fix the upright to the floor with two M12 WARNING! Do not remove the lifting
bolts. Fit 1 mm shim between the car chains before securing the floor to the
floor and the upright. Hand tighten the uprights.
bolts.

Repeat for the other upright.

© 2005 KONE Corporation 101 (453) AM-01.01.084

Step Action Note

1007203.wmf
2xM12

Ensure that the uprights are at 90° to

the floor.
12 Finally tighten the bolts.
13 Remove the chains and lifting eyes
from the car floor.

8.5 Fixing the automatic safety gear trigger rope to the safety gear linkage

Step Action Note

1 Connect the horizontal safety gear
linkage with the synchronisation bar on
both sides of the bottom beam.
2 Check that the linkage is operating.

1007204.wmf

© 2005 KONE Corporation 102 (453) AM-01.01.084

Step Action Note

3 Attach the rope to the shackle.
4 Attach the shackle to the safety gear
linkage:
• Automatic safety gear trigger (if
applicable) on the machine side

1007205-1.wmf

8.6 Car walls

Step Action Note

1 Ensure that the M6 bolts are fitted in Raise the cable ties on the uprights.
the correct place and leave them loose
about 7 mm to hold the wall panels.

a1184j.wmf
1007210.wmf

2 Remove the plastic protection from the

edges of the wall panels.
3 Transport the wall panels using the Wear gloves.
vacuum handles. Clear the wall panels
if needed.
NOTE! Transport the glass wall using
the site trolley.
1009392.wmf

© 2005 KONE Corporation 103 (453) AM-01.01.084

Step Action Note

4 Slide the rear wall down on the bolts. If the rear wall is glass type install it, the
Leave it to lean against the elevator centre wall panels and jointing panels
shaft wall. according to the following chapter.

a1184q.wmf

© 2005 KONE Corporation 104 (453) AM-01.01.084

Step Action Note

5 Slide the centre wall panel one at a
time on the M6 bolts.

Secure the wall panel to the upright

using one M6 bolt.

Centralise the wall panel in the back to

front direction according to the uprights.

Press the wall panel to stick it to the

upright using 3M dual lock (2). Ensure
the dual lock positions of wall panel and
upright are in line and level.

Repeat for the other wall panel.

=
a1184e.wmf

6 Fit all the M6 bolts between the wall

panel and car floor that you are able to
reach from the car floor.

1010749.wmf

© 2005 KONE Corporation 105 (453) AM-01.01.084

Step Action Note

7 Use vacuum handles to handle the
single back panel and the side wall
panels.

1009392.wmf

8 Install the M6 bolts at the top of panel.

9 Align the tops of the panels with M6
bolts.
(The correct alignment of the panel tops
ensure that the car will be square.)
Install the side panels. a1184ad.wmf

WARNING! Fix minimum one M6 bolt

between the front junction panel and
the car floor.
10 Align the tops of the panels with M6
bolt.

8.7 Glass walls

Step Action Note

1 Ensure that the M6 bolts of the floor are
fitted in the correct place.
Leave them loose for approximately
7 mm.
Protect the platform from scraping.

1007210.wmf

© 2005 KONE Corporation 106 (453) AM-01.01.084

Step Action Note

2 Transport the side wall panel (upper
side in front) using the vacuum
handles.

Clean the wall panel if needed.

Lift the wall panel into correct position

with the hoist.

Fix the wall panel to the car floor with

M6 bolts. Do not tighten the screws all
the way.

1051525.wmf

3 Centralise the wall panel in back to

front direction according to the uprights.
Ensure that the fixing holes of platform M6
and wall are in line and level.
Secure the wall panel to the upright
using a M6 bolt. This is to keep the side ==
wall from leaning down.

Install the other side wall panel in the

a1184r.wmf
same way.

© 2005 KONE Corporation 107 (453) AM-01.01.084

Step Action Note

4 Transport the back wall panel (upper
side in front) using the vacuum
handles.

Clean the wall panel if needed.

Lift the wall panel into correct position

with the hoist.

Fix the wall panel to the car floor with

M6 bolts. Do not tighten the screws all
the way.

Connect the screw fixings of the back

and side walls.

a1184s.wmf

5 Fix and tighten all screws connecting

the walls and platform.

Fix the cover plate to the back of the

wall with 4.2 mm self-drilling screws.

1051528.wmf

© 2005 KONE Corporation 108 (453) AM-01.01.084

Step Action Note

6 Drill two D10 holes to the platform for
handrail supports, optional for partial
glass (PG) and full glass (FG) walls.

1051579.wmf

301 D1 301

61
0

BB
1051529.wmf

7 Assemble the handrail and transport it

into car.

Fix the handrail supports (A) to the

platform with M8 screws. Do not tighten
the screws all the way. A

1051530.wmf

8 Fix the handrail to the wall with M8

screws using ring spanner. Do not
tighten the screws all the way.

Adjust and level the handrail.

1051531.wmf

© 2005 KONE Corporation 109 (453) AM-01.01.084

Step Action Note

9 Tighten the handrail fixing screws.

1051580.wmf

8.8 Top beam

Step Action Note

1 Working from the work stool lift the top
beam up by hand. Fit 8 pcs M12 bolts.
Do not fit the bolts to the centre holes.
Do not tighten the bolts finally.

WARNING! Wear a safety harness

attached to a life line if the gap
between the car floor and elevator
shaft wall is more than 300 mm.

a1184f.wmf

Only with trap door: Check that the slot

in the top beam is at the trap door side.

top1.wmf

© 2005 KONE Corporation 110 (453) AM-01.01.084

Step Action Note

2 Check that the fixing holes without bolts
align centrally on both sides.

a1184t.wmf

3 Fit rest of the bolts and finally tighten

them.

© 2005 KONE Corporation 111 (453) AM-01.01.084

8.9 Balustrade

NOTE! Alternatively the balustrade can be installed later from the car roof.

WARNING
The car top balustrade is designed to prevent movement into hazardous areas in the
elevator shaft where there is risk of falling. Never sit or stand on the car top balustrade.

If the balustrade is installed from the car roof use the harness attached to an approved
fixing point.

8.9.1 Preparations

Step Action Note

1 Fit an angle bracket to the top of each
balustrade upright.
2 Wrap a piece of tape around each
upright 250 mm from the top.
250 mm

3 Align the top of the lower angle bracket

to the bottom edge of the tape and
secure hand tight. Repeat for each
balustrade upright.
550 mm

4 Mark the final position of the lower

angle bracket 550 mm on each
balustrade upright.
5 Mark the final height of the balustrade
1100 mm on each balustrade upright.
1100 mm

WARNING! During the installation the

balustrade height must be 1100 mm
in all cases. After removing the hoist
the balustrade must be adjusted
according to the layout drawing/
EN81-1.

1007218-1.wmf

© 2005 KONE Corporation 112 (453) AM-01.01.084

8.9.2 Installing the balustrade

Step Action Note

1 Ensure that the four M6 bolts are in
place on the top corners. Fit the M6
balustrade bolts in place working from
the work stool.

2 1007219.wmf

1. Fixing bolts M6 on the top

corners
2. Balustrade fixing bolts M6 a1184u.wmf

2 Ensure that the angle brackets are

fixed to the uprights in the correct way.
Fit the four uprights to the car allowing
each to rest on the lower rail bracket.
3 The balustrade can be telescopic.
Use coach bolts to fix the balustrade
parts.
Locate the joint near the rear
balustrade.
4 Fit and secure the three upper
horizontal rails.

a1184v.wmf

© 2005 KONE Corporation 113 (453) AM-01.01.084

Step Action Note

5 Raise the balustrade uprights to the Take care not to over stretch the top rail
height of 1100 mm. fixings.
6 Move the lower angle brackets to the
final position.

1100mm
550mm
1007222.wmf

7 Fit the lower horizontal rails to the

brackets.

a1184w.wmf

© 2005 KONE Corporation 114 (453) AM-01.01.084

8.10 Car roof

Step Action Note

1 Lift the rear roof panel into position.
Lift the front roof panel into position.
Fit the jointing bolts. Do not tighten
them finally.

NOTE! If the car roof is not safely

accessible from the floor above, use
the front roof panel area for
temporary access to the roof from
inside of the car.

The front roof panel must be fitted as

soon as use of the hoist allows
access from the floor above.

a1184x.wmf

Car roof with the trap door:

trap1.wmf

© 2005 KONE Corporation 115 (453) AM-01.01.084

Step Action Note

2 Centralise the roof panels in the DBG Use hearing protection.
direction according to the uprights.

The clearance must be the same on

both sides.

Tighten all the roof fixing bolts. If

available, use cordless drilling machine
with adjustable torque and 1/4
extension and socket.

= =

= =
1009409.wmf

8.11 Kick plates and finalising the balustrade

Step Action Note

1 Cut and bend the kick plates in
accordance with the car roof
dimensions.
2 Fix the kick plates using self-drilling
screws.

a1184z.wmf

© 2005 KONE Corporation 116 (453) AM-01.01.084

Step Action Note

3 If the DD ≥ 1550 mm, fix additional
stands with coach bolts to the triangular
plates.

a1184g.wmf

4 Insert the plastic buffers to the top of

the stands and to the ends of the
balustrade at the front side of the car.

© 2005 KONE Corporation 117 (453) AM-01.01.084

9 CAR INSTALLATION, MCD

CF10UP

1029528.wmf 1029529.wmf

CAUTION!Always lift the CFE10-type sling (and car)

CFE10 using appropriate lifting equipment and holes at the
top beam ends. *) Fixing axle of Tirak installation
hoist. *) Maximum 120 degrees.

**)

*)
a1184aa.wmf 1040531.wmf

© 2005 KONE Corporation 118 (453) AM-01.01.084

CF10TD

8000178.wmf

9.1 Preparations for bottom beam installation

Step Action Note

1 Ensure that the safety gear lever is on
the correct side (refer to the layout
drawing).

1017994.wmf

© 2005 KONE Corporation 119 (453) AM-01.01.084

Step Action Note

2 At least one of the guide shoes must be
removed to get the bottom beam
between the guide rails.

1017995.wmf

9.2 How to use guide clamp

WARNING

MAX
2500kg

MAX
MAX 3 0º
2500kg
P17000203.wmf

• Maximum load 2500 kg per one clamp.

• Loading direction is maximum 30° of vertical.
• Use correct counter part size.

Construction
1. Body
2. Eccentric cam
2 3. Counter part
4
3 4. Cotter bolt
9 5. M20 nut
8 6. Locking screw
1 7
6 7. Washer
5 P17000204.wmf
8. Diaphragm springs
9. Nut and sleeve

© 2005 KONE Corporation 120 (453) AM-01.01.084

Step Action Note

1 Select correct counter part for the T
guide rail. Put the counter part in its
place.

P17000205.wmf

2 Open the eccentric cam and put the

installation clamp over the guide rail.

P17000206.wmf

3 Tighten the locking screw until it

suddenly needs more power. Stop
tightening.

P17000207.wmf

4 Install the second clamp at the exactly

same level on the other guide.

MAX
5000 kg
P17000208.wmf

5 Ensure that clamps are level.

P17000209.wmf

6 To remove the clamp from the guide rail

open the locking screw and eccentric
cam.

© 2005 KONE Corporation 121 (453) AM-01.01.084

9.3 Installing car sling CF10UP

9.3.1 Installing bottom beam (CF10UP)

Step Action Note

1 Fit the installation clamps onto the
guide rails. Ensure that they are exactly
at the same level on the both guide
rails.

See section 15.1 for more details about

the clamp installation.

8000 82 9. wmf

2 Lift the bottom beam between the guide

rails.

Lift from the front lifting points to ensure

balanced lifting.

1038309.wmf
3 Install the guide shoes in approximate
position and fix the guide shoes hand-
tight.

1036220.wmf

© 2005 KONE Corporation 122 (453) AM-01.01.084

Step Action Note

4 Lower the bottom beam onto the
installation clamps.

Check that the beam is horizontal in the

DBG direction. Adjust the installation
clamps, if necessary.

1038311.wmf

5 Centralise the beam in the middle of the Reposition the guide shoes (if
guide rails. Note that the gripping necessary) and tighten the fixing bolts.
wedge of the safety gear must overlap
guide rail blade on both sides.

1038312.wmf

9.3.2 Safety gear setting (CF10UP)

Step Action Note

1 Operate the safety gear lever by hand.
Check that both safety gears begin
gripping at the same time. If not, adjust
the length of the synchronisation rod. 1011919.wmf

© 2005 KONE Corporation 123 (453) AM-01.01.084

Step Action Note

2 Check the safety gear contact function. The contact must break just before
gripping.

1029540.wmf

3 Adjust the safety gear according to AM-

07.04.015.

0 mm
X = dimension from edge of the guide
rail to the edge of the gripping wedge
(1)
• SGB01, SGB05 and AQ11:
X = 2 mm
• SGB03:
X = 3.5 mm

>0 mm
X

1011922.wmf

1038868.wmf

© 2005 KONE Corporation 124 (453) AM-01.01.084

Step Action Note

4 Pull in the safety gear lever (1) and tie it
up. 1

8000330(2008-08)

9.3.3 Rope guard adjustment and overspeed governor rope (CF10UP)

Step Action Note

1 Turn the upper rope guard slightly (20°)
downwards.

1036233.wmf

2 Install the overspeed governor rope to

the safety gear arm.

P03000467.wmf

© 2005 KONE Corporation 125 (453) AM-01.01.084

9.3.4 Uprights (CF10UP)

Step Action Note

1 Fit the aligning bolts in the threaded
holes at top of the uprights. (87) 18 (87)

(12)
P06000158.wmf

2 Lift the uprights to the correct position.

P06000163-1.wmf

3 * Align the v in the top of the upright to

the centre line of the guide rail.

M10x50

M10x100 (2x)

P06000160-1.wmf

© 2005 KONE Corporation 126 (453) AM-01.01.084

Step Action Note

4 Loosely bolt the uprights to the lower Ensure that you use the correct bolt
beam. length to avoid interfering with the safety
gear.

1036237.wmf
5 Adjust the uprights in plumb and in
centre to the guide rail.
6 Before tightening the screw joints, pack
out the spaces between upright and
lower beam using the shims supplied.

1017682.wmf

© 2005 KONE Corporation 127 (453) AM-01.01.084

9.3.5 Isolation profiles (CF10UP)

Step Action Note

1 Fit the rope guards and isolation If there is a marking hole (* ), it must be
profiles to the bottom beam. on the landing side. In the two-entrance
type, it must be on the A landing door
side. Refer to the layout drawing. Do not
tighten the screw joints.

1011939.wmf
1036591.wmf

2 Check that the profiles are horizontal. If

necessary, add shims between
isolation profile and bottom beam.

1011940.wmf

3 Remove the lock screws.

1011941.wmf

© 2005 KONE Corporation 128 (453) AM-01.01.084

9.3.6 Ring beams (CF10UP)

Step Action Note

1 Remove the nuts and washers at the When no ring beams are fitted, install an
ends of the isolation profiles before adapter plate and a shim plate at both
installing the ring beams (if delivered). ends of the isolation profiles.

M10x20

1036239.wmf M12
1011942.wmf
1. Do not remove the centre
limitation device
2 Install the ring beams (if delivered). Check the position of the ring/balancing
Tighten the screw joints slightly. beams and balance weight fittings in the
layout drawing.

1036240.wmf

© 2005 KONE Corporation 129 (453) AM-01.01.084

Step Action Note

3 Check for square by cross
measurement (M1=M2 +/-1 mm).
Adjust, if necessary.

8000335(2008-08)

4 Tighten all platform screw joints.

9.4 Installing car sling CFE10

9.4.1 Bottom beam and uprights (CFE10)

Step Action Note

1 Fix the switch fixing plate to the upright
on the opposite side of the machine.
2 Set the upright to horizontal position
using installation hoist and working
stool.

© 2005 KONE Corporation 130 (453) AM-01.01.084

Step Action Note

3 Fix the bottom beam to the upright with
4 bolts (M12).
4 SGB01 / SGB05: Fit the axle to final
position. Secure with the split pins.

1032920.wmf

1032911.wmf

5 Align the bottom beam using a big Bottom beam must be flush with the
square. Tighten the bolts. upright.

=
=

1032924.wmf

6 Fix the remaining M12 and M16 bolts *) Note the shim plates between the
and safety gear adjustment bolt (M8). upright and the axle support at the
lowest fixings.
Do NOT fit the safety gear springs yet.
SGB01 / SGB05 SGB08

* 1032949.wmf
* 1032947.wmf

© 2005 KONE Corporation 131 (453) AM-01.01.084

Step Action Note

7 Fit the installation clamps onto the
guide rails. Ensure that they are exactly
at the same level on the both guide
rails.

See section 15.1 for more details about

the clamp installation.

8000 82 9. wmf

8 Fit the CFE-sling adapter plates on to

the clamps.

1040537.wmf

9 Move the installation hoist to the centre

holes of the upright.
10 Lift the bottom beam and upright
between the guide rails.

1032976.wmf

11 Push the upright against the guide rail

and lower the assembly on to the
installation clamps. Secure the upright
to the guide rail using a cable tie.

1032980.wmf

© 2005 KONE Corporation 132 (453) AM-01.01.084

Step Action Note

12 Centralize the safety gear block. Fit the
safety gear spring.
SGB01, SGB05 SGB08

1032982.wmf 1032998.wmf

13 Fix the other upright to the bottom

beam with 4 bolts (M12). Secure to the
guide rail using a cable tie.
14 SGB01 / SGB05: Secure the safety
gear block with the axle.

1032920.wmf

15 Align the upright. Fix and tighten

remaining M12 and M16 bolts and
safety gear adjustment bolt (M8). Fit
1033006.wmf
the safety gear spring.

16 Ensure that the guide shoes are Final safety gear adjustment will be done
aligned with the safety gears. later.

© 2005 KONE Corporation 133 (453) AM-01.01.084

9.4.2 Car platforms (CFE10)

Step Action Note

1 Fix and align the platform beams and Maximum deviation in square dimension
rope guards to the bottom beam. is 1 mm.

Remove the lock screws (*).

**) Ensure the 15 mm space between

upright and platform beam.

** = **

=
1033162.wmf

9.4.3 Safety gear synchronisation and pulley assemblies (CFE10)

Step Action Note

1 Fix the synchronisation bar to the
platform beams. Leave the bolts hand
tight.

1033014.wmf

© 2005 KONE Corporation 134 (453) AM-01.01.084

Step Action Note

2 Fix the synchronisation levers to the
safety gears. Fit the tension springs.
Tighten all the bolts.
SGB01 / SGB05 SGB08

1033212.wmf 1033214.wmf

3 Fix the overspeed governor rope to the

anchorage plate.

1033018.wmf

4 Adjust the safety gear.

SGB01 / SGB05: SGB08:
Screw in the screw (1) so that the Adjust the gap between the guide rail
counter wedge (3) contacts the guide and safety gear to 3 mm on the opposite
rail. Slacken the screw ~1.5 turns so side to the overspeed governor.
that the gap between the wedge and Use 3 mm shim to check gap.
guide rail is 2 mm. Lock the setting with
locking nut (2).
3mm
3mm

3 1007197.wmf

2mm
1038420.wmf

© 2005 KONE Corporation 135 (453) AM-01.01.084

Step Action Note

5 Adjust the synchronisation switch.

3mm

1038423.wmf

6 Install the pulley assemblies. Secure

the axles with the axle retaining plates.

1033051.wmf

9.5 Installing car sling CF10TD

9.5.1 Installing bottom beam (CF10TD)

Step Action Note

1 Fit the installation clamps onto the
guide rails. Ensure that they are exactly
at the same level on the both guide
rails.

See section 15.1 for more details about

the clamp installation.

8000669.wmf

© 2005 KONE Corporation 136 (453) AM-01.01.084

Step Action Note

2 Lift the bottom beam between the guide One side guide shoe must be removed
rails. so that the bottom beam can be put
between the guide rails.
Lift from the front lifting points to ensure
balanced lifting.

8000179(2008-06)

3 Fit the guide shoe onto the bottom

beam in approximate position.

8000180(2008-06)

© 2005 KONE Corporation 137 (453) AM-01.01.084

Step Action Note

4 Lower the bottom beam onto the
installation clamps.

Check that the beam is horizontal in the

DBG direction. Adjust the installation
clamps, if necessary.

8000331(2008-08)

8000332(2008-08)

9.5.2 Safety gear setting (CF10TD)

Step Action Note

1 Operate the safety gear lever by hand.
Check that both safety gears begin
gripping at the same time. If not, adjust
the length of the synchronisation rod. 1011919.wmf

© 2005 KONE Corporation 138 (453) AM-01.01.084

Step Action Note

2 Check the safety gear contact function. The contact must break just before
gripping.

1029540.wmf

3 Adjust the safety gear according to AM-

07.04.015.

0 mm
X = dimension from edge of the guide
rail to the edge of the gripping wedge
(1)
• SGB01, SGB05 and AQ11:
X = 2 mm
• SGB03:
X = 3.5 mm
X

1 >0 mm

1011922.wmf

1038868.wmf

© 2005 KONE Corporation 139 (453) AM-01.01.084

Step Action Note

4 Pull in the safety gear and tie it up.

8000330(2008-08)

9.5.3 Uprights (CF10TD)

Step Action Note

1 Fit the aligning bolts in the threaded
holes at top of the uprights. (87) 18 (87)

(12)
P06000158.wmf

© 2005 KONE Corporation 140 (453) AM-01.01.084

Step Action Note

2 Lift the uprights to the correct position.

8000333(2008-08)

3 Align the v centre marking (1) in the top

of the upright to the centre line of the
guide rail.

M10x100(2x)
M10x50

8000182(2008-07)

© 2005 KONE Corporation 141 (453) AM-01.01.084

Step Action Note

4 Fix the uprights to the lower beam. Do Ensure that you use the correct bolt
not tighten the screws. length avoiding interfering with the safety
gear.

M16x45

8000183(2008-0 7 )

5 Adjust the uprights in plumb and in

centre to the guide rail.
6 Before tightening the screw joints, pack
out the spaces between upright and
lower beam using the shims supplied.

8000181(2008-0 8 )

© 2005 KONE Corporation 142 (453) AM-01.01.084

9.5.4 Isolation profiles (CF10TD)

Step Action Note

1 Fit the isolation profiles to the bottom If there is a marking hole (1), it must be
beam. on the main door side. Refer to the
layout drawing. Do not tighten the screw
joints.

8000184(2008-06)

2 Check that the profiles are horizontal. If

necessary, add shims between
isolation profile and bottom beam.

1011940.wmf

© 2005 KONE Corporation 143 (453) AM-01.01.084

Step Action Note

3 Remove the lock screws (1). 1

8000334(2008-08)

9.5.5 Balancing beam and adapter plates (CF10TD)

Step Action Note

1 Remove the nuts and washers at the
ends of the isolation profiles before
installing the balancing beam.
2 Install the balancing beam. Tighten the
screw joints slightly.

8000831.wmf

© 2005 KONE Corporation 144 (453) AM-01.01.084

Step Action Note

3 Remove the nuts and washers at the
other end of the isolation profiles before
installing the adapter plates.

M10x20

1036239.wmf M12
1. Do not remove the centre
limitation device
1011942.wmf

4 Install an adapter plate and a shim

plate at both ends of the isolation
profiles. Tighten the screw joints
slightly.

8000 373 (2008-09)

© 2005 KONE Corporation 145 (453) AM-01.01.084

Step Action Note

5 Check for square by cross
measurement (M1=M2 +/-1 mm).
Adjust, if necessary.

8000374(2008-09)

6 Tighten all platform screw joints.

9.5.6 Diagonals (CF10TD)

Step Action Note

1 Install diagonals to the uprights and the
adapter plates/balancing beam.

M16x40

8000 375 (2008-0 8 )

© 2005 KONE Corporation 146 (453) AM-01.01.084

9.5.7 Travelling cable hanger

Step Action Note

1 Fit the travelling cable hangers.
Position them according to the layout
drawing.

Wear harness if it is possible to fall

more than 1.8 m.

1011950.wmf

9.5.8 Compensation chain hanger (if applicable)

Step Action Note

1 Fit the compensation chain hanger. Position it according to the layout
drawing.
This detail may change. Refer to your
delivery instructions.

1 2 3

1017094.wmf

1. Platform without ring beam: Fixing package 611604G02/G03

2. Platform with ring beam: Fixing package 611604G02
3. Ring beam on different level: Fixing package 611604G02/G04

© 2005 KONE Corporation 147 (453) AM-01.01.084

9.6 Installing car floor

NOTE! If the car type is MCD refer to AM-06.06.012.

Step Action Note

1 Wind down the locking bolt. Then
remove the car floor fixings at the ends 1
of the isolation profiles.

2
14

1011952.wmf

1011951.wmf
1. Car floor fixing
2. Locking bolt
2 Install two lifting shackles (minimum WARNING!Do not work directly under a
capacity 1000 kg) to the car floor. suspended load.

Lift the car floor into the car sling using NOTE! CF10TD sling is not shown on
the shackles. this picture.

Remove the shackles from the car floor.

WARNING!When transporting the car

floor using site trolley, ensure that the
load capacity of the trolley is not
exceeded. Use a piece of plywood as
a kick plate to prevent the trolley
dropping to the pit.

1029743.wmf

© 2005 KONE Corporation 148 (453) AM-01.01.084

9.7 Positioning car floor

NOTE! If the car type is MCD refer to AM-06.06.012.

Step Action Note

1 Check that the car floor is in the middle NOTE! CF10TD sling is not shown on
of the car sling. this picture.

1029744.wmf

2 Position the car floor to the landing door Refer to the delivery documents.
plumb lines.
3 Secure the car floor with 4 G-clamps.

CL
1029745.wmf

© 2005 KONE Corporation 149 (453) AM-01.01.084

Step Action Note

4 Reinstall the car sling T-bolts. Tighten
them to final tightness.

1036248.wmf

5 Check that the floor is horizontal on all NOTE! CF10TD sling is not shown on
planes. this picture.

8000336(2008-08)

6 Lock the floor by winding up the stop No one is allowed to be on the car floor
screws (2) slightly against the fixing until the floor is stabilized.
bolts (1). 1
2
Do not overtighten the stop screws (2).

The stop screws (2) secure the car floor

until the car sling is installed
completely.

1036249.wmf

© 2005 KONE Corporation 150 (453) AM-01.01.084

9.8 Wall panels

Refer to the delivery documents. If the car type is MCD refer to AM-06.06.012.

9.9 Car roof

Refer to the delivery documents. If the car type is MCD refer to AM-06.06.012.

9.10 Top beam

9.10.1 Installing top beam to CF10UP sling

Step Action Note

1 Lift the top beam above the car.
2 Lower the top beam into the uprights.

P06000169.wmf

© 2005 KONE Corporation 151 (453) AM-01.01.084

Step Action Note

3 Fit the top beam to the uprights. If
necessary, add shims between the
beam and the uprights.

Remove the lifting eye bolts.

P06000170.wmf

4 Align the sling.

5 Install the guide shoes.
1m
Do not remove the locking pin yet. m
6 Adjust the guide shoes to achieve
1 mm clearance on both sides.

P06000172.wmf

7 Remove the aligning bolts.

P06000173.wmf

8 Install the oil lubricators to the guide

shoes.

P06000174 wmf

© 2005 KONE Corporation 152 (453) AM-01.01.084

9.10.2 Installing top beam to CFE10 sling

Step Action Note

1 Fix and align the sling top beams.

M12x30

a1184ac.wmf

9.10.3 Installing top beam to CF10TD sling

Step Action Note

1 Lift the orthogonal pulley beam and
place it on the car top.
NOTE! Locate the pulley beam to its
appropriate position according
to layout. Only one person is
allowed to operate on car roof.

8000337(2008-08)

2 Lift the top beam above the car.

8000188(2008-0 8 )

3 Lower the top beam into the uprights.

© 2005 KONE Corporation 153 (453) AM-01.01.084

Step Action Note

4 Fit the top beam to the uprights. If
necessary, add shims between the
beam and the uprights.

Remove the lifting eye bolts.

P06000170.wmf

5 Lift the orthogonal beam to the

appropriate position and fix it onto the
top beam using four M16 screws.

8000187(2008-08)

6 Align the sling.

7 Install the guide shoes.
1m
Do not remove the locking pin yet. m
8 Adjust the guide shoes to achieve
1 mm clearance on both sides.

P06000172.wmf

© 2005 KONE Corporation 154 (453) AM-01.01.084

Step Action Note

9 Remove the aligning bolts.

P06000173.wmf

10 Install the oil lubricators to the guide

shoes.

P06000174.wmf

9.11 Upper isolations

Step Action Note

1 Fit the upper isolations to the car roof
channel. Hand tighten the T-bolts.
2 Push the isolations tight against the
uprights.
3 Align the car in all directions. Tighten
the isolation studs so that the bracket
can slide on the upright. ( One fitter on
the car roof and one fitte in the car.)
4 Tighten the T-bolts.

© 2005 KONE Corporation 155 (453) AM-01.01.084

Step Action Note

CFE10
CF10UP
CF10TD

1033070.wmf

800189(2008-06)
1033068.wmf

9.12 Car front installation

Refer to the delivery documents. If the car type is MCD refer to AM-06.06.012.
NOTE! Remember to install the car front walls and car door before fitting the last landing
door.
Store the parts in the original package (plastic wrap). Do not open the packages until the
installation begins.

9.13 Balustrade and skirtings

Refer to the delivery documents.

© 2005 KONE Corporation 156 (453) AM-01.01.084

9.14 Lifting pockets and guide rail securing chains

Step Action Note

1 Install the guide rail securing chains on top of the car above the lifting pockets
using self-drilling screws or T-bolts.

P17000225.wmf

1. Fixing to balustrade
2. Alternative fixing

© 2005 KONE Corporation 157 (453) AM-01.01.084

10 THIRD RING OF GUIDE RAIL BRACKETS

10.1 For SMiniSpace with side counterweight and XMiniSpace

10.1.1 Installing bracket on machine side

Step Action Note

1 Measure the height of the bracket from
the previous bracket’s fixing position.
Refer to the layout drawing for the
distance.

1007258.wmf

2 Fit the bracket to the guide rail.

Push the bracket back to the wall.

1029751.wmf

3 Measure 60 mm from the guide rail to

the plumb wire. Centre the wall base
with bracket.

1029753.wmf
4 Drill a hole in the wall through the
horizontally slotted hole and fix the
bracket to the wall.

1009072.wmf

© 2005 KONE Corporation 158 (453) AM-01.01.084

Step Action Note

5 Drill another hole, level and fix the
bracket.

6 Bolt the counterweight guide rail to the

bracket.

1007260.wmf

10.1.2 Installing bracket on single side

Step Action Note

1 Fit the bracket to the guide rail.
Push the bracket back to the wall.

1029759.wmf

2 Measure the height of the bracket from

the previous bracket’s fixing position.

Ensure that single side and

combination side brackets are at the
same level.

1029761.wmf

© 2005 KONE Corporation 159 (453) AM-01.01.084

Step Action Note

3 Measure 60 mm from guide rail to the
plumb wire. Centre the wall base with
bracket.

60
1029763.wmf

4 Drill a hole to the wall through the

horizontally slotted hole and fix the
bracket to the wall.

1009073.wmf

5 Drill another hole. Level and fix the

bracket.

1009075.wmf

10.1.3 Installing counterweight guide rail bracket

Step Action Note

1 Measure the height of the bracket from
the previous bracket’s fixing position.
Refer to the layout drawing for the
distance.

8000836.wmf

© 2005 KONE Corporation 160 (453) AM-01.01.084

Step Action Note

2 Fit the bracket to the guide rail.
Push the bracket back to the wall.

8000841.wmf

3 Drill a hole in the wall through the

horizontally slotted hole and fix the
bracket to the wall.

8000838.wmf

4 Level the bracket and tighten the bolts.

8000847.wmf

10.2 For SMiniSpace with rear counterweight

10.2.1 Installing bracket for car guide rail

Step Action Note

1 Measure the height of the bracket from
the previous bracket’s fixing position.

Ensure that the brackets at two sides of

the car guide rails are at the same
level.

8000837.wmf

© 2005 KONE Corporation 161 (453) AM-01.01.084

Step Action Note

2 Fit the bracket to the guide rail.
Push the bracket back to the wall.

8000842.wmf

3 Measure 60 mm from guide rail to the

plumb wire. Centre the wall base with
bracket.

8000843.wmf

4 Drill a hole to the wall through the

horizontally slotted hole and fix the
bracket to the wall.

8000839.wmf

5 Drill another hole. Level and fix the

bracket.

8000848.wmf

© 2005 KONE Corporation 162 (453) AM-01.01.084

10.2.2 Installing counterweight guide rail bracket

Step Action Note

1 Measure the height of the bracket from
the previous bracket’s fixing position.
Refer to the layout drawing for the
distance.

8000836.wmf

2 Fit the bracket to the guide rail.

Push the bracket back to the wall.

8000841.wmf

3 Drill a hole in the wall through the

horizontally slotted hole and fix the
bracket to the wall.

8000838.wmf
4 Level the bracket and tighten the bolts.

8000847.wmf

© 2005 KONE Corporation 163 (453) AM-01.01.084

10.3 Aligning guide rails

Step Action Note

1 Align the car and counterweight guide Refer to sections 7.7 and 7.9.
rails.

© 2005 KONE Corporation 164 (453) AM-01.01.084

11 HOIST ATTACHMENT, EURECA CAR

WARNING
The Tirak must be attached to the car in 2:1 mode using the approved adaptors provided
with the hoist. The Tirak may not be used for man riding unless it is in this configuration.
Do not raise the car unless the automatic safety gear trigger has been fitted and adjusted.

Step Action Note

1 Lower the installation hoist to the car Install the axle so that the securing ring
roof and bolt it to the structural ring, is on same side of the structural ring as
always on the opposite side to the the car top connection box.
machine.

1007230.wmf

2 Install the parking chain to the axle on The installation hoist can only be used
the opposite side of the hoist. for man riding when it is attached to the
3 Take the hoist hook from the hoist and car as shown.
attach it using the adapter piece of the
hoist anchorage kit to the structural ring
opposite to the hoist.

a1184c1.wmf

4 Route the trailing flex for the power Locate the power supply connector, so
supply carefully. that it can be easily disconnected in case
of hoist failure.

© 2005 KONE Corporation 165 (453) AM-01.01.084

Step Action Note

5 Place the rope reeler on the car roof.
Secure the rope reeler to the
balustrade using two shackles as
shown. Secure the Tirak rope to the
balustrade using a shackle and a rope
grip.

a1184c2.wmf

© 2005 KONE Corporation 166 (453) AM-01.01.084

Step Action Note

6 Fix the counterweight screen
temporarily to the elevator shaft wall to
guide the hoist rope tension weight.

Position the weight to the top edge of

the screen when the car is on the
buffer.

NOTE!Route the hoist rope so that it

does not interfere with the
overspeed governor rope.

1028218.wmf

7 Secure the Tirak with a chain around

the car guide rail to prevent it falling
whenever the hoist rope is slack.

1011119-1.wmf

© 2005 KONE Corporation 167 (453) AM-01.01.084

12 HOIST ATTACHMENT, MCD CAR

WARNING
Do not drive the car upwards before safety device test.

Step Action Note

1 Lower the installation hoist to the car
roof. Install it into the holes of the car
sling top beam on the opposite side
to the machine.

a1149ni.wmf
a1143b.wmf

8000849.wmf 8000845 wmf

© 2005 KONE Corporation 168 (453) AM-01.01.084

Step Action Note

2 Take the hoist hook from the hoist and
attach the hook to the hook anchorage
on the opposite side of the hoist.
Tirak X750 Tirak X1000 Tirak X2000

P17000215.wmf

3 Route the trailing flex for the power Locate the power supply connector, so
supply carefully. Use cable ties to that it can be easily disconnected in case
secure it to the balustrade. of hoist failure.
4 Place the rope reeler on the car roof
and clamp the rope to the balustrade.
5 Install the tension weight provided for
the hoist rope.

If the rope starts to twist, unravel the

twist by turning the rope reeler.

1028217.wmf

6 Fix the counterweight screen

temporarily to the elevator shaft wall to
guide the hoist rope tension weight.

Position the weight to the top edge of

the screen when the car is on the
buffer.

NOTE!Route the hoist rope so that it

does not interfere with the
overspeed governor rope.

1028218.wmf

© 2005 KONE Corporation 169 (453) AM-01.01.084

13 GUIDE RAIL INSTALLATION

13.1 Second ring of guide rails

Step Action Note

1 Leave the car on the installation clamps
before disconnecting the hoist hook.
2 Lift the second ring of car and
counterweight guide rails into position
using the sliding clamp and Tirak.
3 Bolt the guide rail to the fish plate.

P01000091.wmf

4 Attach the Tirak hook to the car sling.

5 Align the joint using a 1 metre straight Do not rest the car on the safety gear
edge or spirit level and tighten the joint. during the alignment.

P01000093.wmf

6 Install and align next ring of the guide

rail brackets.

© 2005 KONE Corporation 170 (453) AM-01.01.084

13.2 Installation and use of automatic safety gear trigger

13.2.1 General

The automatic safety gear trigger is an automatic spring loaded jack which is connected
between the Tirak hook and working platform. A steel rope is connected to the safety gear
operating arm and this engages the safety gear:
• automatically when the automatic safety gear trigger is not under tension and
• manually when the latch release has been opened.
Depending on the layout there are 3 possible orientations of the automatic safety gear trigger
position on the working platform. Two ropes are provided. In situations where the automatic
safety gear trigger is on the opposite side of the overspeed governor long rope is required.

13.2.2 Safety

WARNING
Before using the automatic safety gear trigger check the information on the body of the
automatic safety gear trigger. This is to ensure that the automatic safety gear trigger is
suitable for the safety gear on your installation.

Do not effect repairs yourself. There must be no possibility of repairing the automatic safety
gear trigger on site. Because the automatic safety gear trigger is a safety critical item it must
be returned for inspection and repair by an authorised person in the following situations:
• If it has operated in a free fall situation.
• If it has sustained accidental damage.
• In any case it must be submitted for regular inspection and record updating
(recommendation is 6 monthly).
For daily and weekly checks of the automatic safety gear trigger refer to AM-01.03.003.

13.2.3 Installation

Step Action Note

1 Attach the safety gear trigger to the
Tirak lifting hook adapter with the bolts,
plates and washers provided.
2 Attach the hoist hook to the safety gear
trigger.
3 Drive the car up with Tirak so that the
Tirak rope is tensioned and the gas
springs are fully compressed.

© 2005 KONE Corporation 171 (453) AM-01.01.084

Step Action Note

4 Fix the angle bracket to the car roof c-
profile above the temporary safety gear
arm. Fit the rope to the angle bracket.
Keep the rope as vertical as possible.
5 Carefully route the rope guiding tube to Ensure that there are no kinks or tight
the automatic safety gear trigger. bends. Minimum bend radius allowed is
100 mm.
6 Secure the rope guiding tube to the
automatic safety gear trigger.
7 Tension the rope by pulling it. Secure
the rope to the safety gear trigger using
rope fixing plate.

WARNING! The rope should be tight.

Ensure that the safety gear arm has
not moved. No slack is permitted.

1007239-1.wmf

8 Adjust the tension of the rope by

loosening or tightening the nut on the
angle bracket.

1010310-1.wmf

© 2005 KONE Corporation 172 (453) AM-01.01.084

Eureca car

1007240-1.wmf

© 2005 KONE Corporation 173 (453) AM-01.01.084

MCD car

X2000 X1000

X750

1029767-1.wmf

© 2005 KONE Corporation 174 (453) AM-01.01.084

X2000 X1000

X750

8000844.wmf

© 2005 KONE Corporation 175 (453) AM-01.01.084

13.2.4 Test

WARNING
It is essential that the rust protection is removed from the rails. Otherwise, the safety gear
will not operate correctly.
Test the operation of the automatic safety gear trigger and safety gear each day before
commencing installation work from the car top.

Step Action Note

1 Drive the car approximately 500 mm
above the buffer.
2 Open the latch release to engage the The safety gear must engage.
safety gear.

1007241.wmf

3 Drive the car downwards to ensure that

the safety gear has engaged.
4 Drive the car downwards until the Tirak The automatic safety gear trigger must
rope is slack. Check that the upper part be latched.
of the safety gear trigger lowers onto
the lower part. Ensure that the latch
release has engaged to the pin.

1007243.wmf

a1149qh.wmf

5 Drive the car upwards. Secure the car

with the parking chain.
6 Check the safety gear marks on the The marks should be at the same height
guide rails. and of the same depth and length.
7 If the marks are not equal the safety
gear must be adjusted.

© 2005 KONE Corporation 176 (453) AM-01.01.084

13.2.5 Use of automatic safety gear trigger

Step Action Note

1 Open the latch release to engage the The safety gear must engage.
safety gear.

1007241.wmf

2 Drive the car downwards to ensure that

the safety gear has engaged.
3 Drive the car downwards until the Tirak The automatic safety gear trigger must
rope is slack. Check that the upper part be latched.
of the safety gear trigger lowers onto
the lower part. Ensure that the latch
release has engaged to the pin.

1007243.wmf

4 Secure the car with the parking chain.

5 Detach the Tirak hoist hook from the
safety gear trigger.
6 Perform the required operation.
7 Re-attach the hoist hook to the safety
gear trigger.

13.3 Fixings under the Eureca car

Step Action Note

1 Lift the car up so that the pit and car
bottom can be reached.

© 2005 KONE Corporation 177 (453) AM-01.01.084

Step Action Note

2 Install the wall panels to the car
platform using M6 bolts.

Fit the wall joint bolts.

1007248.wmf

3 Bolt the car floor to the bottom beam

using two M12 bolts (delivered for this
purpose).

Install the four pulley beam fixings to

the car floor. Insert the bolts from the
top.

NOTE! If BB > 1100 mm, the front

fixings of the pulley beam are
fixed to the car floor stiffeners
with two bolts.

MX05
MX06
1027450.wmf 1009737-1.wmf MX10
4 Tighten the diagonal support fixing
bolts.

© 2005 KONE Corporation 178 (453) AM-01.01.084

Step Action Note

5 Fix the rope guards to the car floor. Ensure that the rope guards will not
Tighten the fixing bolts. touch the suspension ropes.

1009739.wmf

1. Machine side
6 Adjust the safety gear contact switch.
2...3mm

1007250.wmf

13.4 Fixings under the MCD car

Step Action Note

1 Secure the bottom edges of the wall
panels.

a1150bw.wmf

© 2005 KONE Corporation 179 (453) AM-01.01.084

Step Action Note

2 Fit the travelling cable hangers. Fixing package: 611604G01
Position them according to the layout
drawing.

1
2

a1150eh.wmf

1. Travelling cable hanger 600671G01 with or without option cable hanger

2. Travelling cable hanger 600671G02 with round option cable.
3 Fit the compensation chain hanger (if
applicable). Position it according to the
layout drawing.
Compensation chain hanger 600674G..

a1131vck.wmf

1
2
1. Platform without ringbeam, Fixing package: 611604G02/G03
2. Platform with ringbeam, Fixing package: 611604G02
4 Store the load weighing sensor
equipment to be installed with car
electrification.

© 2005 KONE Corporation 180 (453) AM-01.01.084

13.5 Guide rail clamps

Step Action Note

1 Remove the guide rail clamps.

a1149rb.wmf

13.6 Intermediate guide rails

Step Action Note

1 Drive the car to the pit.
2 Park the car using both the parking
chain and the safety gear before
disconnecting the hoist hook.

© 2005 KONE Corporation 181 (453) AM-01.01.084

Step Action Note

3 Lift the guide rails into the lifting
pockets on the car using the sliding
clamp and hoist.

Always control that the installation hoist

diverter can rotate on its axle and line
up with the lifting point.

Secure the guide rails using the

securing chain on the car roof.

P17000228.wmf

1007265-1.wmf

4 Attach the Tirak hook to the car sling.

5 Drive the car 1-1.5 m below the next
guide rail joint.

© 2005 KONE Corporation 182 (453) AM-01.01.084

Step Action Note

6 Engage the safety gear and fit the Keep the parking chain tight.
parking chain.

P17000182.wmf

1057502.wmf

7 Disconnect the hoist hook from the car.

8 Lift the rails into position in the normal
way using the sliding clamp.

1007266-1.wmf

9 Fix the guide rail to the fish plate.

10 Connect the hoist hook to the car and Do not rest the car on the safety gear
lift the car slightly. during the alignment.

© 2005 KONE Corporation 183 (453) AM-01.01.084

Step Action Note

11 Align the joint using a 1 metre straight
edge or spirit level and tighten the joint.

P01000093.wmf

12 Move the car up and park it at a

comfortable working height to install the
next ring of brackets.
13 Install the next ring of brackets.
14 Align the car guide rails.
15 Align the counterweight guide rails.

13.7 Topmost guide rails

Step Action Note

1 Engage the safety gear and fit the
parking chain.
2 Attach the chain hoist to the lifting eye
near the guide rail.
3 Fit the guide clamp to the car guide rail Ensure that the guide clamp is fitted so
approximately 500 mm from the top of as to operate in the right direction.
the guide rail. Fit the sliding guide
clamp below the guide clamp.

© 2005 KONE Corporation 184 (453) AM-01.01.084

Step Action Note

4 Attach the chain hoist hook to the
sliding guide clamp and take up the
slack.

0.5 m
1029769.wmf

5 Lift the guide rail into position using the WARNING! The angle between the
hoist and sliding guide clamp. guide rail and the hoist chain must
never be more than 30 degrees.
6 Install the topmost guide rail.
7 Remove the chain hoist and guide
clamp. Align the guide rail joint.
8 Install the second topmost guide rail
brackets.

13.8 Checking guide rail installation

Step Action Note

1 When all the guides are installed and Shim as necessary.
aligned, recheck the fish plate joints.
*
*

P01000076.wmf

*) Shims
2 Dress the joints using surform file.

© 2005 KONE Corporation 185 (453) AM-01.01.084

13.9 Bottom pulley beam and travelling cable hanger, Eureca car

Step Action Note

1 Position the car so that the pit and car
bottom can be reached.
2 Engage the safety gear.
3 Elevators with two car buffers:
Temporarily remove two M12 bolts *).
*

1011001.wmf

4 Fix the telescopic pipes to the bottom of

the car floor using T-bolts and pipe
fixings.
Secure the telescopic pipes and pipe
fixings together using G-clamps.

1007512.wmf

5 Place the other end of the telescopic

pipes onto the work stool.

1007511.wmf

© 2005 KONE Corporation 186 (453) AM-01.01.084

Step Action Note

6 Lift the bottom pulley beam onto the Check that the rope guards are at the
telescopic pipes sideways so that it front side of the pulley beam.
does not touch the car floor.
7 Move the pulley beam along the
telescopic pipes to correct location.

1007513.wmf

8 Turn the pulley beam to the upright

position.
9 Set the pulley beam so that the fixing
bolts will align to the proper fixing holes. 305 341

1
355 391

1007514.wmf

1. machine side
10 Insert the plate between the pulley
beam and the spacer.
11 Lift up the end of the pulley beam and
fix the nuts.

1007516.wmf

12 Repeat for the other end of the pulley

beam.
13 Tighten the nuts.

© 2005 KONE Corporation 187 (453) AM-01.01.084

Step Action Note

14 1.6 m/s elevators:
Secure the pulley beam to the car floor
with 2 x 0.5 m chain.

This is to prevent damage to rubber

isolations.

1011206.wmf

15 Detach the telescopic pipes from the

car floor.
16 Fit the travelling cable hanger between
the front of the car floor and the pulley
beam.

Use one of the holes in the stiffener.

1007249.wmf

13.10 Preparing the machine and the car for transportation

Step Action Note

1 Drive the car to the lowest level.
2 Bridge the gap between the car and
landing. Use plywood board or two
50 mm x 100 mm thick pieces of wood.

P05000102.wmf

© 2005 KONE Corporation 188 (453) AM-01.01.084

Step Action Note

3 Turn the machine box on its side.
Use your legs while lifting -- not your
back.

P15000073.wmf

4 Fix the axles and wheels to the box.

Draw the sleeves on the axles to
position the tyres.

Fix the tyres with the air valves facing

to the box, so the securing pin will not
damage the valves.

1 1

P03000472.wmf

1. Air valve
5 Guide the box using the site trolley
handle. Avoid moving the box over
uneven or bumpy surfaces.

P03000471.wmf

© 2005 KONE Corporation 189 (453) AM-01.01.084

13.11 Transporting machine to the topmost floor

Step Action Note

1 Place the machine inside the car. One fitter drives from the car top.
Do not damage the car interior.
2 Drive the car to the highest floor level The hoist may not be to close to the
and bridge the gap between the car and diverter pulley.
landing as before.
3 Bring the machine onto the landing.

© 2005 KONE Corporation 190 (453) AM-01.01.084

14 MACHINE ROOM INSTALLATION

8000169(2008-07)

© 2005 KONE Corporation 191 (453) AM-01.01.084

14.1 Transporting machine and control panel to machine room

Step Action Note

1 Transport the machine and control Contact to your supervisor before
panel to machine room from the making any actions to transporting.
topmost landing (if needed).

1038620.wmf

© 2005 KONE Corporation 192 (453) AM-01.01.084

14.2 Marking up machine room component positions on machine room floor

Step Action Note

1 Mark up car center line (1) and car SMiniSpace with side counterweight
guide rail center line (2) on machine 2 1
room floor based on the plumbing
template.

NOTE!
Car center line overlaps the plumbing
template center line.

d
The distance between car guide rail
center line and the plumbing template
is:
L. A. R.
• d=4.5 mm, if the car guide rail
type is T82;
• d=8 mm, if the car guide rail type 8000833.wmf
is T89/T114.
SMiniSpace with rear counterweight
1
d

L. A. R.
2

8000835.wmf

2 Mark up the positions of I-beams, XMiniSpace

motor, controller, overspeed governor
and rope hitch plate to the machine
room floor based on their relative 1
distance to the machine room floor
center lines. Refer to layout drawing for
the required distance values.
d

L. A. R.

8000834.wmf

© 2005 KONE Corporation 193 (453) AM-01.01.084

14.3 Fixing machine for K3000S MiniSpace™ (side counterweight)

Step Action Note

1 Unpack the machine.

P03000473.wmf

2 Fix the bottom stand to the machine

4
bed plate. 2
3
1 = Bolt
2 = Wedge washer
3 = Lock plate
4 = Spring pin
MX10 1009856.wmf 1
3 Fit I-beams to machine room floor.

1038644.wmf

4 Attach the hoist to the lifting hook in the

machine room ceiling.

Attach the hoist hook to the machine

lifting eye.

Lift the machine and turn it to right

position.

Lower the machine on the bottom

stand.

Leave the hoist attached until the bed

plate is fixed.

1038646.wmf

© 2005 KONE Corporation 194 (453) AM-01.01.084

Step Action Note

5 Fix the machine top fixing and tighten
the bolts. 3
1 = Bolt
2 = Wedge washer 4
3 = Nut
4 = Washer
2
1

1007283.wmf

6 Fix the brake release lever to the guide

rail of the machine bed plate with three
bolts.

8000318(2008-08)

14.4 Fixing machine for K3000S MiniSpace™ (rear counterweight)

Step Action Note

1 Unpack the machine.
2 Fit the I-beams to the machine room
floor based on the marks on the floor.
Check the I-beams horizontal with a
spirit level.

8000170.wmf

© 2005 KONE Corporation 195 (453) AM-01.01.084

Step Action Note

3 Fit the U-beams onto the I-beams by
spot welding. Refer to layout drawing
for their positions on I-beams.

8000320(2008-08)

4 Fit the rope hitch plates to their

appropriate positons on the U-beams.

Align the rope hitch plates with the

corresponding marks on the floor using
plumb lines. Relocate the rope hitch
plate if needed.

8000783.w

5 Fit the bottom stand to the machine

bed plate with four M12 x 40 mm
screws.

M12x40(4x)

8000366(2008-09)

© 2005 KONE Corporation 196 (453) AM-01.01.084

Step Action Note

6 Fit the bed plate onto the U-beams with
four M12 x 40 mm screws. Refer to
layout drawing and the machine M12x40(4x)

position mark on the floor for its

appropriate positon.

Do not tighten the nuts. The bed plate

is roughly fixed for further adjustment.

8000321.wmf

7 Put the rubber isolation plate to the

yellow painted area on the bed plate.

8000784.wmf

8 Attach the hoist to the lifting hook in the

machine room ceiling.

Attach the hoist hook to the machine

lifting eye.

Lift the machine and turn it to right

position.

Lower the machine on the bottom

stand and check the verticality of the
machine.

NOTE! Leave the hoist attached until

the bed plate is fixed.
8000171.wmf

© 2005 KONE Corporation 197 (453) AM-01.01.084

Step Action Note

9 Fix the machine top fixings including a
space plate (1).
NOTE! Do not tighten the bolts until
adjusting the machine to be
vertical by a plumb line.

8000785.wmf

10 Fix the brake release lever to the M5x12(3x)

square tube of the machine bed plate
using three M5x12 mm screws.

8000322(2008-08)

14.5 Fixing machine for K3000X MiniSpace™

Step Action Note

1 Unpack the machine.
2 Fix the bottom stand to the machine
bed plate.

a1184ah.wmf

© 2005 KONE Corporation 198 (453) AM-01.01.084

Step Action Note

3 Fit I-beams to machine room floor
based on the position marks on the
floor.

1038644.wmf

4 Attach the hoist to the lifting hook in the

machine room ceiling.

Attach the hoist hook to the machine

lifting eye.

Lift the machine and turn it to right

position.

Lower the machine on the bottom stand

and check the verticality of the
machine.

NOTE! Leave the hoist attached until

the bed plate is fixed.
1038646.wmf

5 Fix the machine top fixing.

NOTE! Do not tighten the bolts until
adjusting the machine to be
vertical by a plumb line.

a1184ag.wmf

6 Fix the brake release lever to the

M5x12(3x)
square tube of the machine bed plate
using three M5x12 mm screws.

8000322(2008-08)

© 2005 KONE Corporation 199 (453) AM-01.01.084

14.6 Plumbing machine

8000323.wmf

Step Action Note

1 Place plumb lines over the machine
traction sheave.
2 Align the machine according to the
markings on the floor.
3 Cover the front side of the machine to
protect it from welding sparks (if
applicable).
4 Secure machine in position by welding.
NOTE!In case of SMiniSpace with rear
counterweight, tighten the four bolts
jointing the bed plate and U-beams.
If screw holes do not match well
after plumbing the machine, adjust
U-beam positions according to the
range specified on layout. Finalize 1038650.wmf

U-beam positions by welding to the

I-beams.

CAUTION! Cover holes prior to any hot

works in the machine room.

© 2005 KONE Corporation 200 (453) AM-01.01.084

14.7 Fixing rope anchorages and overspeed governor

14.7.1 Manual tripping test before installing overspeed governor

Step Action Illustration/Note

1 Fix the overspeed governor to the base
M12x40
(alternative 1 or 2), if any.

1. Base 85599G01 (OL100)

Base 86318G01/G02 (OL120)
2. Base 85967G02 (OL100)
Base 85967G01 (OL120)
1 2

pict.4

2 Remove the additional cover above the

brake clamps, if installed.

pict.6a

3 Put in one end of the overspeed

governor rope between the brake
clamps, this to prevent the brake
clamps get damaged when the
governor trips during the test.

pict.25

© 2005 KONE Corporation 201 (453) AM-01.01.084

Step Action Illustration/Note

4 Set the tripping lever (1) in operation
position against the limiter (2) using the 3
lifting lever (3).

2
1

pict.11

5 Cut off the cable tie and remove the

wood spacer (5).

WARNING!
Do not keep your hands between the
lever (4) and the governor when the
governor is in operation mode.
5
4

pict.22

6 Hold a tachometer (1) against the rope

wheel.
7 Slowly speed up the rope wheel (in the
arrow direction) using an electric drill
1
equipped with a plastic roller (2).
2
Electric drill 2500 rpm
Plastic roller diameter 120-130 mm

pict.10

8 Read the speed from the tachometer

when the governor trips.

© 2005 KONE Corporation 202 (453) AM-01.01.084

Step Action Illustration/Note

9 Compare the result with the tripping Example 1
speed on the sign. Nominal elevator speed v is 0.8 m/s
Min allowed tripping speed=
According to EN-81, chapter 4.3 must 0.8 x 1.15= 0.92 m/s
the tripping speed be: Max allowed tripping speed=
• minimum 115% of nominal less than 1.5 m/s
elevator speed v
Example 2
• less 1.5 m/s at maximum nominal Nominal elevator speed v is 3.0 m/s
elevator speed v 1.0 m/s Min allowed tripping speed=
3.0 x 1.15= 3.45 m/s
• less than 1.25 x v + 0.25/v if Max allowed tripping speed=
nominal elevator speed v is more 1.25 x 3.0 + 0.25/3.0= less than 3.83 m/s
than 1.0 m/s.
10 Check visually that the overspeed
contact (1) and the tripping contact (2)
are in OFF position after tripping. 1
NOTE! The overspeed contact (1)
must switch OFF a just before
the governor trips.

2
pict.18

11 Check the contacts function by

resistance measuring from the plint at
the side of the governor.
13 14 11 12
1. Overspeed contact 21 22 23 24
2. Tripping contact
1 2

NOTE! The pre wiring of the contacts

and the connection box are
options.

pict.19

© 2005 KONE Corporation 203 (453) AM-01.01.084

Step Action Illustration/Note

12 Re-install the wood spacer without
activating the overspeed governor.

Secure the spacer with a cable tie but

remember;

KEEP WHENEVER POSSIBLE YOUR

HANDS OUTSIDE THE AREA
BETWEEN LEVER AND GOVERNOR!
pict.20

13 Re-set manually the overspeed

contact.

pict.21

© 2005 KONE Corporation 204 (453) AM-01.01.084

14.7.2 Placing overspeed governor on the machine room floor

Step Action Illustration/Note

1 Position the governor over the rope
holes according to dimensions given in
the layout drawing.

The governor brake must be turned to

same side as the safety gear side
(when the car (or cwt) travel
downwards, the governor must rotate in
the arrow direction).

pict.14

2 Shim underneath if the governor not

standing perpendicular.

pict.5

© 2005 KONE Corporation 205 (453) AM-01.01.084

14.7.3 Installing the governor rope

Step Action Illustration/Note

1 Install the rope.
2 Check that the rope runs in line into the
pulley groove.
Try also to check that the rope has free
space through the brake blocks.
NOTE! as it is difficult to check the free
space, listen for sounds indicating
the rope is scratching against the
brake blocks later when the elevator
is running.

pict.7
pict.23

Adjust the governor position if needed.

3 Bolt the governor to the floor with
M12x110 (1).
4 Install the additional rope cover (2).
5 Set the governor in operation mode and
remove the wood spacer (3).
3

pict.17

NOTE! keep your fingers away when doing test on OSG.

© 2005 KONE Corporation 206 (453) AM-01.01.084

14.7.4 Installing the rope anchorages

Step Action Illustration/Note

1 Fix the rope anchorages (A) in position
according to layout drawing.

1039321.wmf

1038652.wmf

1043069.wmf

1043070.wmf

© 2005 KONE Corporation 207 (453) AM-01.01.084

Step Action Illustration/Note

B A

8000172(2008-06) 8000173(2008-06

8000176(2008-06)
8000177(2008-06)

© 2005 KONE Corporation 208 (453) AM-01.01.084

14.8 Fixing control panel

Step Action Note

1 Fix the control panel in position
according to layout drawing.

1038655.wmf

1039322.wm

1043071.wmf 1043072.wmf

© 2005 KONE Corporation 209 (453) AM-01.01.084

Step Action Note

8000174(2008-06
8000175(2008-06

fixV3F16L.wmf

v3f16ltop.wmf

14.9 Closing machine room holes

Step Action Note

1 Install steel sheet profile round the rope
opening, so that the profile ends
75

overlap.

1011847.wmf

© 2005 KONE Corporation 210 (453) AM-01.01.084

Step Action Note

2 Cover all other holes with protective For KONE 3000S MiniSpace™ elevators
steel plate. with rear counterweight use the provided
steel plate and 4 plastic expanding
anchors.

1011848.wmf

14.10 Sticking adhesive tape (optional)

Step Action Note

1 In case of installing KONE 3000S
MiniSpace™ elevators with rear CWT,
stick yellow/black adhesive tape on the
I-beams and U-beams for warning
operators.

300 nx300
8000312(2008-07)

© 2005 KONE Corporation 211 (453) AM-01.01.084

15 BRAKE ADJUSTMENT

15.1 Fixing the brake release cable to the brake release lever

Step Action Note

1 Route the wire rope through the sleeve
and around the fixing screws.

8000347(2008-08)

2 Remove the slack by pulling the wire

rope. Tighten the fixing screws. Cut
extra length.

15.2 Installing the brake release cable to the machine

Step Action Note

1 Dismantle the nuts, bushing and the
spring at the machine end of the cable. 1026959.wmf

© 2005 KONE Corporation 212 (453) AM-01.01.084

Step Action Note

2 Lead the cable in through the channel
on the back of the machine.

r > 100 mm

1039323-1.wmf

3 Re-install the springs, washer, bushing

and end nuts on the other side.
CAUTION!Minimum bending radius of
the cable is 100 mm.

15.3 Main construction of the brake

Step Action Note

1 The machine is equipped with two
direct acting type drum brakes.

The brakes operate independently and

must therefore be adjusted separately.

The brakes operate only after the

machine has stopped.

The brake torque is not adjustable.

© 2005 KONE Corporation 213 (453) AM-01.01.084

15.4 Checking the stroke of the brake

Step Action Note

1 Open the brake fully by tightening the
centre nut in the bottom. 1. Centre nut

2 Measure the air gap between the brake

lining and the drum by sliding a feeler
gauge round the air gap.

If the air gap is:

• 0.05 mm but less than 0.10 mm,
then close the brake
(go to section 15.5).
• 0.10 mm or more, or less than
0.05 mm
then re-adjust the air gap
(go to section 15.6).

15.5 Adjusting the stroke of the brake

Step Action Note

1 Remove the locking plates of the
adjustment screws.

© 2005 KONE Corporation 214 (453) AM-01.01.084

Step Action Note

2 Adjust the air gap from one end at a
time by alternately turning the two
adjusting screws.

The adjusting screws are very

sensitive.
(1/4 turn corresponds to 0.25 mm
change in the air gap).

1. Adjusting screws at the upper

end
2. Adjusting screws at the lower
end
Set the air gap at the upper end to
0.10 mm.

Set the air gap at the lower end to

0.05 mm.

Set the air gap at the upper end to

0.05 mm.

© 2005 KONE Corporation 215 (453) AM-01.01.084

Step Action Note

3 Secure the adjustment screws in
position with the lock plates.
NOTE!Do not alter the adjusting screw
position, place the lock plates to suit.

15.6 Closing the brake

Step Action Note

1 Loosen the centre nut and ensure that
the washer is not tight. It must be free
to rotate.

CAUTION!After any adjustment always

check and test the brake release
operation.

1. Centre nut

© 2005 KONE Corporation 216 (453) AM-01.01.084

15.7 Adjusting the manual brake release device

Step Action Note

1 Adjust the brake levers parallel to the 1. Lever
brake face using the set screw. 2. Set screw
1

1007491.wmf

2 Tighten the test screw. 1. Test screw

3 Adjust the centre nut so that the test 2. Centre nut
screw slightly touches the brake body 1
while by hand pressing the lever.

1007492.wmf

4 Screw out the test screw. 1. Test screw

5 Ensure that the washer is not tight. It 2. Washer
must be free to rotate. 1

1007493.wmf

6 Adjust the nut at the cable end so that 1. End nut 1

the levers at both sides lean against the 2. Bushing
set screws and the bushings are sitting 3. Set screw 4
2
flush inside the levers. 4. Counter nut
7 Loosen the end nut 2...3 turns to slack 3
the cable tension a little.
8 Tighten the counter nut.
1007494.wmf

© 2005 KONE Corporation 217 (453) AM-01.01.084

15.8 Checking the operation of the manual brake control

Step Action Note

1 Check the brake function:
• pull the lever to release the
mechanical brake

The car must lower slowly and stop

when the lever is released. 2
Any further adjustments must be
done by the cable end nut, not by the 1
centre nut!
2 Ensure that the lever returns to the
“brake closed” position by itself.

If the lever does not return, check the

brake cable for sharp radii, twists and 1031763-1.wmf

damage to protective sheath.

1. Brake closed
2. Brake fully open

15.9 Checking after the brake is adjusted

Step Action Note

1 The brake air gap should be maximum
0.1 mm.
2 The central nut washers must be free to
rotate.
3 Cover machinery and controller with
polythene.

© 2005 KONE Corporation 218 (453) AM-01.01.084

16 LANDING DOOR INSTALLATION

Refer to the AM-03.12.047, Augusta landing doors.

© 2005 KONE Corporation 219 (453) AM-01.01.084

17 CAR SILL AND FRONT WALLS INSTALLATION, EURECA CAR

17.1 Car sill

Step Action Note

1 Remove the guide rail lifting pockets
and car roof securing chains.
2 Place the car front wall panels
temporarily into position. Place the X
3 mm spacers between the car floor
and front wall panels temporarily.
3 Install the sill base brackets to the front
of the car floor. X

*
1007289.wmf

X = 115 mm to 315 mm
1009814.wmf
*) If the LL>950 mm install the third
bracket in the middle
4 Place the car sill profile on the base Centralise the sill profile.
brackets.
Align the car sill profile so that both
ends are at the same level.
DD

45
35

LL
32

1007290.wmf
LL 1007291.wmf

© 2005 KONE Corporation 220 (453) AM-01.01.084

Step Action Note

5 Adjust the sill profile in back to front
direction using M8 bolt.

M8
1009830.wmf

6 Check that the sill is level with the

finished car floor.
7 Tighten the car sill fixing bolts. 1007292.wmf

17.2 Car front walls

These instructions are for installing AMD car doors.

17.2.1 Wall panels, lintel and operator brackets

Step Action Note

1 Place the aluminium sill groove profile
on top of the steel profile.

Centre opening door:

to the centre

Secure the aluminium profile to the

steel profile with a self tapping screw
4.2x13.

© 2005 KONE Corporation 221 (453) AM-01.01.084

Step Action Note

2 Fix the front wall panels; first the upper *) Use M6 bolt to keep the stiffener (if
end and the side, then the lower end. any) in position. Remove after front wall
Place the 3 mm spacers between the installation.
car floor and the front wall panels on
both sides.

If the car has side opening doors with

railing 2, fix the additional stiffener to
the opposite side of the slampost.

NOTE! If FR (or FL) < 50 mm, cut off a

piece from top and bottom of
the stiffener.
45 *

1027849.wmf 1027847.wmf

3 Fix the operator brackets, lintel and

front panels together. Tighten the bolts.

See the following tables.

1007340.wmf

© 2005 KONE Corporation 222 (453) AM-01.01.084

Table 1: Operator fixing brackets (Low duty)

Centre opening AMDC-1, bracket 602334

M8
HH+362

1009990.wmf

Table 2: Operator fixing brackets (Mid and High duty)

AMDC-1 (35 mm car return), bracket 601191 (35 mm)

1
2
M5
HH + 293

LL - 100
M8
1009992.wmf

1 Car door sill line

2 Suspension screw

© 2005 KONE Corporation 223 (453) AM-01.01.084

17.3 Completing the car front installation

Step Action Note

1 Fix the slam post to the front wall using
bolts.
2 Fix the compensative lintel to the slam
post and lintel using M6 bolts and nuts.

1007346.wmf

3 Move the front wall assembly to the

correct height. Tighten the bolts.

1007345.wmf

4 Fix the lintel and door operator brackets In case of AMDC-2 with railing 2 install
to the roof. Tighten the M6 bolts. the additional support. Refer to the
delivery documents.

1007343.wmf

© 2005 KONE Corporation 224 (453) AM-01.01.084

Step Action Note

5 Fix the slam post fixing to the sill profile.
Peel the cover of the adhesive tape.
Check that the slam post is in 90° with
the car sill.

1010206.wmf

6 Ensure that the car door entrance is A misaligned entrance may cause
square and in plumb. problems when installing the door
Tighten all the fixing bolts to final operator.
tightness.
7 Place the carpet profile on top of the
aluminium sill groove.

1007347.wmf

© 2005 KONE Corporation 225 (453) AM-01.01.084

18 CAR SILL FRONT WALLS INSTALLATION, MCD CAR

Refer to the delivery documents.

Refer to AM-06.06.012.

© 2005 KONE Corporation 226 (453) AM-01.01.084

19 CAR DOOR

If the car door type is AMD refer to AM-03.12.087.

© 2005 KONE Corporation 227 (453) AM-01.01.084

20 MACHINE ROOM ELECTRIFICATION V3F16L DRIVE ELEVATORS

WARNING
The builders electrician connects the main power supply after the electrification works are
completed.

NOTE! For the correct location of the machine room components, for example, main switch,
refer to layout drawing.

20.1 V3F16L control panel

The drive and control panels are pre-tested at the factory. The basic adjustments in the
inverter module are preset.

15
1. Terminal block
1 13 with switches
2 2. Cable trunking
9 8 5 7 7

3. LCECPUnc board
RL1

RL2

RS1

RS2

1 3 1

366

2 4 2

4. Brake resistors
PE/1

PE/2

PE/3
T3

6 8 8

3
270 270:RB

5. Ground terminal
XL1 XL8
PE4

XL9 4 6. LCE230 board

XM17

7. LCEOPT board
XH12
XM25

XM16

XM13

XG4A

XG4B

XG3B

XG3A
X4

17 8. LOBCB board
9. V3F16L drive
XL1

module
XH11

10.LOB230 board
X20
X3

X4
XM14

37 21 20
XM18

XC12
XC11

11.Transformer
XL2

XL3 XL4 XL5 XL6

5
12.LCEREC board
6 (18) 13.TSD module (if
ordered)
XM5

XM1
XD1

XH1

14.LCERAL board
XLH9 XLH1 XLH2
XLH3

XM2
XLH8

XLH4

15.Maintenance
XM3

XLH7 XLH6 1 XLH5

XM4
X5

telephone
XH2

10
XC1

16.LCEGTW board
XM9

XM7
XC3

XC4

17.LCECAN board
18.LCEADO module
11 7 (14/16)
X6
X7
XM13A

12
X1

X5
XM13B
X2

X8
X3

XM25
X4

XM16 XM20 XM17

X1
X8

XM5
X2

XG2A
XM13B
X5

X2
X1
XM13A
X7
X6

v3f16lpos.wmf

© 2005 KONE Corporation 228 (453) AM-01.01.084

20.2 Installing main switch unit

Step Action Note

1 Ensure that the main supplies are
locked off and tagged.

2 Install the main switch unit and shaft Refer to the layout drawing.
network switch unit (if any) to the wall.
3 Ensure that all the circuit breakers and
OFF
switches are in OFF position.

1017328.wmf

4 Do not connect the supply voltage.

Lock the main switch in OFF position.

WARNING! Do not insert the fuses.

Refer to the delivery documents.

OT
DO N CH
SWIT
1017329.wmf ON

© 2005 KONE Corporation 229 (453) AM-01.01.084

20.3 Connections at the controller

Step Action Note

1 Connect the controller ends of the main
supply cable to the terminals L1, L2, L3
and PE in the controller.
2 Connect the controller ends of the
elevator shaft lighting cable to terminals
14, N/14 and PE in the controller.
3 Connect the controller ends of the car
lighting supply cable to terminals 10, 11
and PE in the controller.

3 1. Knockouts
2. Main supply cable (L1, L2, L3,
2 4 PE)
5 7 7
RL 1

RL 2

RS1

RS2

3. Elevator shaft lighting supply

1 3 1

366

2 4 2

cable (14, N/14, PE)

PE/1

PE/2

PE/3
T3

6 8 8

270 270:RB

PE4
4. Car lighting supply cable (10, 11,
PE)
XL1 XL8 XL9
XM17

XH12
XM25

XM16

XM13

XG4A

XG4B

XG3B

XG3A
X4

LCECAN
LCECPUnc

(LCEKNX)

LOPCB
XL1

X3
XH11

X20
X3

X4
XM14

37 21 20
XM18

XC12
XC11
XL2

XL3 XL4 XL5 XL6

LOP230
XM5

XM1
XD1

XH1

XLH9 XLH1 XLH2

+ADO/ACL
XLH3

XM2
XLH8

XLH4

LCE230

XM3

XLH7 XLH6 1 XLH5

XM4
X5

XH2
XC1
XM9

XM7
XC3

XC4

X6
X7
XM13A
X1

X5
LCEOPT 2
LCEOPT 1 XM13B
X2

X8
X3

XM25
X4

XM16 XM20 XM17

X1
X8

XM5
X2

XG2A
XM13B
X5

X2
X1
XM13A

LCEREC
1
X7
X6

v3f16l.wmf

© 2005 KONE Corporation 230 (453) AM-01.01.084

20.4 Connections at the main switch

Step Action Note

1 Before working with electrical
OFF
equipment, ensure that the elevator
main electricity supply and car lighting
are switched OFF and locked.

1017328.wmf

2 Route the elevator, elevator car lighting WARNING! Do not insert the fuses.
and elevator shaft lighting supply
cables between the main switch unit
and the controller.
3 Connect the main supply cable to the Refer to the delivery documents.
terminals 1L1, 3L2, 5L3 and PE in the
main switch unit.
4 Connect the elevator shaft lighting
cable to the terminals F5/2, N and PE in
the main switch unit.
5 Connect the car lighting cable to the
terminals F4/2, N and PE in the main
switch unit.
6 Connect the power supply cable for
segmented shaft network to shaft
network switch unit (if any).
7 Connect the supply cable from building
to shaft network switch unit (if any).
8 Re-install the covers and relock the
main switch.

OT
DO N CH
SWIT
1017329.wmf ON

© 2005 KONE Corporation 231 (453) AM-01.01.084

3
N

387

PE
L
N
Q5

4
5

6
7
8

1012017.wmf

1. Supply cable from building (Do not connect yet. This will be connected in the beginning of
the commissioning.)
2. Main switch unit
3. Shaft network switch unit
4. Power supply cable for segmented shaft network
5. Supply cable from building
6. Car lighting supply cable
7. Main supply cable
8. Elevator shaft lighting
NOTE! Main switch unit (2) and cables 1, 5 and 7 are delivered by the builder. Layout and
wiring of main switch unit case by case.

© 2005 KONE Corporation 232 (453) AM-01.01.084

20.5 Routing and connecting the machine cables

20.5.1 Routing and connecting the machine cables for K3000S MiniSpace™ elevators with
side counterweight

Step Action Note

1 Install trunking in accordance with the
machine room layout drawing.

1038684.wmf

2 Connect the resolver cable shield to the

resolver cover (if not preconnected at
the factory).

1026658.wmf

3 Route the motor supply cable to the Keep the resolver and tachometer
controller. cables separated from other cables to
Connect the outermost shield to the minimize electromagnetic disturbances
earth sleeve outside the controller. (minimum distance 100 mm).
4 Route the resolver cable to the If it is unavoidable, cross them over
controller. Connect the shield to the other cables at 90 degree angle.
earth sleeve outside the controller.
5 Route the brake cable to the controller.
Connect the shield to the earth sleeve
outside the controller.
6 Route cable for fan, brake switch and
thermistor to the controller.
7 Route tachometer cable to the
controller.
Connect the shield to the earth screw
on the external wall of the controller.

© 2005 KONE Corporation 233 (453) AM-01.01.084

1
6

2
3
4
5

1025642.wmf

1. Motor supply cable

2. Brake cable
3. Cable for fan, brake switch and thermistor
4. Resolver cable
5. Tachometer cable
6. Insulation removed from shielded cable (Fix the cable fixing clamps to the drive panel
using self-drilling screws. Cable fixing clamps and self-drilling screws are delivered inside
the panel.)

© 2005 KONE Corporation 234 (453) AM-01.01.084

1
XM3

6
U

1 V
W

XT
XG1

XR1
4
J4(MX18,MX32) 4
J4(MX32) 5
XST(MX18,MX32) 3
XST(MX32) 2
XMF 2

1019457.wmf

1. Motor supply cable (U, V, W, PE)

2. Brake cable (J4)
3. Cable for fan (XMF) and brake switch (XST) and thermistor (XT)
4. Resolver cable (XR1)
5. Tachometer cable (XG1)
6. Overspeed governor cable (XM3)
7. Knockouts (open all while installing)

© 2005 KONE Corporation 235 (453) AM-01.01.084

20.5.2 Routing and connecting the machine cables for K3000X MiniSpace™ elevators

Step Action Note

1 Install the trunking between the main
switch and the controller.

8000326(2008-08)

2 Route the machine cables to the Route the machine cables through the
connectors in the drive panel. tubes on the bed plate to the elevator
shaft. Route the machine cables from
elevator shaft to through the hole under
the control panel.
U-clips are sent with the deliver to fix
cables to the elevator shaft roof.
Ensure to maintain the minimum 100
mm clearance between relevant cables.

routing.wmf

© 2005 KONE Corporation 236 (453) AM-01.01.084

Step Action Note

3 Push the cable bushings into the slots
in the drive panel lid and tighten the
nuts.
Ensure that there is smooth radius from
the wall to the drive to avoid the cable
leading humidity or water to the
bushings.

4 Connect the wiring to the terminals and Ensure that all connections are clean
the earth sleeves to the earthing and clamps are secure. Firm contact
clamps (1): between earthing clamps and cable
• Motor supply cable to U, V and W sleeves is very important.
• Braking resistor cables to XBRE2
• Brake cable to XBR3
• Thermistor cable to XT1
• Tachometer cable to XG1
(underneath the drive panel)

XBR3
1

U, V, W

XG1

XBRE2

XT1
1007434-1.wmf

© 2005 KONE Corporation 237 (453) AM-01.01.084

20.6 Overspeed governor wiring

Step Action Note

1 Connect the car overspeed governor
cable to the XM3.
XM3
2 Connect the counterweight overspeed
governor cable (if applicable) to the XM4
XM4.

overspeed.wmf

20.7 Connecting travelling cable

• Travelling cable: XC1, XC3, XC4, XC11

and XC12
• Earth bar: PE XC11
XC12

XC1
XC3
XC4

travelling.wmf

© 2005 KONE Corporation 238 (453) AM-01.01.084

21 MACHINE ROOM ELECTRIFICATION V3F25S DRIVE ELEVATORS

WARNING
The builders electrician connects the main power supply after the electrification works are
completed.

NOTE! For the correct location of the machine room components, for example, main switch,
refer to layout drawing.

21.1 V3F25S control panel

The drive and control panels are pre-tested at the factory. The basic adjustments in the
inverter module are preset.

NORMAL R
E
C
270:U 270:RB 270:N
2 14 1. Recall drive unit
A

3 2. LCERAL board
L
L
D

15
R

3. LCEDOM/
I
V
E
STOP
4
270

279 267
LCEEAQ/FRD FR
5 board
16 4. Maintenance
6
telephone
7 17
5. LCEGTWO board
1 8 6. LCEOPT board
18 7. Optional devices
9 8. Elevator shaft
lighting relay (268)
19 9. Braking resistors
10 10.Steel trunking
11.Brake control
module
12.Brake control
11 module (only with
MX32 machine)
12 13.Cross connection
module
20 14.Power module
13 15.Dynamic braking
module
16.LCECPU module
17.LCECAN board
18.LCEADO module
19.V3F25S drive
1012535.wmf module
20.Filter module
NOTE! The steel trunking (10) is for routing travelling cables, shaft bundle and wiring
between the control panels.

© 2005 KONE Corporation 239 (453) AM-01.01.084

21.2 Installing main switch unit

Step Action Note

1 Ensure that the main supplies are
locked off and tagged.

2 Install the main switch unit and shaft Refer to the layout drawing.
network switch unit (if any) to the wall.
3 Ensure that all the circuit breakers and
OFF
switches are in OFF position.

1017328.wmf

4 Do not connect the supply voltage.

Lock the main switch in OFF position.

WARNING!Do not insert the fuses.

Refer to the delivery documents.

OT
DO N CH
SWIT
1017329.wmf ON

© 2005 KONE Corporation 240 (453) AM-01.01.084

21.3 Connections at the controller

Step Action Note

1 Connect the controller ends of the main
supply cable to the terminals L1, L2, L3
and PE in the controller.
2 Connect the controller ends of the
elevator shaft lighting cable to terminals
14, N/14 and PE in the controller.
3 Connect the controller ends of the
power supply for segmented shaft
network (if any) to terminals 13, N/13
and PE in the controller.
4 Connect the controller ends of the car
lighting supply cable to terminals 10, 11
and PE in the controller.

© 2005 KONE Corporation 241 (453) AM-01.01.084

PE L1 L2 L3

11 13 14 10 N/13 N/14 PE

2
3
4
5
1012539.wmf

1. Knockouts
2. Main supply cable (L1, L2, L3, PE)
3. Elevator shaft lighting supply cable (14, N/14, PE)
4. Power supply cable for segmented shaft network (13, N/13, PE)
5. Car lighting supply cable (10, 11, PE)

© 2005 KONE Corporation 242 (453) AM-01.01.084

21.4 Connections at the main switch

Step Action Note

1 Before working with electrical
OFF
equipment, ensure that the elevator
main electricity supply and car lighting
are switched OFF and locked.

1017328.wmf

2 Route the elevator, elevator car lighting WARNING!Do not insert the fuses.
and elevator shaft lighting supply
cables between the main switch unit
and the controller.
3 Connect the main supply cable to the Refer to the delivery documents.
terminals 1L1, 3L2, 5L3 and PE in the
main switch unit.
4 Connect the elevator shaft lighting
cable to the terminals F5/2, N and PE in
the main switch unit.
5 Connect the car lighting cable to the
terminals F4/2, N and PE in the main
switch unit.
6 Connect the power supply cable for
segmented shaft network to shaft
network switch unit (if any).
7 Connect the supply cable from building
to shaft network switch unit (if any).
8 Re-install the covers and relock the
main switch.

OT
DO N CH
SWIT
1017329.wmf ON

© 2005 KONE Corporation 243 (453) AM-01.01.084

3
N

387

PE
L
N
Q5

4
5

6
7
8

1012017.wmf

© 2005 KONE Corporation 244 (453) AM-01.01.084

21.5 Routing and connecting the machine cables

21.5.1 Routing and connecting the machine cables for K3000S MiniSpace™ elevators with
side counterweight

Step Action Note

1 Install trunking in accordance with the
machine room layout drawing.

1038684.wmf

2 Connect the resolver cable shield to the

resolver cover (if not preconnected at
the factory).

1026658.wmf

© 2005 KONE Corporation 245 (453) AM-01.01.084

1
6

2
3
4
5

1025642.wmf

1. Motor supply cable

© 2005 KONE Corporation 246 (453) AM-01.01.084

1
XM3

6
U

1 V
W

XT
XG1

XR1
4
J4(MX18,MX32) 4
J4(MX32) 5
XST(MX18,MX32) 3
XST(MX32) 2
XMF 2

1019457.wmf

1. Motor supply cable (U, V, W, PE)

© 2005 KONE Corporation 247 (453) AM-01.01.084

21.5.2 Routing and connecting the machine cables for K3000S MiniSpace™ elevators with
rear counterweight

Step Action Note

1 Install the trunking between the main
switch and the controller.

8000327.wmf

2 Route the motor supply cable to the Keep the resolver and tachometer
controller. cables separated from other cables to
Connect the outermost shield to the minimize electromagnetic disturbances
earth sleeve outside the controller. (minimum distance 100 mm).
3 Route the resolver cable to the If it is unavoidable, cross them over
controller. Connect the shield to the other cables at 90 degree angle.
earth sleeve outside the controller.
4 Route the brake cable to the controller.
Connect the shield to the earth sleeve
outside the controller.
5 Route cable for fan, brake switch and
thermistor to the controller.
6 Route tachometer cable to the
controller.
Connect the shield to the earth screw
on the external wall of the controller.

© 2005 KONE Corporation 248 (453) AM-01.01.084

4
5

a1143b23.wmf

1. Motor supply cable

© 2005 KONE Corporation 249 (453) AM-01.01.084

U
V
W
PE

XM3
6

1
1

XT
XG1 4
4
XR1
2
J4 5

XST 2

XMF
7
3

1012599.wmf

1. Motor supply cable (U, V, W, PE)

© 2005 KONE Corporation 250 (453) AM-01.01.084

21.5.3 Routing and connecting the machine cables for K3000X MiniSpace™ elevators

Step Action Note

1 Install the trunking between the main
switch and the controller.

8000326(2008-08)

© 2005 KONE Corporation 251 (453) AM-01.01.084

4
5

a1143b23.wmf

1. Motor supply cable

© 2005 KONE Corporation 252 (453) AM-01.01.084

U
V
W
PE

XM3
6

1
1

XT
XG1 4
4
XR1
2
J4 5

XST 2

XMF
7
3

1012599.wmf

1. Motor supply cable (U, V, W, PE)

© 2005 KONE Corporation 253 (453) AM-01.01.084

21.6 Overspeed governor wiring

Step Action Note

1 Connect the car overspeed governor
cable to the XM3.
2 Connect the counterweight overspeed
governor cable (if applicable) to the
XM4.
XM3

1018459.wmf

© 2005 KONE Corporation 254 (453) AM-01.01.084

21.7 Connecting travelling cable

XC11
XC12
XC20
PE XC3
2
XC1

10,11,PE
XW

1 3

1012020.wmf

1. Travelling cable 1: XC11 and XC12

2. Earth bar
3. Travelling cable 2: XC1, XC3, XC4

© 2005 KONE Corporation 255 (453) AM-01.01.084

22 KDL32 CONTROL PANEL

For more information on KDL32 control panel, refer to AM-11.65.029.

© 2005 KONE Corporation 256 (453) AM-01.01.084

23 KDL16 DRIVE

For more information on KDL16 drive, refer to AM-11.65.041.

23.1 KDL16L drive module

D3
1

1066466.wmf

POS Name Number

1 Contactor board (CO16) KM964619G23
2 Varistor board (VRB) KM960575G21

LED Color Status Indication meaning

DANGER (D1) Red ON Dangerous voltage in DC-link.
D3 Green ON 201:2 relay is picked.

© 2005 KONE Corporation 257 (453) AM-01.01.084

23.2 KDL16R drive module

NOTE! In picture at the left the finger protection cover is removed.

2
D3

1066241.wmf

NOTE! VRB board (2) is located under the BCK board (4).

POS Name Number

1 Contactor board (CO16) KM964619G23
2 Varistor board (VRB) KM960575G21
3 Module fan KM870403G08
4 Brake control board (BCK) KM946246G01

LED Color Status Indication meaning

DANGER (D1) Red ON Dangerous voltage in DC-link.
D3 Green ON 201:2 relay is picked.

© 2005 KONE Corporation 258 (453) AM-01.01.084

23.3 Control cabinet with KDL16 drive

23.3.1 Control cabinet with KDL16L drive

1. Control cabinet with KDL16L drive

2. RDF and stop buttons
3. Braking resistor
4. LCECPU board
5. KDL16L drive
6. LCEADO board
7. LCE option boards
8. THD-filter (optional)
9. Transformer and LCEREC board
10. ECB-1 (optional)

© 2005 KONE Corporation 259 (453) AM-01.01.084

23.3.2 Control cabinet with KDL16R drive

1. Control cabinet with KDL16R drive

2. RDF and stop buttons
3. Braking resistor
4. LCECPU board
5. KDL16R drive
6. LCEADO board
7. LCE option boards
8. THD-filter (optional)
9. Transformer and LCEREC board
10. ECB-1 (optional)

© 2005 KONE Corporation 260 (453) AM-01.01.084

24 ELEVATOR SHAFT ELECTRIFICATION

24.1 Travelling cables

24.1.1 Connecting travelling cable

Step Action Note

1 Fix the travelling cable hanger to the
wall or to the guide rail.
Check the location of the travelling
cable hanger in the layout drawing.
2 Bend the cables carefully and check
that the text on the cable faces the
elevator shaft wall.
3 Secure the upper end of the travelling
cables in the cable hanger.
4 Feed the control panel end of the
travelling cables to the control panel.
5 Unwind the travelling cables down to Check that the text on the cables is on
the elevator shaft and fix the ends the outside of the loop and the cable
temporarily to the car roof balustrade. loop is not twisted.

1
xxxx----xxxxx

100 mm

1018572.wmf

1. Text

1039708.wmf

© 2005 KONE Corporation 261 (453) AM-01.01.084

24.2 Support channels and trunkings for group elevators

Step Action Note

1 Fit the trunking support channel to the
dividing beams with pop rivets.

1008678.wmf

2 Stick the cable tie anchors to the

trunking and trunking support. Drill
fixing holes through the anchors. Fix
the trunking using pop rivets.
3 Make the necessary openings in the
side of the elevator shaft trunking at
each landing level.

1008679.wmf

© 2005 KONE Corporation 262 (453) AM-01.01.084

24.3 Trunking and elevator shaft wiring

24.3.1 Wiring in the elevator shaft

Step Action Note

1 Unpack the controller ends of the Refer to the delivery documents.
elevator shaft cables and bring the
ends to the controller.
Protect the lead-in using openable
plastic sleeve.
2 Route the cables inside controller.
3 Connect the elevator shaft cable. Coil the cable ends inside the controller
V3F16L trunking.
V3F25S

XH12
XH11
XH12

XH1
XLH4
XH2
XLH7
LOP230

shaftbundle.wmf

1020419.wmf

© 2005 KONE Corporation 263 (453) AM-01.01.084

Step Action Note

4 Connect the earth wires to the earth Refer to the delivery documents.
bar.
5 Feed the safety chain cables (and The safety chain wiring (and optional
optional cables, if applicable) first into cables, if applicable) MUST NOT GO in
the trunking. Then, fit the signalisation front of the floor control boards of the
wiring in front of them. signalisation wiring.

The additional landing door contact

plugs of the safety chain must be
overconnected. Refer to the delivery
documents.

1017276.wmf

6 Fix the elevator shaft cables using

cable ties inside the trunking.

7 Connect the additional power supply See shaft wiring diagram.

cable at the intermediate floor level if
applicable.
8 Continue installation until the lowest
landing floor.
9 Lower the remaining pit wiring down to
the pit.

© 2005 KONE Corporation 264 (453) AM-01.01.084

24.3.2 Installation of the trunking and elevator shaft bundle wiring

Step Action Note

1 Put the trunking against the wall. 3 tabs / 2 m trunking
Drill 8 mm holes for the fixing tabs
through the trunking.
2 Push the tabs into the holes.
3 Fit a cable tie in the end of the tab.
4 Drill holes for the cable fixings for the
signalling cables.
The maximum distance between two
fixings is 250 mm.
If there is a rear side door, drill the
holes for that at the same height as for
the front side door.

5 Open the cable entries for signalling

and lock cables.
The floor boards are fitted to the shaft
bundle.

Route the shaft bundle wires behind the

floor board.

In case of through-type car, check the

jumper (X1) setting on the board.

1030103.wmf
6 Drill holes for the elevator shaft light Refer to the layout drawing.
fixings.
7 Continue fixing the elevator shaft
lighting and cables while going
downwards in the elevator shaft.

© 2005 KONE Corporation 265 (453) AM-01.01.084

24.3.3 Installing shaft bundle

Step Action Note

1 Install the safety chain shaft bundles
first on the bottom of the trunking.
2 Install the safety chain socket for the
top landing door lock in the trunking at
height of the topmost landing door top
track.
3 Unwind the door lock cable, fix it to the
wall and connect to the safety chain
socket.

4 Secure the bundle to the fixing tabs

with cable ties.

© 2005 KONE Corporation 266 (453) AM-01.01.084

24.3.4 Routing elevator shaft wiring

Step Action Note

1 Route the signalling cables for the
signalling devices at the landings.

1030104.wmf

2 Route the signalling cables to the floor

control boards.
3 Connect the optional signalling devices In case of through-type elevator, check
to the floor control board. (Refer to the that you connect the C-side door cable
delivery documents.) to correct floor control board. The pre-
setted side selection jumper (FRONT or
REAR) on the floor control board is
same as the side of each signalling
device.
4 Move the car downwards to suitable
working height for each floor.
5 Continue installing of the safety chain
shaft bundles, signalling shaft bundle
and elevator shaft lighting and cables
for each floor.
6 Keep the safety chain shaft bundles
under the plastic protections of the
signalling network floor control boards.

WARNING!The board must not touch

the high voltage wires.

© 2005 KONE Corporation 267 (453) AM-01.01.084

24.4 (OSS) out of service switch and (OSI) out of service indication at landing

Step Action Note

1 Route the cable to the LCEFCB board Fix the cable like other signalling cables
in the shaft bundle. for the landing devices.

1030105.wmf
2 Connect the OSS switch cable to the In case of through-type car, check that
XF3 connector and the indication unit you connect the cable to the correct floor
cable to the XF4 connector on the control board. The side selection jumper
LCEFCB floor control board. (FRONT side or REAR side) is pre-
setted.

24.5 (PRL) priority landing call cables

Step Action Note

1 Route the cable to the separate Fix the cable like other signalling cables
LCEFOB board in the shaft bundle. for the landing devices.
2 Connect the cable to the XF9 connector In case of through-type car, check that
on the LCEFOB floor control board. you connect the cable to correct floor
This board is 0.5 metres above or control board. The side selection jumper
below the normal floor control board. (FRONT side or REAR side) is pre-
setted.

© 2005 KONE Corporation 268 (453) AM-01.01.084

24.6 (FRD) fireman’s drive switch cables from landings

Step Action Note

1 Route the cable to the trunking and in
the trunking up to the control panel.
2 Connect the cable to the X5 connector For the correct pins refer to the circuit
on the LCEOPT board in the control diagrams. Remove the jumpers when
panel. connecting the cable.

NOTE! For more options refer to the delivery documents.

24.7 Optional devices in the machine room

Step Action Note

1 Fix the Emergency Battery Drive unit Refer to the AM-13.30.008 for further
on the machine room wall. information.
2 Fix the option connection box (if Refer to the delivery documents.
applicable) on the wall.

© 2005 KONE Corporation 269 (453) AM-01.01.084

24.8 Installation in the pit

1030099.wmf

Step Action Note

1 Drill holes for the cable fixing for the The maximum distance between two
tension weight switch, pit stop switch fixings is 250 mm.
and additional pit equipment (if
applicable) in the elevator shaft pit. Install the buffers cable inside the
conduit to protect the cables.
2 Install the lowest elevator shaft light unit
0.5 metre above the pit floor.
3 Install the lighting switch maximum
0.6 metre above the height of the
landing sill.
4 Connect the tension weight contact
cable, if not preconnected.
5 Fix the cable and connect to the shaft The maximum distance between two
bundle. fixings is 250 mm.
6 Install the pit stop switch on the
elevator shaft wall maximum 0.6 metre
above the height of the lowest landing
sill.
7 Fix the cables and connect to the shaft
bundle.
8 Fix the intercom socket to the elevator Refer to the delivery documents for the
shaft wall if applicable. location and connections.

© 2005 KONE Corporation 270 (453) AM-01.01.084

25 SIGNALLING DEVICES AT LANDINGS (KDS)

Refer to the AM-12.20.007-CHN, AM-12.20.008-CHN or AM-12.20.009-CHN, KONE

signalisation system (KDS) installation.

© 2005 KONE Corporation 271 (453) AM-01.01.084

26 CAR ELECTRIFICATION, EURECA CAR

NOTE! Clear the unnecessary tools and materials from the car roof.
Check the location and number of the car roof devices in the delivery documents. The main
principle is shown in the layout picture.

26.1 Install the magnet switches on top of the car roof

Switch Magnet strip and number Magnet fixing

61:U and 61:N car position 120 mm long magnet for each Single car guide rail
switches level
30 Door zone switch, front 270 mm long magnet for each Single car guide rail
side front door
B30 Door zone switch, rear 270 mm long magnet for each Separate bracket on the
side rear door single guide rail
77:U Deceleration switch, 80 mm long magnet at the top Machine side guide rail
upwards part of the elevator shaft
77:N Deceleration switch, 80 mm long magnet at the Machine side guide rail
downwards bottom part of the elevator shaft
77:S Synchronisation switch, 80 mm long magnet between Separate bracket on the
if 77:N is not between the the lowest and second lowest single guide rail opposite
lowest and second lowest floor and another 80 mm long side to final limit switch
floor or if 77:U is not magnet between the topmost
between the topmost and and second topmost floor.
second topmost floor.

30
61:U, 61:N
B30 2
51
77:S 77:N
30
61:U, 61:N
1 Shaft bundle B30
2 Trap door contact (option) 77:U
3 Car top connection box 6
3 4 5
4 Door operator 1
5 Photo cell amplifier / COL
amplifier
6 Travelling cable
a1183am.wmf

© 2005 KONE Corporation 272 (453) AM-01.01.084

26.2 Installing the car top connection box

Step Action Note

1 Drill two 6 mm holes for the cable ties
with clearance of the travelling cable
width.
2 Route the travelling cables and the
safety gear switch cable up to the car
roof.
Route also the alarm button cable from
the bottom of the car up to the kick
plate side and down to the COP.
3 Fix the travelling cable to the kick plate
so that the length of the larger cable
inside the car top connection box is 440
mm and the smaller cable 380 mm.
Tie the travelling cable as a loop over
the kick plate so that it will not be
damaged against the sharp edges.
1007448.wmf

4 Fix the car top connection box to the Use self-tapping screws.
car roof.
Locate the car top connection box on Leave at least 40 mm clearance
the front side of the car roof opposite to between the securing pin of the hoist
the machine. and the car top connection box so that
you can remove the hoist from the car
roof.

≥4
0

1007447.wmf

© 2005 KONE Corporation 273 (453) AM-01.01.084

Step Action Note

5 Connect the travelling cables to the car Refer to the markings on the plugs.
top connection board.
LCECCEB KNXRIF

LCECCB

1007449-1.wmf
1007450.wmf

6 Connect the earth wires to the earth bar Ensure the connection tightness.
in side the car top connection box.

26.3 Install the electrification on the car roof

1
77:N
77:U

1
77:S
61:U
30
61:N

51
30
61:U
a1184c3.wmf
B30
61:N

© 2005 KONE Corporation 274 (453) AM-01.01.084

1. Oil lubricator

Step Action Note

1 Fix the oil lubricators to the switch
brackets.
2 Fit the final limit switch to the switch Refer to the layout drawings.
bracket.
Adjust the roller so that the minimum
distance between the edge of the roller
and back of the guide rail is 10 mm.

min. 10mm

1007479.wmf

3 Fit the following switches to the switch Set the distance between the car
bracket beside the final limit switch. position switches 61:U and 61:N to 130
• front side door zone switch 30 mm to ensure the correct levelling.
(and B30 if there is also a rear CAUTION!Handle the switches with
door)
care.
• car position switches 61:U and
61:N
• synchronisation switch 77:S (if it
is delivered)
4 Fit the deceleration switches 77:U and
77:U on the machine side of the car.
5 Route the cables along the kick plates
of the balustrades and the channel on
top of the structural ring to the car top
connection box and tie them using
cable ties.
6 Route the safety gear contact cable Pass the cable inside the profile of the
and car bottom alarm button up to the structural ring and secure with cable ties.
car roof.
7 Route the COP cables up to the car
roof and alarm button cables down to
the COP.
8 Route the cable of the trap door to the
car top connection box.
9 Install the KONEXION equipment on Refer to appendices.
the car roof.

© 2005 KONE Corporation 275 (453) AM-01.01.084

26.4 Connect into the car top connection box

Step Action Note

1 Connect the earth wires to the earth
bar.
2 Connect the car position switches.
3 Connect the door zone switch(es).
4 Connect the deceleration switch.
5 Connect the synchronisation switch, if
any.
6 Connect the final limit switch.
7 Connect the door operator cables.
8 Bring the COP cables up to the car roof
and connect to the car top connection
board.
Route the cable of the second COP (if
any) to the normal COP.
9 Connect the photo cell or curtain of light
cables.
10 Connect the safety gear contact cable
and all other possible safety chain
cables.
11 Connect the trap door contact cable.
12 Connect the ventilation and car lighting,
all the optional cables.

26.5 Install the provision for lift announcer

Step Action Note

1 Fix LCEOPT board in plastic box on the For further details refer to delivery
car roof. documents.
2 Route the cable from COP to LCEOPT-
board.

© 2005 KONE Corporation 276 (453) AM-01.01.084

26.6 Install the intercom socket on the car roof

Step Action Note

1 Fix the intercom socket to the car roof
with the self tapping screws that are
delivered with the socket.
2 Route the cable to the car top
connection box.
3 Connect the cable to the connector Refer to the delivery documents.
XB9 on the LCECCB board.

© 2005 KONE Corporation 277 (453) AM-01.01.084

26.7 Connectors on LCECCB board

LCECCB board
XB1 - Final limit switch 51
XB2 - Safety gear contact 52
XB3 - Inspection station 42
FAIL 24V OK BATTERY OK
XB4 - Rear door button B41 XB21 P1 XB1
30 L3 L1 L8 L2
XB5 - Safety lock 63 L11 BATTERY
XB22 51
XB6 - Trap door 57 61U
FUSE F2 OK
L12 XB11
XB7 - Door contact front side 87 XB23 INSULATION XB2
61N L13 TEST
XB8 - Door contact rear side B87 XB12 52
XB24
XB11 - Insulation test B30 L14
24 V 42
XB3
XB12 - Inspection station 24 VDC signals XB25 XB13
77U L15
42 XB26 230 V 42
77N L16 45 230V
XB13 - 230 VAC plug 45 XB27 XB14
77S L17
XB14 - Car light 44 XB28
LIGHT 44
XB4
XB15 - Car ventilation 43 84 XB15 B41
A DOOR FAN 43
XB16 - Front door power supply
XB29 XB5
XB17 - Rear door power supply 90
A PHOTOCELL
XB16
DOOR A 63
XB18 - To Car Operating Panel XB30 230V
XB6
XB21 - Door zone switch front side 30 B84 XB17
B DOOR DOOR B
XB22 - Car position switch upwards 61:U XB31
230V 57
B90
XB23 - Car position switch downwards B PHOTOCELL XB7
XB32
61:N 227 LCECCB
BATTERY 713713 H05
87
XB24 - Door zone switch rear side B30
XB25 - Deceleration switch, upwards XB34 44:2
EM. LIGHT
XB8

77:U XB35 XB18 XT3 XT4 B87

65 COP
XB26 - Deceleration switch, downwards ALARM BELL XT1 XB33
XT2 XB9
77:N
XB27 - Synchronisation switch 77:S KONEXION
1010458.wmf
XB28 - Door operator front side 84
XB29 - Photocell front side 90
XB30 - Door operator rear side B84
XB31 - Photocell rear side B90
XB32 - Battery 227
XB33 - KoneXion
XB34 - Emergency lighting for car roof
XB35 - Alarm bell 65
XT1, XT2, XT3, XT4 - Travelling cables

© 2005 KONE Corporation 278 (453) AM-01.01.084

26.8 Curtain of light

Refer to AM-03.17.011 for more detailed information.

26.8.1 Fixing the curtain of light

Step Action Note

1 Fix both detector parts (the transmitter For railing type 2 when LL=700, 750 or
and the receiver) to the opposite ends 850 mm, cut off a piece from the fixing
of the sill. bracket.
Railing 1:
HH+254

5 2
94.5

0
L+1 CL
L
1
1011158-1.wmf

1. Buffer

© 2005 KONE Corporation 279 (453) AM-01.01.084

Step Action Note

Railing 2, centre opening door:

LL=700...850 LL=900...1100

5
LL+8 / LL+15

64.5
+8 5
LL +1
LL
CL CL 1011159.wmf

© 2005 KONE Corporation 280 (453) AM-01.01.084

Step Action Note

2 Adjust the detectors in vertical position
in both directions.

HL=
2100mm

HL=
2000mm

6mm
1
1011161.wmf

1027471.wmf

1041530.wmf

3 Check the running clearance of the Minimum running clearance:

detectors at each landing. • 10 mm to landing door
Inspect the running clearance visually • 25 mm to wall
at top and bottom of the elevator shaft.

© 2005 KONE Corporation 281 (453) AM-01.01.084

26.9 Routing the cables of the curtain of light

1011168.wmf

1. Cable tie
2. Cable behind the operator

Step Action Note

1 Route the cables to the car roof. Avoid tight bends and sharp edges. Do
not over tighten the cable fixings.
2 Fix the cables properly using cable ties. Ensure that cables do not hit any moving
Fixing accessories are supplied in the objects (for example door panels,
plastic bag. landing doors)

26.9.1 Connecting the cables

Step Action Note

1 Connect the cables direct to the
terminals in the door operator board.

© 2005 KONE Corporation 282 (453) AM-01.01.084

Step Action Note

45
44 X15
46

49
47 X16
48 X16 X15
1

3
4 5
X15 X16
TX RX
1011198.wmf

1. Drive 1
2. Drive 2
3. Car
4. Transmitter
5. Receiver
2 Set the DIP switches.

1 on off
3 on off
2
1011174.wmf

1. Receiver lens
2. Pos. 1. Overconnection of
single beam
3. Pos. 2. Set this to ON

© 2005 KONE Corporation 283 (453) AM-01.01.084

26.10 Install the ramps and magnets (driving up)

2 5...10 mm 3 4

77:S
77:U

**
*
30
61:U
=

1
77:S
77:N
=

61:N 2

**
*

1010459-2.wmf

1. Floor level
2. Bottom ends at the same level

Step Action Note

1 Fit the limit switch ramps. The switch should start to operate when
the car is 80... 120 mm below the lowest
floor level or 80... 120 mm above the top
floor level.
1
The electrical contacts of the limit switch
80...120 mm

must break before the car or

counterweight contacts the buffer.

1010460.wmf

1. Final limit switch position,

when the car is at the
bottom floor level

© 2005 KONE Corporation 284 (453) AM-01.01.084

Step Action Note

2 Place the magnets for car position Magnet positions:
switches 61:N and 61:U and door zone
switch(es) 30 (B30) according to the
vane diagram.
The distance between the switch and
the magnet must be 5...10 mm.
Install magnets for dummy floors (the
floor to floor distance > 5 m).
Place extra 61 magnets for each 5
metre. Equalise the distance between
magnets.

1. Ramp to fix
1 the magnets 1049635.wmf
for the B30-
switch

1010573.w

3 Place the magnets for the deceleration

switches 77:U and 77:N on the guide
(* see vane diagram).
Remember to place the white marked
side of the lower magnet upwards and
the upper magnet downwards. 77:U 77:N
If there are guide rail fixing bolts at the
required area, raise/lower the magnet,
but keep it horizontally in front of the
switch. These bistable magnet switches
have a narrow detection area only at
front of the switch. The magnet must
not be placed closer than 100 mm from
a bolt or guide rail clip, because it may a1184c4.wmf
disturb the deceleration switch.
4 77:S Synchronisation switch is needed,
if 77:N is not between the lowest and
second lowest floor or 77:U is not
between the topmost and second
topmost floor. One switch and two
magnets are required. (** see vane
diagram)

© 2005 KONE Corporation 285 (453) AM-01.01.084

26.11 Wiring of door operator and curtain of light (or photo cell)

Step Action Note

1 Connect the cables on the operator and Refer to the layout drawing.
route the cables outside of the kick
plates to the car top connection box.
Secure the cables with cable ties.

26.12 Options

Step Action Note

1 Acu

1019624.wmf

2 Intercom

© 2005 KONE Corporation 286 (453) AM-01.01.084

27 CAR ELECTRIFICATION, MCD CAR

27.1 Installation under the car

27.1.1 Fixing the travelling cables

Step Action Note

1 Move the car at 100 mm below the
lowest floor level.
2 Check that the travelling cable loops The inner diameter of the loop must be
are correct and the cables are not 400 mm and the min. distance between
twisted. travelling cables 100 mm.
The text on the cable must be in the
outer side of the loop.
3 Move the car 1 metre above the lowest Refer to AM-01.03.003 Take 2.
landing floor and secure the car with
safety gear and parking chain.
4 Fix the travelling cable to the travelling The min. bending radius of the travelling
cable hanger. cable is 30 mm when the cable is fixed.
5 Tie the car cable below the car shell
module trunking with cable ties.
6 Tie the rest of the travelling cable under
the platform using cable ties.
7 Adjust the platform stop screws.
14

1011951.wmf

© 2005 KONE Corporation 287 (453) AM-01.01.084

27.1.2 Load weighing sensor and alarm button

Step Action Note

1 Push cage nuts to D13 mm holes in
floor profiles.

1011955.wmf

2 Fix the angle profile for the load

weighing sensor to the car floor and
position it as central as possible.
Tighten with M8x20 screws and
washers.
3 Fix the sensor to the support plate as shown. Fix the support plate to the rear lower
beam.
1 M8x20
1. Car floor
2. Load
weighing
2 sensor
5
3. Bottom

60...140 mm
beam
-13...71 mm
3 - 5 mm

4. Entrance
side
3 5. Adjustment
plate

4
1029850.wmf

4 Fix the object plate to the angle profile.

5 Put a 5 mm thick adjustment plate Ensure that there is a 3-5 mm gap
between the sensor and the measuring after final decoration.
plate. Adjust and tighten the screws. Horizontal distance from the measuring
Remove the adjustment plate and store head of sensor to any other metal
it for readjustments. surfaces must be more than 40 mm.
Distance to synchronization lever must
be at least 15 mm.

© 2005 KONE Corporation 288 (453) AM-01.01.084

Step Action Note

6 Route the load weighing sensor cable
to the trunking (on the car wall) and fix
the cable to the sling lower beam using
cable ties.

1017849.wmf

7 Install the alarm button to the bottom of

the car to the same side as the pit
ladders.
8 Route the alarm button cable to the
trunking (on the car wall).
9 Route the safety gear contact cable to
the trunking.
10 Route the load weighing device, safety
gear contact and alarm button cables
inside the trunking to the car roof. 1017850.wmf

27.2 Car operating panel installation

Step Action Note

1 Install the car operating panel. For KONE signalisation system (KDS)
type car operating panel refer to
AM-12.20.007-CHN or
AM-12.20.008-CHN.
2 Route the cables to the car top
connection box.

© 2005 KONE Corporation 289 (453) AM-01.01.084

27.3 Magnet switches, oscillators and final limit switch on the car roof

(Refer to the layout drawing.)

1. Deceleration switch
(77:U)
2. Deceleration switch
(77:N)
1
3. Synchronisation switch
2 3
(77:S)
4. Oscillator bracket
4
5. Impulse switch (61:N) 5
8
7 9
6. Impulse switch (61:U)
6
7. Door zone switch (30)

8. Door zone switch (B30) 10

9. Magnets for deceleration
switches (fitted to guide rail) 11

10. Final limit switch (51)

11. Oscillator vanes

(fitted to guide rail) 12
12. Final limit switch ramp
(fitted to guide rail)

1029851.wmf

© 2005 KONE Corporation 290 (453) AM-01.01.084

Step Action Note

1 Position the oscillator bracket to the c-
profile on top of the car (refer to the
layout drawing).
==

30
- 35
mm

1018076.wmf
2 Install the deceleration switches (77:U,
77:N) to the sling upright (refer to the
shaft vane diagram).

Install the synchronization switch (77:S)

(if applicable) to the sling upright (refer

5...10mm

5...10mm
to the shaft vane diagram).

1018077.wmf

3 Install the final limit switch to the c-

profile on top of the car (refer to the
layout drawing)
4 Install the final limit switch ramp.
=
=

20 1018078.wmf

© 2005 KONE Corporation 291 (453) AM-01.01.084

Step Action Note

5 Bend the vanes of the base plate. Bend Refer to the shaft vane diagram.
the separate vane and fix it to the base
plate.

1018930.wmf

Vane levelling principle (* Refer to the shaft vane diagram, ** Only used when
through-type car)

61:U
61:U

30
B30 30
130 mm

B30

61:N

1018931.wmf

6 Install the magnets. Refer to the shaft vane diagram.

© 2005 KONE Corporation 292 (453) AM-01.01.084

27.4 Connections in the car top connection box

Step Action
1 Connect the earth wires to the earth bar.
2 Connect the final limit switch to the LCECCB board.
3 Connect the safety gear contact cable to the LCECCB board.
4 Connect the load weighing sensor cable to the LCECCEB board.
5 Connect the trap door contact cable to the LCECCB board if applicable.
6 Connect the car ladder contact cable to the LCECCB board if applicable.
7 Connect the slack rope switch to the LCECCB board if applicable.
8 Connect the fan cable to the LCECCB board if applicable.
9 Connect the rear side stop switch to the LCECCB board if applicable.

LCECCEB board
XB50 - load weighing device
XT11 - travelling cable

1029854.wmf

© 2005 KONE Corporation 293 (453) AM-01.01.084

LCECCB board
XB1 - final limit switch FAIL 24V OK BATTERY OK
XB21 P1 XB1
XB2 - safety gear contact L3 L1 L8 L2
30
XB4 - stop switch, rear side XB22
L11 BATTERY 51
FUSE F2 OK
XB15 - fan 61U L12 XB11
INSULATION XB2
XB5 - slack rope switch, car XB23
TEST
61N L13
ladder XB12 52
XB24
XB6 - trap door B30 L14
24 V 42

XT1, XT2, XT3, XT4 - XB25 XB13

XB3

travelling cables 77U L15

XB26 230 V 42
77N L16 45 230V
XB27 XB14
77S L17 LIGHT 44
XB28 XB4

84 XB15 B41
A DOOR FAN 43
XB29 XB5
90 XB16
A PHOTOCELL DOOR A 63
XB30 230V
B84 XB17 XB6
B DOOR DOOR B
230V 57
XB31
B90
B PHOTOCELL XB7
XB32 227
BATTERY
LCECCB 87
713713 H05

XB34 44:2 XB8

EM. LIGHT
XB35 XB18 XT3 XT4 B87
65 COP
ALARM BELL XT1 XT2 XB33 XB9

KONEXION
1029853.wmf

27.5 Final adjustment of magnets, oscillator vanes and final limit switch
ramps

Step Action Note

1 Position the car exactly to the floor level Refer to the shaft vane diagram.
and adjust oscillator vanes to the
correct height.
2 Adjust the magnets.
3 Adjust the ramps of the final limit switch
(XB1).

© 2005 KONE Corporation 294 (453) AM-01.01.084

28 INITIAL COMMISSIONING OF THE MACHINE (WITHOUT ROPES), V3F25S

Refer to AM-11.65.020 delivered with the control panel.

Pay special attention when working on the car roof if there are live electrical parts in your
working area. Refer to AM-01.03.002 "Take 5 - Electrical safety when working on elevators".
The following 5 steps must be taken in the specified order unless there are essential reasons
for doing otherwise:
Take 5 steps to ensure electrical safety:
1. Disconnect power supply completely.
2. Secure power supply against re-connection.
3. Verify that the installation is de-energised.
4. Check the requirements for earthing in special circumstances. (This operation may only
be carried out by qualified personnel in co-operation with the person responsible for the
building electrification who must ensure that the technique can be safely employed in this
situation.)
5. Provide protection against adjacent live parts.

28.1 Health and safety at work

Mandatory Note
Follow your local National Elevator Codes If there is a conflict between the Code and
and Regulations. these commissioning instructions, follow
your local regulations.
Be extremely careful when working with the There are high voltages in the main circuit
electrical components and their enclosures. capacitors (>500 VDC), on the inverter
Refer to AM-01.03.002 Take 5. board, in the safety chain and inside the
control panel.
Inverter drives remain energised for about 5 minutes after the power has been
disconnected. DO NOT work on the drive, hoisting motor or braking resistors until you
have verified that this energy has been discharged.

Test equipment must be set to the 1000 V DC range. The test equipment must be checked
before and after the test to ensure it functions correctly.
While the LED DANGER is ON on the inverter board, there are high voltages in the drive
module.
When making electrical connection in the Car light and power socket are not
car, the power must be turned OFF from the controlled by the main switch. These
main switch and car light supply. circuits have their own supplies.
Refer to AM-01.03.002 Take 5.

© 2005 KONE Corporation 295 (453) AM-01.01.084

28.2 Check list

Before starting the commissioning for installation drive check that the following things have
been done:
1. Ensure that there is NO POWER in the control panel (the main switch is in OFF-position).
2. Machine room equipment (main supply L1, L2, L3, N and PE, motor supply wires and
shield, fan cable, brake cable, thermistor cable, resolver cable, tachometer cable) are
installed and connected according the wiring diagrams. These diagrams are delivered
with the control panel.
3. All connections are tightened.
4. Machine brakes are adjusted and the operation is checked.
5. Overspeed governor is installed, roped, connected and rotation direction checked.
6. Landing entrance safety barriers are in place.
7. All installation items as described in the previous chapters are completed.
8. Buffers are installed. Oil levels are checked.
9. Car top connection box is installed and service drive unit is connected.
10.Travelling cables are installed and connected to both the car top connection box and the
controller.
11.All connections are done according to the delivery documents.
12.Safety gear is installed and adjusted. Refer to the document delivered with the sling.
Safety gear contact 52 is installed and connected.
13.Car emergency exit door contact pos. 57, (if applicable), is installed and connected.
14.Final limit switch 51 on the car roof is installed and connected.
15.Car roof and machine room stop buttons and the stop button under the car and in the pit
are installed and operate correctly.
16.Load weighing sensor is installed and connected to the LCECCBN board in the car top
connection box.
17.There is nothing leaning against the traction sheave.
18.The elevator is not roped yet.
19.Cables are connected and covers of the panels and boxes are closed.

28.3 Connecting supply cable(s) from building

Step Action Note

1 Connect the supply cable from building
to main switch unit.

© 2005 KONE Corporation 296 (453) AM-01.01.084

28.4 Tests and checks when driving the motor for the first time with RDF

NOTE! These checks must be performed using RDF, not car top control buttons.

Step Action
1 Check the safety chain operation using RDF. Activate one at a time.
Push RDF RUN button after every activation and check that the SAFETY INPUT
LED on the user interface remains OFF. This means that the safety chain is broken.
1. Stop button in the service drive unit and any additional buttons on the car
roof or below the car
2. Ladder contact (if applicable) on the car roof
3. Emergency exit contact (if applicable) on the car roof
4. Control panel stop button in the machine room
5. Other stop buttons (if applicable) in the machine room
6. Slack rope contact (if applicable) at the rope fixing
7. Maintenance door contact (if applicable)

28.5 Motor first drive

WARNING
The first run must always be made from the control panel. Car light is not controlled by the
main switch. It has separate switch.

28.5.1 Setting the RDF and overspeed governor ready for the first drive

Step Action Note

1 Ensure that the POWER IS OFF. (Main
switch and car light are in 0-position).

2 Turn the RDF ON.

3 Turn the service drive switch on the car
roof to NORMAL.
4 Check the connections of tachometer, Refer to the AM-11.65.020.
resolver and load weighing device.

© 2005 KONE Corporation 297 (453) AM-01.01.084

28.5.2 Turning the power ON

Step Action Note

1 Unlock the main switch unit and turn
the power ON.
2 Turn power ON from main switch unit.
WARNING!Do not turn the car light
main switch ON.
3 Check that LEDs turn ON. Refer to the APPENDIX in the end of this
manual.
4 Push RDF RUN button and check that Refer to the APPENDIX in the end of this
the SAFETY INPUT LED turns ON. manual.
When the LED is ON, the safety chain
is unbroken.
WARNING!Do not push direction
buttons.

28.5.3 Drive commissioning

Step Action Note

1 Continue by following the instructions in • Setting parameters
the AM-11.65.020. • Setting the input information
• Initial setting of the resolver angle

28.6 Tests and checks when driving the motor for the first time on inspection
drive

Step Action Note

1 Turn the Service Drive switch on the
car roof to the inspection position.
2 Turn the RDF OFF. RDF overbridges certain switches in the
safety chain.

© 2005 KONE Corporation 298 (453) AM-01.01.084

Step Action Note

3 Activate one at a time. From the car roof, check that the motor does not rotate after
each activation. Check also at the controller that the safety input LED is OFF. This
means that the safety chain is broken.
1. Final limit switch on the car roof
2. Safety gear contact under the elevator car
3. Car overspeed governor contact
4. Counterweight overspeed governor contact (if any)
5. Stop button in the service drive unit and any additional buttons on the car
roof or below the car
6. Ladder contact (if any) on the car roof
7. Emergency exit contact (if any) on the car roof
8. Control panel stop button in the machine room
9. Other stop buttons (if any) in the machine room
10.Slack rope contact (if any) at the rope fixing
11.Maintenance door contact (if any)
4 Check the operation of the service drive
unit buttons on the car roof.
Press each direction button and see
that the corresponding LED is lit in the
controller.
5 Turn the power OFF from the main
switch unit.

Lock the main switches in OFF position

using your personal pad lock.

OT
DO N CH
SWIT
1017329.wmf ON

© 2005 KONE Corporation 299 (453) AM-01.01.084

29 INITIAL COMMISSIONING OF THE MACHINE (WITHOUT ROPES), KDL16

For KDL16, refer to AM-11.65.041 delivered with the control panel.

© 2005 KONE Corporation 300 (453) AM-01.01.084

30 INITIAL COMMISSIONING OF THE MACHINE (WITHOUT ROPES), KDL32

For KDL32, refer to AM-11.65.029 delivered with the control panel.

© 2005 KONE Corporation 301 (453) AM-01.01.084

31 ROPING

NOTE! Refer to Appendix E for the roping method of high rise lift (rise > 120 m).

31.1 Roping principle

KONE 3000S MiniSpace™ with side KONE 3000X MiniSpace™

counterweight

2
4

1
3
6 5

1
2
3
4
5
6

1
32
6 54

1
23
4 56 8000190(2008-08)

KONE 3000S MiniSpace™ with rear counterweight

2
4
6

1
3
5

5
3
1

6
4
2

1
2
3
4
5
6

12
3 45
6

8000342(2008-08)

31.2 Preparations in the machine room

Step Action Note

1 Dismantle the rope bottles from the Leave the top securing pins, nuts,
rope hitch on the rope fixings. washers and springs in the machine
room.

31.3 Attaching the compensation chain under the Eureca car (optional)

Step Action Note

1 Check the suspension points *) from
the layout drawing. *

1052mi1.wmf

2 Drive the car down. Install the compensation chain hanger to the pre-drilled holes.

1052mi2.wmf

3 Install the compensation chain to the Expose at least one free link of the chain
hanger under the car. at the fixing point.
Fix the securing rope to the hanger.

1052mi3.wmf

31.4 Roping for SMiniSpace with side counterweight and XMiniSpace

31.4.1 Routing the ropes under the car

Step Action Note

1 Position the car so that the pit can be Mind the toe guard support brackets
accessed and the bottom pulleys when entering or leaving the pit.
reached from the pit
2 Engage the safety gear.
3 Place rope coil/drum on the car roof
4 Lower the free rope end down at the
machine side of the car.
5 Pass the rope round the diverter
pulleys under the car.
*
6 Lift the rope end back to the car roof
using a lifting rope.
*
Ensure that the rope end is long
enough to reach the anchorage in the
machine room (min. 3 m).
7 Tie the rope end to the balustrade using
cable ties (*), so that the rope cannot
run away or interfere with elevator shaft
components while driving up.

a1185a6.wmf

1039631.wmf

8 Tie the rope to the balustrade on the

other side. Secure the rope coils using
cable ties, if needed.
9 Repeat steps 3-8 for all other ropes.
10 Ensure that all rope guards are fitted
and adjusted.

The rope guards are required to keep

the ropes in place during roping.

1039632.wmf

31.4.2 Positioning car for roping

Step Action Note

1 Position the car sill about 1.0 m below Ensure safe access to the landing.
the topmost floor.
2 Tie pulley back to frame using large
cable ties.
3 Open the front plate of the
counterweight diverter pulley to prepare
for the roping.

1039722.wmf

31.4.3 Routing the ropes to the counterweight pulley

NOTE! During the following steps one fitter is on the car roof and the other is in the machine
room.

Step Action Note

1 Remove the rope coils/drums from the
car roof to the topmost landing.
2 Fix the free end of the rope to the rope
anchorage at the car side in the
machine room.
3 Make a loop of the other end and send
it to the machine room through the rope
hole (A). A
B
4 Pass the rope loop over the traction
sheave and lower it through the hole
(B).
5 Fix the rope into the rope hitch at the
counterweight side.

1038731.wmf

6 Continue to lower the rope as a loop

down to the counterweight.

In high travels, due to the weight of the

rope, the rope should be lowered
attached to rope clamp and material
hoist, which will prevent it from
escaping and can be used to pull it up
again.

1038732.wmf

31.4.4 Roping the counterweight pulley

Step Action Note

1 Go to the pit after all the ropes are
lowered.
2 Set the ropes around the diverter pulley Select the groove in accordance with the
on top of the counterweight. roping principle described in section
3 Re-install the rope guards and close 27.1.
the diverter pulley.

1038734.wmf

4 Fix the loose rope ends to the rope

anchorage on the machine side.

31.5 Roping for SMiniSpace with rear counterweight

NOTE! Repeat the following steps for each rope.

31.5.1 Routing ropes above the car

Step Action Note

1 Position the car sill 1.0 m below the
topmost floor.

Step Action Note

2 Place rope coil/drum on the car roof.
3 Pass the rope round the diverter
pulleys.
4 Lift the rope end back and fix it into the
car rope anchorage.

8000343.wmf

5 Ensure that all rope guards are fitted The rope guards are required to keep
and adjusted. the ropes in place during roping.

1039632.wmf

31.5.2 Routing the ropes to the counterweight pulley

NOTE! During the following steps one fitter is on the car roof and the other is in the machine
room.

Step Action Note

1 Tie counterweight pulley back to frame
using large cable ties.
2 Open the front plate of the
counterweight diverter pulley to prepare
for the roping.

1039722.wmf

Step Action Note

3 Move the rope coils/drums from the car
roof to the topmost landing.
4 Remove the moter rope guard.

Make a loop of the other end and send

it to the machine room through the
motor rope hole (A).
5 Pass the rope loop over the traction B
A
sheave and lower it through the motor
rope hole (B).
6 Fix the rope end into the rope
anchorage at the counterweight side.

8000192.wmf

7 Continue to lower the rope as a loop

down to the counterweight.

In high travels, due to the weight of the

rope, the rope should be lowered
attached to rope clamp and material
hoist, which will prevent it from
escaping and can be used to pull it up
again.

1038732.wmf

31.5.3 Roping the counterweight pulley

Step Action Note

1038734.wmf

4 Fix the loose rope ends to the rope

anchorage on the machine side.

31.6 Lifting the counterweight frame

WARNING
Ensure that there are no loose tools or equipment on car top.

Step Action Note

1 Lift the counterweight up by lowering Open the MX machinery brake using the
the car. brake lever during travel.
If the car does not move down because
the counterweight is heavier than the car
(for example due to uninstalled car
finishes), add weight to the car. This is to
ensure that the car is slightly heavier.
2 Engage the safety gear.
3 Place two pit props under the WARNING!Do not work under a
counterweight. suspended load.
Pack out the side of the guide rail blade
using suitable pieces of timber
(minimum length 1.5 m).
Secure the pit prop to guide rail using
two G-clamps.

Alternatively:
If the counterweight guide rails are solid
type the counterweight can be secured
up for roping using two guide rail 40%
clamps.

1030251.wmf

4 Carefully lower the counterweight in

small increments using the brake.
Ensure there is no shock load onto the
prop.

31.7 Shortening the ropes

Step Action Note

1 Calculate the car position X2 for
shortening the ropes.

X2 = X1 - 50 mm* - B - A

X2 = Car position below the topmost

2m
X1
landing
X1 = Distance between the buffer and

X2
the counterweight spacer

A
* = Spring compression of the rope
hitch (car and counterweight on the
ropes) + clearances in the wedge
housing of the rope hitch + rope slack 1030252.wmf
B = Rope stretch, length of one
suspension rope metre x 1 mm
A = Overtravel (see layout drawing)
2 Drive the car in 300 mm steps upwards.
Retighten the ropes after each drive.
3 Drive the car upwards until the car sill is
at the calculated height below the
landing sill.
4 Tighten the ropes.
5 Secure the rope fixings.
6 Drive the car downwards so that the Check that the overtravel distance is
counterweight is lifted up from the pit according to the layout drawings.
prop or guide clamps.
7 Remove the pit prop or guide clamps
from the counterweight guide rails.
8 Cut off the excess rope length.

P08000041.wmf

31.8 Attaching the compensation chain to the counterweight

Step Action Note

1 Cut the compensation chain to the
correct length.
2 Install the chain to the fixing under the
counterweight.
3 Check that the distance from the chain
to the pit floor is min. 200 mm. Check
that the chain is not twisted.

≥ 200
1048386.wmf

Step Action Note

4 Install the compensation chain guides. When installing the guides the car and
the counterweight must be located in the
halfway of the elevator shaft length. The
guides must be located so that the cable
hangs freely between the rollers. The
distance of the guides to the pit floor
must be according to layout drawings.

X L
200 (min. 100)

a1143ga.wmf

1033260.wmf

5 Check that the guides have enough

clearance when the car and
counterweight are on compressed
buffers.

31.9 Finalising the roping

Step Action Note

1 Secure the rope ends with rope grips.
2 Check that the rope grips do not touch
each other.
3 Check the rope bottle springs. Length
of the springs must be equal (±3 mm)
on each rope bottle. Adjust if
necessary.

=
P04000195.wmf

4 Install the split pins to the rope bottles.

5 Fix the slack rope device (if delivered).

1043124.wmf

31.10 Slack rope switch

Step Action Note

1 Check the 3 mm distance at the slack
rope switch.

3mm
1027496.wmf

2 Check the 1.5 mm distance.

±0.5
1.5
3 Adjust the switch position.

~0.5

1027503.wmf

4 Connect the cable to LOP-230 board

inside the maintenance access panel.

LOP-230/XLH3 P153 P121:E

1027518.wmf

32 CAR INTERIOR INSTALLATION, EURECA CAR

32.1 Ceiling

Refer to AM-06.23.008-CHN.

32.2 Mirror and handrails

Step Action Note

1 Fix the lower mirror fixing supports to
the wall panel.
2 Fix adhesive tape to the mirror and peel
the cover of the adhesive tape.

1007251.wmf

3 Align the mark on the mirror with the

fixing support. Place the lower mirror in
position.

4 Fix the handrail brackets to the wall

panel just above the mirror.

Step Action Note

5 Install the upper mirror in the same way
as the lower one. Fix the upper fixings
on the top of the upper mirror.

6 Fit the flooring cover strips.

32.2.1 HR51TR handrails

2-side handrail 3-side handrail

1037709-1.wmf

Step Action Note

1 Detach the fixings from the handrail.

a1126_46.wmf

2 Fix the fixing supports to the car walls. *) Required when B and D walls are not
laminated (two washers per support).
Use the jig (J) to centre the fixings. Do not use washers in C-side supports.

1037710-1.wmf

3 Install the back wall handrail. Place it in centre position between B and
D walls.
= =

1037706-1.wmf

4 For the other side handrail, turn the

handrail fixing tube:

Loosen the securing screw.

Rotate the T-bolt 90° inside the tube.

Detach the fixing tube.

Ensure that the groove of the T-bolt is

on the same side as the securing screw
and fit the fixing tube back upside
down.
a1126_47.wmf

Step Action Note

5 Push the back handrail backwards by
leaning on it.
At the same time, slide the side
handrail to connect it to the wall fixings.
Release the back handrail so that the
side handrail snaps into the end of the *
back handrail.
Tighten the allen screw. 1037714-1.wmf

CAUTION!Do not remove the plastic

protection (*) until the handrails are
completely installed.
6 Install the second side handrail in the
same way, if applicable.
7 Tighten the handrails using the allen
spanner.

1037718-1.wmf

32.3 Skirting installation

Step Action Note

1 Position the skirting against the back
wall centred between the side walls. =
2 Adjust and tape steel caps to the both
ends of the skirting.

1027284-1.wmf

Step Action Note

3 Remove the protection tape from the
upper tape stripe on the back wall
skirting.

a1126_39.wmf

4 Fit the profile onto the wall. Keep the

lower part of the skirting in contact with
the car floor.
5 Fix the skirting to the wall with self-
drilling screws starting from the side
holes.

In scenic car pre-drill the wall. Always

protect the car floor when using a drill.
Use a long extension piece.
1027288.wmf

1027633.wmf

6 Repeat the operation for each wall.

In case of full height COP there will be

two profiles.

1027292-1.wmf

32.4 Handicap seat and the top beam cover

Step Action Note

1 Install the handicap seat.

1007255.wmf

2 Fit the top beam cover in place. The channel under the top beam cover is
used to route cables to the car top
connection box.

1007527.wmf

33 CAR INTERIOR INSTALLATION, MCD CAR

Refer to the delivery documents.

Refer to AM-06.06.012.
For ceiling installation, refer to AM-06.12.008-CHN.
NOTE!Route the fan cable to the hole (1) on the trap door, then pass it through the holes on
roof panel joints to the electrification box on car top.

8000786.wmf

34 CHECKING MACHINE BRAKE AND REMOVING HOIST

34.1 Checking the machine brakes

Step Action Note

1 Check that the machine brakes are Refer to the chapter Brake adjustment.
adjusted and operating correctly.

34.2 Dismantling the hoist from the car

NOTE! The Tirak tension weight was removed from the Tirak rope during the roping phase.

Step Action Note

1 Secure the securing rope hook of the
Tirak diverter pulley to second topmost
guide rail bracket.
2 Tie the gate of the diverter pulley hook
open using a cable tie.

a1184c5.wmf

3 Tighten the brake centre nuts (1) to

open the brakes. Drive the car down
using the Tirak so that the car roof is
about 400 mm above the landing level.

4 Re-adjust the brake centre nuts to Ensure that the washer is not tight. It
engage the brakes. must be free to rotate.

Step Action Note

5 Roll the Tirak rope up on the rope
reeler. Move the rope reeler onto the
landing.
6 Disconnect the hoist hook from the car
and connect it to the hoist body.
Disconnect the Tirak from the car.
7 Drive the hoist out on the landing and
place it on the site trolley.

a1184c6.wmf

8 From the landing remove the Tirak

diverter pulley using the telescopic
pipe.

a1184c7.wmf

9 Detach the securing rope hook of the Use the telescopic pipe to remove the
diverter pulley. hook from above the car guide rail
bracket.

34.3 Changing the temporary installation time overspeed governor to the final
one (OL100)

Step Action Note

1 Drive the car down so that you have
access to the pit.
2 Engage the safety gear and push the
stop button on car roof.

2 Lift overspeed governor tension weight

and place a block of wood underneath
it.
4 Disconnect the rope at the top of the
safety gear rope anchorage.

1043296.wmf

5 In the machine room pull up the rope

and secure it, so that it does not run
back down the elevator shaft.
6 Remove temporary overspeed
governor.
7 Feed the rope onto the final overspeed
governor and back down the elevator
shaft
8 Fix the final overspeed governor.
OL100

Step Action Note

9 Reconnect the rope.

1012131.wmf

10 Remove wood block underneath the

tension weight.
11 Open stop switch on car roof and
release the safety gear.

35 BALANCING

35.1 Balancing the MCD car

Step Action Note

1 Check that the gap between the car
door and the landing door is equal at
top, bottom, left and right.
2 Drive the car to the floor which is
nearest to the mid-point of the elevator
shaft, take a suitable amount of balance
weights with you.
3 Detach the top guide shoe linings.
4 Place the balancing weights onto the
car floor, directly above the fixing
profile.

1018191.wmf

5 The car is balanced, when the guide

shoe bases are loose or touch the rails
to such an extent that the car can be
moved ‘with one finger’.
6 Adjust the weights so that the
corresponding balance is achieved in
DBG and back to front direction.

Step Action Note

7 Refit the guide shoe linings.

1018192.wmf

8 Remove the locking pins from the guide

shoe linings.

1018390.wmf

9 Drive the car down.

10 Transfer the weights to the same
positions at the fixing profile.
11 Fasten the weights to the fixing profile.
Refer to page 331.

1018193.wmf

35.2 Adding extra weights to MCD car sling

Step Action Note

1 Fix extra weights to the car sling.

1036601.wmf

35.3 Balancing car and counterweight

Step Action Note

1 Ensure that the car is empty.
2 From the pit check that the air gap of Refer to 27.1.2 Load weighing sensor
the load weighing device is 3-5 mm. and alarm button on page 288.
3 Drive the car to the middle of the Transport the filler weights on the car
elevator shaft. roof.
4 Put the remaining filler weights into the
counterweight frame from the car roof.
5 Add extra weights to the car to
correspond to 50 % of nominal load.
6 Drive car and counterweight to the
same height in the elevator shaft.

50% Q

1017315.wmf

7 Push the button inwards to release the

handle and open the brake and see if
the car moves.
• The car should not move if car
and counterweight are at same
level.
2

1031763-1.wmf

1. Brake closed
2. Brake fully open
8 Drive the car little upwards with RDF.

Step Action Note

9 Hold the brake open for a while and The car should not move.
check if the car moves.
CAUTION!Be careful while releasing
the brakes. If the car moves, do not
let it over speed.
10 Do the same in the other direction.
11 Add or remove filler weights to the
counterweight frame if necessary.
12 Repeat until you are sure that the car
and counterweight are balanced.

35.4 Counterweight screen

Step Action Note

1 Secure the screen panels using self- *) Cut-out for compensation chain
drilling screws. (210 x 210 mm)

2500 mm

*
cwtscreen.wmf

Step Action Note

In case of rear counterweight, follow
the steps marked with sequence
numbers to install the counterwieght
screen.

1 2

~25
6

6 mm
1043780.wmf

NOTE! For more information, refer to AM-05.02.010.

35.5 Finalising the travelling cable installation

Step Action Note

1 Drive the car 700 mm above the lowest
floor.
2 Isolate the car so that it cannot be
moved (car top stop button).
3 Enter the pit and press the pit stop
button.
≥ 400mm
4 Adjust the height and the loops of the
travelling cables.

1
5 Tie the travelling cable to the platform
using cable ties, so that it is not

100 mm
hanging loose on the car wall.
6 Tie the rest of the travelling cable under
the platform. 2 1034560.wmf

1. Distance between the buffer and car

2. Distance between the buffer
and car /2 +100mm

36 COMMISSIONING, V3F16L

36.1 Health and safety at work

Mandatory Note
Observe the requirements of your national In case of conflict between the Code and
Elevator Regulation Code. the present commissioning instructions, rely
on your Code.
Be extremely careful when working with the There are high voltages:
electric components and their enclosures. • in the main circuit capacitors
Refer to AM-01.03.002 Take 5. (>500 VDC) and on the inverter board
• in the safety chain and inside the
shaft electrification panel (230-
400 VAC)
Inverter drives remain energised for about 5
minutes after the power has been
disconnected. DO NOT work on the drive,
hoisting motor or braking resistors until you
have verified that this energy has been
discharged. Test equipment must be set to
the 1000 V DC range. The test equipment
must be checked before and after the test to
ensure it functions correctly. While the LED
DANGER is ON on the inverter board, there
are high voltages in the drive module.
When making electrical connections in the Car light is not controlled by the main
elevator shaft or in the car, the power must switch 220 in control panel. This circuit
be turned OFF from the main switch (220) has its own switch.
and car light supply (262) in control panel. Refer to AM-01.03.002 Take 5.
No personnel are permitted in the elevator
shaft during this phase.

36.2 Commissioning with construction-time power supply

Step Action Note

1 Check that all other connectors, wires
and cables are connected correctly and
main switch is OFF.
2 Use double sided adhesive tape to fix
battery near the connector XCM.
3 Remove XCM-plug cover and connect XCM
the battery to XCM-connector.
9V

1037985.wmf
Drive module is in construction mode
and residual current device of the lift
supply does not trip.
NOTE! In order to maximise the life of the battery, do not leave the battery plugged into the
drive unit while the lift is not switched on / being commissioned (e.g. overnight).
NOTE! After elevator commissioning (construction-time power supply is replaced with final
power supply), disconnect and remove the battery. Fix XCM-plug cover.

36.3 Commissioning

Before starting the commissioning, check that the following basic things have been done:

Item Done
Tripping speed reducing weights are removed from the overspeed governor.
Elevator shaft installation.
Machine installation.
Car installation.
Car and landing door installation.
Rope installation.
Car and elevator shaft electrification including the signalling devices.
The positioning magnets are installed accurately according to the shaft
diagram.
The installation hoist is removed from the car.

Item Done
Car and counterweight are balanced.
Covers of the electrification panels are placed.
Safety device checks.

WARNING
No people are allowed to be on car roof.

CAUTION
The hoist must be removed from the car, the parking plate should be in position and the
parking bolt must be retracted.

36.3.1 Checking the drive connections

Always ensure that the connections at the drive module are completed correctly.
NOTE! Keep the motor supply cable by a minimum distance of 100 mm from any other
parallel cables (especially tachometer cable). A blinking speed LED (or tachometer
LED) at controller may indicate a poor earthing.
Check that:
• Cables are routed correctly inside the drive module.
• The wires at the connectors are looped to avoid gravity water entering connectors. This is
valid for cables entering the drive module from the top.
• Cables are connected properly:
– no loose connections
– check by pulling the wire
• Connectors are clean.
• Earthings have been done.
• Stress relief is in place. Cables (coming from the lower part of the drive) are secured with
cable ties.
• LCECPU cable connector is locked properly.

1010987-2.wmf

36.3.2 Switching the power on

WARNING
No one is allowed to be on the car roof when driving the car with RDF.

NOTE! V3F16L is a drive type which supports more detailed diagnostic information, called subcodes.
Subcode can be seen by pressing SELECT button when a drive fault (6_101...6_139) is
displayed. Refer to 804611: V3F16L drive fault codes (appendix).

Step Action Note

1 Check that the earth of the main supply This earthing is provided by the builder.
is connected to the main earth of the
building.
2 Check the earth continuity is ensured
between:
• the controller and drive
• the controller and car top
connection box
• the controller and topmost
landing door.
3 Turn the elevator to RDF. RDF over connects final limit switch (51),
safety gear switch (52) and overspeed
governor (127).
4 Turn the Inspection Drive mode on the
car roof to NORMAL.
5 Turn power ON from the main switch
(220).
6 Check that FUSE LEDs on the LOP- Refer to Electrification panels,
230 board turn on. introduction (appendix).

36.3.3 LON protocol

Step Action Note

1 Ensure that the elevator is in RDF
mode.
2 Go to menu 5_7.
3 Press SELECT. With up and down Then the new LON protocol is in
buttons select 1. Press ACCEPT. progress. Various numbers are scrolling
on the user interface. Downloading may
take about 1 - 3 minutes, depending on
the system.

CAUTION!Do not interrupt downloading

by power break, turning elevator to
normal mode, and so on.
Downloading is finished when the
numbers 5_7_1 are continuously on the
user interface.
4 Go to menu 5_8.
5 KSS (KONE Signalisation System): set
the value of parameter (5_8) to 2.
6 Make a power break. Then the elevator is ready for load
weighing device setup and shaft setup.

36.3.4 Setting the drive parameters

Step Action Note

1 Check the drive software version. 6_97, should be version 0.63 or newer.
2 Set number of pole pairs to 0. 6_59, value 0
3 Set other elevator dependent 6_1, according to machine type (see
parameters. Motor parameters on page 342)
6_2, according to rated speed
6_3, according to elevator load
4 Save parameters to permanent 6_99, value 1
memory.
5 Switch power OFF and ON.
6 Verify parameters. Check parameters 6_1…6_3.

Motor parameters (normally used machine types)

Note the machine label marking. For example MX05/10 means MX05=machine type and
10=rated speed 1,0m/s.
Note the motor parameters marking. For example 05.20 means 05=machine type MX05,
2=motor winding and 0=application number

Machine label Application Motor Motor

parameters winding
MX05/10 MonoSpace 05.20 q2
MX06/10; MX06/10 EA; MX06/05 06.20
MX10/10; MX10/10 RU; MX10/10 EA; MX10/05 10.20

36.3.5 First checking of the safety circuit

Step Action Note

1 Push RUN button in the RDF unit Refer to Electrification panels,
(270:RB) and check SAFETY INPUT introduction (appendix).
LED. CAUTION!Do not push direction
buttons!
2 Check the safety chain operation with RDF.
Activate, one at a time:
• the emergency stop push buttons on the car
• stop button and tension weight contact in the pit
After each activation, push the RDF/RUN button and check that the SAFETY
INPUT LED does not light.

36.4 Temporary adjustment of the load weighing device

Empty car and counterweight are approximately balanced.

The car is at the top of the elevator shaft.
NOTE! You must not attempt to drive the elevator before this adjustment is done.

Step Action Note

1 Turn the GAIN potentiometer first to CAUTION!Turn the potentiometer
one end. Then turn 15 rounds to set the carefully to avoid damage.
potentiometer to centre position.
A “click” sound indicates that the
potentiometer is turned to the other end.
2 Turn the OFFSET potentiometer so that This is not the final adjustment. This is
the load indication in the user interface used only to drive the elevator for the
shows 50 %. first time.

Action Display
Push MENU button until number 5 5 _ _ __
shows on the MENU display.
Push ACCEPT button. 5 _1 __
Push ACCEPT button. L _ _ xx where xx is load%
Turn the OFFSET potentiometer on L _ _ 50
drive module until number 50 shows on
the screen.

36.5 Driving the elevator for the first time

WARNING
No one is allowed to be on the car roof when driving the car with RDF.

Step Action
1 Check tachometer polarity and motor rotation direction with RDF.
Try to drive the car downwards and check the operation of the speed/direction
LEDs (car movement).

Press DOWN.

IF
Speed LED Running Tacho Motor
DOWN on DOWN OK OK
The tachometer polarity and motor rotation direction is OK. Go to step 2.

IF
Speed LED Running Tacho Motor
UP on UP WRONG WRONG
Car is moving in the wrong direction, switch the power off. Swap two phases in the
motor supply cable in the drive module and swap the wires of the tachometer cable
in the drive module (XG1). Repeat the check.

IF
Speed LED Running Tacho Motor
DOWN AND NOT OK WRONG
UP blinking WRONG OK
Speed / direction LEDs are blinking and the car is not moving, swap the motor
phases and repeat the test.
2 Switch first the Inspection drive unit on the car roof to INSPECTION and then RDF
inside the controller OFF.
3 Check the operation of the inspection drive unit buttons.
4 Activate and reset individually: Start to run using the inspection
• car roof stop button drive unit on the car roof, the
• overspeed governor contact elevator must not run.
5 Drive the car downwards using the inspection The elevator must stop
drive unit on the car roof. Activate manually the immediately.
final limit switch (51).

Step Action
6 Keep the landing door lock open and try to start The elevator must not run.
to drive using the inspection drive unit on the car
roof. Repeat this with all landing doors.
7 Test the car door lock operation by opening the NOTE! CAR DOOR
car door with the test buttons in the car door CONTACT and
operator (possible in the INSPECTION drive). SAFETY INPUT LEDs
Leave the door open and turn the elevator to
should not light.
NORMAL drive.
Check the LEDs in the user interface inside the
controller.
8 Test that the car (87) and landing door contacts (121) break the safety chain (the
safety input LED on the user interface turns OFF).

36.6 Adjusting the load weighing device

Step Action Note

1 Adjust the load weighing device
OFFSET setting to 0% (on LOBCB

R16
board) S1

OFFSET X3
R127
D59

C77

1008802.wmf

Action Display
Push MENU button until there is 5 _ _ __
number 5 on the MENU display.
Push ACCEPT button. 5 _1 _ __
Push ACCEPT button. L _ _ (xx where xx is load %)
Turn the OFFSET potentiometer on L__0
user interface board until there is
number 0 on the screen.

Step Action Note

2 Open the brake and wait until the load
display is steady. Close the brake and
open again for a few seconds to ensure
that all the tension is released.
3 Set the GAIN of the load weighing
device with the user interface in the R146
controller.

1008803.wmf

Action Display
Push MENU button until there is 5 _ _ __
number 5 on the MENU display.
Push ACCEPT button. 5 _1 _ __
Push ACCEPT button. L _ _ xx (where xx is load %)
Adjust the potentiometer GAIN until L _ _ 50
there is 50% on the MENU display.
4 Check the setting by releasing the If the reading is not stabilised, readjust
brake again. Close the brake. the load weighing device.

36.7 Setup

Step Action Note

1 Drive the car using RDF to the lowest The LEDs 61:U, 77:N, (77:S), 30 and
floor level. B30 (if through type car) are lit when the
Observe the LEDs at each level when lowest floor is reached.
driving down.
2 Drive the car using RDF at least 20 mm Check that the LED 61:N is off.
below the lowest floor level.
3 Use user interface to start the setup
(5_2_1).
4 Turn the RDF switch (270) OFF and car
will commence the setup drive.
5 You can follow the setup drive in the
user interface display.
6 After setup is completed, check the Subcodes indicate the minimum and
drive code 118 (subcodes 6010 and maximum floor overlap (the zone, where
6011) from the error log. both 61 switches are active) and the
If necessary, readjust the magnets corresponding floor numbers.
and/or switches. With ACL (accurate levelling) values
should be 5...25 mm.
Without ACL values should be
5...35 mm.
Refer to 804611: V3F16L drive fault
codes (appendix) and AM-11.65.022 for
more information.

User interface during the set up

Step Display Stage

1 = . _ _ . _ _ ., where SUBMENU display SETUP drive going on.
tells the floor number where the car is.
2 = . NN. _ _ ., the number of the topmost Car has arrived back to the topmost
floor in the SUBMENU display. floor.
3 - -- --, lines for a few seconds. Setup OK.
5 Floor number on display. Wait few seconds.
6 Drive code 118 is blinking on display. It is possible to check the drive subcodes
6010 and 6011.
If you wait a minute, a floor number is
displayed.
7 Floor number on display. You can proceed.

37 COMMISSIONING OF THE MACHINE AFTER ROPING, V3F25S

37.1 Checks before commissioning

Before starting the commissioning, check that the following things are done:
• Elevator shaft installation completed.
• Machine installation completed.
• Elevator car installation completed.
• Elevator car door and landing doors installed.
• Ropes installed.
• Elevator car and elevator shaft electrification including the signalling devices are
completed.
• Final limit switch ramps are installed and in correct positions.
• The positioning magnets and oscillators are installed accurately according to the vane
diagram.
• All safety devices are in circuit and working.
• Car and counterweight are balanced.

37.2 Preparations
WARNING
Ensure no one can come into contact with moving machine in the machine room.
No one is permitted in elevator shaft during this stage.

37.2.1 Checking the voltages

Step Action Note

1 Turn power ON from main switch unit.
2 Check that LEDs turn ON. Refer to the APPENDIX in the end of this
manual.
3 Push RUN button. Check that the
SAFETY INPUT LED turns ON. When
the LED is ON, the safety chain is
unbroken.
DO NOT PUSH DIRECTION
BUTTONS.

37.3 Emergency light battery

Step Action Note

1 Connect the emergency lighting battery To prevent unnecessary discharging the
plug “227 Battery” in the car top emergency lighting battery must be
connection box. temporarily disconnected if the elevator
main switch is switched OFF. Note that
landing calls do not operate when the
battery is disconnected.

37.4 LON protocol

Step Action Note

1 Ensure that the elevator is in RDF
mode.
2 Go to menu (5_7).
3 Press SELECT. With up and down Then the new LON protocol is in
buttons select 1. Press ACCEPT. progress. Various numbers are scrolling
on the user interface. Downloading may
take about 1 - 3 minutes, depending on
the system.

CAUTION!Do not interrupt downloading

by power break, turning elevator to
normal mode, and so on.
Downloading is finished when the
numbers 5_7_1 are continuously on the
user interface.
4 Go to menu (5_8).
5 K-Delta signalisation: set the value of
parameter (5_8) to 2.
KDS signalisation: set the value of
parameter (5_8) to ?.
6 Make a power break. Then the elevator is ready for load
weighing device setup and shaft setup.

37.5 Drive commissioning

Step Action Note

1 Continue by following the instructions in • LWD setup
the AM-11.65.024. • Repeat the resolver angle setting
• Shaft setup
• Fine tuning the resolver angle
• Fine adjustments

37.6 Levelling accuracy setting

Check stopping point at each level

Step Action Note

1 Position the car sill exactly at each
landing sill level.
2 Go to the car roof and check the If readjustment was made, perform
levelling vane positions. Adjust, if SETUP drive again.
necessary.
3 Drive the elevator car in normal drive to
all landings.
Drive to the landings in both directions.
4 Measure the difference between the car
and landing sill at each floor.
5 Readjust the final stopping accuracy, if Refer to the AM-11.65.020 (delivered
necessary. with the controller).

37.7 External options

37.7.1 Connecting external inputs to the LCEOPT board

Inputs Connector
Connect external inputs to the LCEOPT Refer to the delivery documents.
board. Refer to the pins of X5 connector in the
circuit diagrams.

37.7.2 Connecting external outputs to the LCEOPT board

Inputs Connector
Connect external outputs to the LCEOPT Refer to the delivery documents.
board. Refer to the pins of X1 - X4 connectors in
the circuit diagrams.

37.7.3 Remote alarm connections

Step Action Note

1 Connect the remote alarm output cable Refer to the circuit diagrams.
to the connector XM30 on the LCERAL
board.

1
XM14
D1
D2
ALARM
DELAY

S2
TIME
ALARM

OFF
S1
ON
RESET

S3
ALARM

LCERAL
K1

1 1017362.wmf

1. Alarm output
2 Check the required alarm method. Set the required alarm transfer delay
using potentiometer S2 on the LCERAL
board.
If necessary, inhibit the remote alarm by
setting the Alarm switch in OFF position.
3 Test and reset the remote alarms.

37.8 Group connections

Step Action
1 Turn the power OFF to all the elevators.
2 Refer to the circuit diagrams and layout drawings for the correct connection order
of the elevators.
3 In the first elevator, connect the first group cable to the connector XG1A on the
LCEGTWO board.
Connect the second group cable to the connector XG3A on the LCECAN board.

LCEGTWO
XG1B XG1A
1017363.wmf

XG3B
XG3A
LCECAN
4 In the second elevator, connect the first group cable to the connector XG1B on the
LCEGTWO board.
Connect the second group cable to the connector XG3B on the LCECAN board.
5 In the second elevator, connect the first group cable to the connector XG1A on the
LCEGTWO board.
Connect the second group cable to the connector XG3A on the LCECAN board.
6 In the third elevator, connect the first group cable to the connector XG1B on the
LCEGTWO board.
Connect the second group cable to the connector XG3B on the LCECAN board.
7 In the third elevator, connect the first group cable to the connector XG1A on the
LCEGTWO board.
Connect the third group cable to the connector XG3A on the LCECAN board.
8 In the fourth elevator, connect the first group cable to the connector XG1B on the
LCEGTWO board.
Connect the second group cable to the connector XG3B on the LCECAN board.
9 Check that the connectors XG1B and XG3B in the first elevator and XG1A and
XG3A in the fourth elevator are equipped with end resistors. Refer to the circuit
diagrams.
10 Turn the power ON to all the elevators.
11 Check that GROUP 24V OK LEDs are lit.

38 COMMISSIONING OF THE ROPING, KDL16

Refer to AM-11.65.041.

39 COMMISSIONING OF THE ROPING, KDL32

Refer to AM-11.65.029.

40 FINAL STEPS OF COMMISSIONING

40.1 Balancing the empty car and counterweight

If final car interior is added later:

Add an equivalent weight in the car for balancing purposes.
After the car interior has been installed, take the unnecessary weights from the car and re-
adjust the offset and gain settings on the load weighing device.

Step Action Note

1 Drive car and counterweight to the WARNING! No one is allowed to be on
same height in the elevator shaft. the car roof or in the elevator shaft.
2 Open the brake and see if the elevator
moves. Observe the speed/direction SPEED
LEDs on the user interface board. >0,6m/s D68
The elevator should not move if the car D67

and counterweight are balanced. D66

0 m/s
3 Drive the car a little upwards with RDF D65

(1-2 seconds). D64

>0,6m/s D63
4 Open the brake for a few seconds and
check if the elevator moves. Observe a1184yh.wmf
the speed/direction LEDs on the user
interface board.

The elevator should not move.

CAUTION! Be careful while releasing
the brakes. If the car moves do not let 2
it overspeed.

1031763-1.wmf

1. Brake closed
2. Brake fully open
5 Do the same in the other direction. Add or remove filler weights if necessary.

Step Action Note

6 Repeat until you are sure that the
empty car and counterweight are
balanced.
7 Check that the rope tensions (length of The rope clips must not rub each other
the springs) are equal at the car side or the ropes.
rope anchorage.

The maximum difference in the spring

lengths is 3 mm.

max 3mm
8 Check that the rope tensions are equal
at the counterweight side rope
anchorage.

1007537-1.wmf

40.2 Adding filler weights to the counterweight to correspond to 50 % of rated

load

Step Action Note

1 Drive the counterweight to the suitable
height.
2 Place all the remaining filler weights to
the counterweight.
The last filler weight to be installed 1
must be steel filler weight.

NOTE! Painted filler weights = 25 % of

the rated load.

1007538-1.wmf

1. Steel filler weight

3 Fit the counterweight clamps.

1007539.wmf a1126_38.wmf

41 COMMISSIONING OF THE CAR DOOR

Refer to component level instructions (for example AM-03.12.067, AMD-type doors).

42 SAFETY INSPECTION, V3F16L

42.1 Standards and rules

This safety inspection procedure is in accordance with the GB 7588 and KONE Corporation
safety policies.
Possible differences between this instruction and local safety regulations must be
considered. Because of the new elevator concept in the MonoSpace® elevator, the use of
local methods must be carefully designed in cooperation with the product designers in order
to avoid any safety hazards or damage to the product.
Compare this instruction to the delivery documents to find possible variations, for example in
the circuit diagrams.

42.2 Prerequisites

Before starting the safety inspection tests, ensure that:

• Installation and adjustments are completed.
• Commissioning with the safety chain checks is completed.
• Buffer heights are correctly aligned.
• Safety spaces above and under car are correct.
• Travelling cable is long enough to drive onto the buffers.
• There are no unnecessary objects in the elevator shaft or on the car roof.

42.3 Safety

All the work must be carefully planned in order to avoid any safety hazards or damage to the
product.

WARNING
Check that there is no-one inside the car or in the elevator shaft during the safety
inspection time.
Disconnect the landing calls using the user interface during the safety inspection time, so
that the inspection will not be interrupted and to avoid trapping passengers in the elevator.

Before going to the car roof, push the car roof stop button down and turn the inspection
drive unit to inspection drive before releasing the stop button.
The safety tests are to be carried out by authorised persons only.

42.4 Visual check (Annex D1.c and d, Annex D2.a, b and c)

NOTE! After the labels of each block there is a short reference to the GB 7588 Annex D.

Step Action Note

1 Locking. Landing doors must be locked while the
car is not at the floor level.
Controller, main switch and lighting
switch must be lockable.
2 Verification of components. Check that the safety devices,
suspension elements and their
attachments are those indicated in the
elevator register.
3 Controlling devices: RDF buttons in the controller and the
Turn the RDF in the controller ON and inspection unit on the car roof MUST
Inspection drive unit on the car roof to NOT control the elevator simultaneously.
Inspection and try to drive with the RDF.
4 Turn Inspection drive unit to normal The elevator MUST NOT run unless the
drive and RDF ON and push both RUN RUN button and one of the direction
and one of the direction buttons in the buttons are pressed simultaneously.
RDF. The car should move in the
correct direction. Release the RUN
button, the elevator should stop.
5 Safety chain check during RDF drive. RDF will bypass the following safety
Check that the safety chain switches devices:
that are not bypassed by RDF are able • Safety gear switch
to prevent driving. • Final limit switches
• Overspeed governor switch
• Buffer contacts (if any)

42.5 Measuring insulation resistance of the main supply (Annex D2.f)

Step Action Note

1 Turn the main switch (220) OFF.
2 Measure the insulation resistance The maximum measuring voltage is
between the earth bar and secondary 500 VDC.
side of the phase terminals in the main
switch (220).
3 Turn the lighting switch (262) OFF.
Measure the insulation resistance
between the earth bar and secondary
side of the phase (L) and neutral
terminal (N) in the lighting switch (262).
4 Measure the insulation resistance
between the motor terminals and the
earth bar.

42.6 Measuring insulation resistance of the safety chain (Annex D2.f)

Step Action Note

1 Turn the main switch (220) OFF.
2 Turn the RDF OFF.
3 Disconnect / unplug the connector
XLH1 from the controller.
4 Measure the insulation resistance XLH3, XLH4, XLH5, XLH6, XLH7, XLH8
between the earth bar and the safety
chain terminals of each connector. The maximum measuring voltage is
500 VDC.

Always refer to the circuit diagrams.

5 Reconnect the connector XLH1.
6 Turn the RDF ON. Check that the
elevator runs with the RDF.

42.7 Short circuit test (Annex D2.f)

Reserve a spare ceramic fuse 1 A, 5 x 20 mm for this test. This test is to verify that a short
circuit at any point of the safety chain will burn the safety chain fuse.

Step Action Note

1 Turn the main switch (220) OFF.
2 Make a temporary connection between Always refer to the circuit diagrams
the earth bar and the end of the safety for correct connections.
chain (XLH8/3).
3 Turn the main switch (220) ON and try The elevator must not start and the
to run the elevator by RDF. safety chain fuse must blow.
4 Turn the main switch (220) OFF and
replace the fuse.
5 Remove the temporary connection.

42.8 Checking the running clearances

Step Action Note

1 Check the clearances indicated A - H and counterweight guided travel as per GB
7588.

2 Ensure that the inspection drive limits

are functioning, before driving on the
car roof.

42.9 Checking the car and counterweight balancing

NOTE! Balancing must be checked before the current measurement, see the section titled
“Motor current measurement (Annex D2.e and h3) (V3F16L)”.

Step Action Note

1 Load 50 % of the rated load into the car. The counterweight is balanced to empty
car weight + 50 % of the rated load.
2 Drive car and counterweight to the
same height in the elevator shaft.
3 Open the brake and check the speed/ The car should not move if car and
direction LEDs in the LOP-CB board in counterweight are at same level.
the controller to see if the car moves.
Alternative indication from tacho
voltage.
4 Drive the car a little upwards with RDF.
5 Open the brake for a few seconds and The car should not move.
check the speed/direction LEDs in the
controller to see if the car moves.
Alternative indication from tacho
voltage.
6 Do the same in the other direction.
7 If the car and counterweight are not
balanced, add or take off filler weights
from the counterweight and re check
the balancing.

42.10 Readjusting GAIN setting of the load weighing device in the middle of the
shaft

NOTE! GAIN must be readjusted before the current measurement, see the section titled
“Motor current measurement (Annex D2.e and h3) (V3F16L)”.

Step Action Note

1 Turn the GAIN potentiometer so that
the load indication in the user interface
shows 50 %.
Action Display
Push MENU button until number 5 5 __ __
shows on the MENU display.
Push ACCEPT button. 5 _1 __
Push ACCEPT button. L __ xx where xx is load %
Turn the GAIN potentiometer in the L __ 50
controller until number 50 shows on the
screen.

42.11 Speed measurement (Annex D2.e and h3)

Step Action Note

1 Measure the inspection drive speed User interface board:
using manual tachometer. Do it from
the car roof with inspection drive.

Measure the tachometer voltage from

the measuring points TP3 (+) and
TP4 (-) during the inspection drive.
2 Run the elevator in normal drive from
the controller.
Measure the tachometer voltage from
the measuring points TP3 (+) and
TP4 (-) during normal drive.
See the following tables for the
acceptable measuring values.

Machine Speed (m/s) Test point voltage (VDC)

Minimum (VDC) Maximum (VDC)
MX05 0.63 1.15 1.31
1.0 1.82 2.08
MX06 0.63 1.15 1.32
1.0 1.83 2.09
MX10 0.63 1.12 1.27
1.0 1.77 2.02
1.6 3.04 3.36

42.12 Checking levelling accuracy (±5 mm)

Step Action Note

1 Check the levelling accuracy.
Adjust if needed.

42.13 Readjusting OFFSET setting of the load weighing device

NOTE! OFFSET must be readjusted before the current measurement, see the section titled
“Motor current measurement (Annex D2.e and h3) (V3F16L)”.

Step Action Note

1 Ensure that the car is empty.
2 Drive car and counterweight to the
same height in the elevator shaft.
3 Turn the OFFSET potentiometer so that
the load indication in the user interface
shows 0 %.
Action Display
Push MENU button until number 5 5 __ __
shows on the MENU display.
Push ACCEPT button. 5 _1 __
Push ACCEPT button. L __ xx where xx is load %
Turn the OFFSET potentiometer in the L __ 00
controller until number 0 shows on the
screen.

42.14 Upper limit switch check (Annex D2.g)

Step Action Note

1 Drive the empty car to the topmost
landing.
2 Turn the main switch (220) OFF.
3 Disconnect the plug XLH8 from LOP-
230 board in controller. Measure with
multimeter in ohm zone the resistance
between the pins XLH8/7 and XLH8/9
on XLH8 plug.
4 Pull the brake release lever and move
the car 1-2 cm at a time.
5 The operation point of the limit switch is The multimeter buzzer is useful if you
reached, when the multimeter shows are working alone.
"infinity". CAUTION! Be careful when releasing
the brake(s). Do not let the elevator
overspeed.

Step Action Note

6 Measure the limit switch operating point The limit switch contact must break the
from the topmost landing sill to the car safety chain before the counterweight
sill. touches the buffer.
7 Connect the plug XLH8. Turn the
electrification ON. Drive the car back to
the topmost landing using RDF.

42.15 Traction test with empty car (Annex D2.h)

Step Action Note

1 Drive the counterweight to the buffers
using RDF.
2 Open the brake to ensure that the
counterweight is resting on the buffers.
3 Fix a piece of paper to the car door so This piece of paper indicates the car
that it projects through the landing movement.
doors.
4 V3F16L: This activates the full power function.
Change the value of the parameter
6_80 to 1. Enable traction test/full power is valid
for one run or 20 seconds.
5 Drive the car upwards with RDF The car should not move.
approximately three seconds. Look at
the LEDs in the controller to ensure that
the motor rotates/ tries to rotate.
6 Bring the car back to the topmost floor
using the RDF drive.

42.16 Thermistor test

Step Action Note

1 Drive the car using RDF drive to
suitable height to reach the car roof.
2 Push the car roof stop button and
switch the elevator to inspection drive.
3 Turn the RDF OFF.

Step Action Note

4 Drive the car using inspection drive to
suitable height to reach the drive unit.
5 Disconnect the thermistor plug XT1.
6 Try to drive the elevator with inspection The elevator should not drive.
drive from car roof.
7 Check the fault code using user
interface.
8 Reconnect the plug XT1.

42.17 Drive time supervision test

Step Action Note

1 Read the DTS function setting from the This function is tested at the factory.
user interface in the control panel
(4_20_xx).
2 Drive the car below 77:U.
Turn the main switch (220) OFF.
3 Remove the plugs of 61:N, 61:U, 30
and B30 (if any) from the car top
connection box.
Turn the main switch (220) ON.
4 Turn the RDF OFF. WARNING! No one is allowed to be on
The elevator starts a correction drive the car roof or in the elevator shaft.
downwards and should stop after 45
seconds.
5 Reset the elevator by turning the main
switch (220) OFF and ON again.
6 Bring the car back using RDF drive.
7 Reconnect the removed plugs 61:N,
61:U, 30 and B30 (if any).

42.18 Lower limit switch check (Annex D2.g)

Step Action Note

1 Drive the car with the rated load to the
lowest floor.
2 Turn the main switch (220) OFF.

Step Action Note

3 Disconnect the plug XLH8 from LOP-
230 board in control panel. Measure
with multimeter in ohm zone the
resistance between the pins XLH8/7
and XLH8/9 on XLH8 plug.
4 Pull the brake release lever and move
the car 1-2 cm at a time.
5 The operation point of the limit switch is The multimeter buzzer is useful if you
reached, when the multimeter shows are working alone.
"infinity". CAUTION! Be careful when releasing
the brake(s). Do not let the elevator
overspeed.
6 Measure the limit switch operating point The limit switch contact must break the
from the lowest landing sill to the car safety chain before the car touches the
sill. buffer.
7 Connect the plug XLH8. Turn the
electrification on. Drive the car back to
the lowest landing using RDF.

42.19 Motor current measurement (Annex D2.e and h3) (V3F16L)

Step Action Note

1 Measure the voltage of the measuring User interface board:
points TP1 (+) and TP2 (-) on the User
interface board.
This voltage is equivalent to the motor
current (0.34 VDC = 1 A).

Drive the empty car downwards and

with 100 % load upwards.
Record the values.
The difference of the measurements
may be about 0.5 A.

2 Compare the values to the table below. If the values are much higher, contact an
expert.

Motor current recommendation

Machine Rated load Driving with empty car down and 100 % load up
(kg) Minimum Test point Maximum Test point
current (A) voltage (V) current (A) voltage (V)
MX05 320 6 2.2 8 2.7
360 7 2.3 9 2.9
400 7 2.4 9 3.1
440 8 2.6 10 3.3
480 8 2.8 10 3.5
MX06 520 9 2.9 11 3.6
560 9 3.1 11 3.8
600 9 3.2 12 4.0
640 10 3.4 12 4.2
MX10 680 10 3.5 13 4.4
720 11 3.7 14 4.6
760 11 3.8 14 4.8
800 12 4.0 15 5.0
840 12 4.2 15 5.2
880 13 4.4 16 5.5
920 13 4.5 17 5.7
960 14 4.7 17 5.9
1000 14 4.9 18 6.2

42.20 Preparations for combined traction test and braking test with 125 % load
(Annex D.d and h)

Step Action Note

1 Switch RDF ON.
2 Drive the car to a suitable height to get
to the car roof.
3 Push the car roof stop button down and
go to the car roof.
4 Mark the ropes and the sheave for the
traction test.
Leave the car roof.

a1184h.wmf

5 Release the stop button and turn the

RDF OFF.
6 Call the car to the topmost floor using Turn the Inhibit door opening OFF for a
landing calls. while.
7 When the door opens turn the RDF ON.
8 Load 90...100% of the rated load into
the car.
9 Turn the RDF OFF. The doors close and elevator starts to
level.
10 Call the car back to the topmost floor
using landing calls.
When doors are opened, turn the RDF
ON.
11 Load the rest of the load to reach 125%
of rated load.

42.21 Combined traction test and braking test with 125% load (Annex D.d and
h)

Step Action Note

1 Turn the RDF OFF. The doors do not close and the overload
Turn the RDF ON. sound is activated.
2 Change the value of the parameter This activates the full power function.
6_80 to 1.
The overload sound turns off.

Enable traction test/full power allows

one run with overload.
3 Turn the RDF OFF.
4 Give a car call down with the user
interface.
5 When the elevator has reached the The elevator should stop immediately.
rated speed, observe the door zone
LEDs and turn RDF ON immediately
when the door zone appears, so the car
is stopping at door zone.
6 After the elevator stops, drive the car Lower the car by the manual brake
down to the next floor level. release or by the car lifting tool if
necessary.
7 Turn the main switch (220) OFF and
ON again.
8 Drive the car back to the top floor using
RDF.
9 Check the markings on the ropes and Record the measured rope slip.
sheave. Measure the sliding of ropes.

42.22 Preparations for car safety gear test (Annex D2.j)

Step Action Note

1 If counterweight safety gear, go into the The counterweight safety gear may
pit and secure the counterweight safety engage during the test if the operation of
gear linkage using wire or a large cable the safety gear is not prevented.
tie (minimum width of the cable tie is
4.7 mm).

Leave the pit.

2 Prevent the access from landings to the Reserve the car lifting tool for this test.
car for this testing

Step Action Note

3 Move the plug of the XL8 connector
from normal (right) position to test (left) 1 2
position.
1 1
1027270.wmf

1. Normal position
2. Test position
4 Call the car to the topmost floor using Turn the Inhibit door opening OFF for a
landing calls. while.
5 When the door opens, turn RDF ON.
6 Load 125 % of the rated load into the
car.

42.23 Car safety gear test (Annex D2.j)

Step Action Note

1 Change the value of the parameter This activates the full power function.
6_80 to 1.
The overload sound turns off.

Enable traction test/full power allows

one run with overload.
2 Turn the RDF OFF.
3 Give a car call downwards using the WARNING! There must be no-one on
user interface. the car roof or in the elevator shaft.
Check that there is enough space
downwards.
4 Observe the door zone LEDs and push The elevator should stop immediately.
the overspeed governor test button
immediately when the door zone
appears, so the car is stopping at door
zone.
5 Change the value of the parameter The car should not move, when the
6_80 to 2. safety gear is engaged.
2=safety gear test
Drive downwards with RDF.
Check the speed/direction LEDs in the
user interface to see that motor rotates.
Check whether the car does move.

42.24 Re-setting the elevator after car safety gear test

Step Action Note

1 Remove half the load from the car.
2 Change the value of the parameter Use the car lifting tool if necessary.
6_80 to 1. Enable traction test/full power allows
one drive with overload.
Drive the car upwards using RDF.
Check that the safety chain remains 1= traction test/full power
broken.
3 Drive the car upwards by the RDF until
the car roof is at topmost floor level.
4 Open the topmost landing door.
5 Push the car roof stop button and enter
onto the car roof.
6 Reset the overspeed governor switch,
using the provided resetting stick.
Reset also the position of the connector
XL8 from the test position between
XL8/3 and XL8/4 to the normal position
between XL8/2 and XL8/3.
7 Put the resetting stick back in place on
the balustrade.
8 Release the stop button on car roof, The safety chain should be complete
exit the elevator shaft and close the after this step.
landing door.
9 Turn the elevator to inspection drive.
10 Check that the safety gear marks are If not, re-adjust the safety gear and carry
level and equal on both sides. out the test again. See AM-08.07.002.
11 Remove the safety gear marks with a
file.
12 Switch the elevator back into normal
operation.
13 Remove the cable tie from the
counterweight safety gear.

42.25 Readjusting the load weighing device setting

Step Action Note

1 Ensure that the car is empty.
2 Drive car and counterweight to the
same height in the elevator shaft.
3 Turn the OFFSET potentiometer so that The weight of the empty car is indicated.
the load indication in the user interface
shows 0 %.
Action Display
Push MENU button until number 5 5 __ __
shows on the MENU display.
Push ACCEPT button. 5 _1 __
Push ACCEPT button. L __ xx where xx is load %
Turn the OFFSET potentiometer in the L __ 00
controller until number 0 shows on the
screen.
4 Add extra weights to the car to
correspond 50 % rated load.
5 Turn the GAIN potentiometer so that
the load indication in the user interface
shows 50 %.
Action Display
Push MENU button until number 5 5 __ __
shows on the MENU display.
Push ACCEPT button. 5 _1 __
Push ACCEPT button. L __ xx where xx is load %
Turn the GAIN potentiometer in the L __ 50
controller until number 50 shows on the
screen.

42.26 Test of alarm devices (Annex D2.m)

Step Action Note

1 Push alarm buttons in the car operating Check the set delay and configurated
panel, under the car and on the car roof alarm connections.
individually.
2 Check that the alarm is forwarded in KRM remote monitoring (RIF board in
accordance with the configuration. the car top connection box):
The alarm buttons on top and bottom of
the car do not activate the alarm bell.
3 Reset all alarms.

42.27 Counterweight safety gear test (Annex D2.k)

Prevent the access from landings to the car for this testing.

42.27.1 Preparations

Step Action Note

1 Position 50% of the test loads to the These weights may be required to
second or third floor. provide additional load in the car to
release the counterweight safety gear
after the test.
2 Drive the car using RDF to a suitable
height to reach the underside of the car
from the pit.
3 Turn inhibit door opening and inhibit The car must be empty. From this
landing calls ON using LCE user moment on no one is allowed to go into
interface. the car.
4 Go into the pit and secure the car The car safety gear may engage during
safety gear linkage using wire or a large the test if the operation of the safety gear
cable tie (minimum width of the cable is not prevented.
tie is 4.7 mm).

Leave the pit.

5 Switch the elevator to normal. WARNING! No one is allowed to be in
the car or in the elevator shaft.
6 Drive the car to the lowest floor by Use LCE user interface.
giving a car call.

Step Action Note

7 Remove the test cable of car
overspeed governor from XL8.
Connect the test cable of counterweight
overspeed governor to XL8 between
pins 2 and 3 (normal position).

42.27.2 Test

Step Action Note

1 Move the plug of the XL8 connector
from normal (right) position to test (left) 1 2
position.
1 1
1027270.wmf

1. Normal position
2. Test position
2 Give a car call to the topmost floor WARNING! No one is allowed to be on
using the user interface. the car roof or in the elevator shaft.
3 Observe the door zone LEDs and push The elevator should stop immediately.
the overspeed governor test button
immediately when the door zone
appears, so the car is stopping at door
zone.
4 Try to drive up with the RDF drive to The elevator should not drive, when the
check that the counterweight safety counterweight safety gear is engaged.
gear is engaged. See tacho LEDs on the LOP-CB board.
5 Drive the car downwards with the RDF. Place test loads in the car or on the car
Check that the safety chain remains roof to release the counterweight safety
broken. gear, if necessary.
6 Reset the overspeed governor switch The safety chain should be complete
using the provided reseting stick. after this reset.
7 Reset the plug XL8 to the normal
position.
8 Remove the test cable of counterweight
overspeed governor from XL8.
Connect the test cable of car
overspeed governor to XL8, normal
position.

42.27.3 Checks before putting the elevator back to normal operation

Step Action Note

1 Drive the car using RDF to suitable Ensure that the car safety gear operates
height to reach the underside of the car correctly.
from the pit.
REMOVE THE CAR SAFETY GEAR
BLOCKING TIE.
2 Turn the elevator to inspection drive.
3 Check that the safety gear marks are If not, re-adjust the safety gear and carry
level and equal on both sides. out the test again. See AM-08.07.002.
4 Remove the safety gear marks with a
file.
5 Switch the elevator back into normal
operation.
6 Turn inhibit door opening and inhibit
landing calls OFF using LCE user
interface.

42.28 One-sided braking test with rated load

Step Action Note

1 Tighten the brake centre nut.
2 Check for car movement. If the brake is correctly adjusted there
will be no movement.
If the car moves, although the brakes are
correctly adjusted, contact your
supervisor for the adequate expertise
and guidance.
3 Release the nut to have washer
movable with a clearance of 0.5 mm.
4 Repeat steps 2...4 to the other brake
side.

42.29 Car overspeed governor test (Annex D2.i and n)

NOTE! If you have both car and counterweight overspeed governors the counterweight
overspeed governor must have the higher tripping speed.

Step Action Note

1 Lift the overspeed governor rope out of
the groove and hang it temporarily to
the overspeed governor fixing. Secure
it with cable ties.
2 Measure the overspeed governor Read the correct operating speed from
electrical tripping speed using a the overspeed governor data plate.
manual tachometer. Accelerate the
overspeed governor manually in car
down direction until the electrical
contact (127) operates. Note the
operating speed.
3 Measure the overspeed governor For correct tripping speed refer to the
mechanical tripping speed using a following table.
manual tachometer. Accelerate the
overspeed governor manually in car
down direction until it trips. Rotate the
overspeed governor to the tripping
direction. Note the tripping speed.
4 Replace the rope in the groove after
testing.

Rated speed Tripping range

Vn x 1.15 Vn x 1.25 + (0.25/Vn)
0.6 m/s > 0.70 m/s < 1.50 m/s
1.0 m/s > 1.15 m/s < 1.50 m/s
1.6 m/s > 1.80 m/s < 2.15 m/s

43 SAFETY INSPECTION, V3F25S

Refer to AM-11.65.024.

44 SAFETY INSPECTION, KDL16

Refer to AM-11.65.41.

45 SAFETY INSPECTION, KDL32

Refer to AM-11.65.029.

46 HANDOVER AFTER INSTALLATION

46.1 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.

46.2 Handover form

In the handover form there is a list of items that are assessed in 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 the KONE quality standards.

46.3 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. Refer to Appendix C.
• There should be no sudden movements or unexpected noises during the drive.
Levelling
• Maximum levelling deviation in either direction is ± 5 mm.
Car and signalisation
• Push buttons and signalisation should work as expected in the car and on the landings.
• Car lighting 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.
• KoneXion and alarm buttons (3 pcs) must function correctly.
• Car labels must be in place.
• Car fan should operate correctly.

Machine room
• Installation complete according to layout drawings including lockable machine room door
and prescribed safety notices.
• Machine room must be equipped with adequate lighting and ventilation.
• Main switch unit, controller and elevator must be clearly marked.
• Main switch must be lockable.
Control panel
• All protections must be correctly positioned.
• All unusual registered faults should be solved and unit reset.
• There should not be any abnormal noise coming from the contactors, etc.
• Safety gear must stop and hold the car when the overspeed governor is operated with the
car moving in the down direction.
• Car emergency light and alarm bell must work when power is off.
• Rescue drive should work in both directions.
• Brake handle must fully open the brake when operated.
• The brake must stop the car in an up direction emergency stop. There must be no
excessive slide.
• All grounding on the whole installation must be correctly connected to the earth terminal.
• Devices used to over bridge parts of the safety chain must have been removed.
Brake
• The brake air gap should be maximum 0.1 mm.
• The central nut washers must be movable by hand.
Machine
• All internal and external fastening should be tight.
• The braking surface on machine should be clean and free from rust.
• There must be no mechanical contact with the machine body and fixing.
Ropes
• Must not show any sign of rust.
• Should not be dry or dirty, and there should be no broken strands, kinks or twists on
ropes.
Rope terminations and springs
• Maximum deviation in spring length is 3 mm.
• Rope anchorages must be correctly secured with two nuts and a split pin.
• There should be no evidence of twisting of rope termination.
• There should not be any mechanical contact between the rope anchorages.
Guide rails
• Should have light film of oil over the full length of the blade faces. Only if sliding guide
shoes.
• Should be smooth and free from safety gear marks.

• All fixings must be tight.

• Maximum DBG deviation is ± 1 mm for elevators up to 1.6 m/s and ± 0.5 mm for elevators
over 1.6 m/s.
Elevator shaft
• Pulleys should rotate quietly and smoothly.
• 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 layout drawing.
• Car insulation should be in place.
Guide shoes
• Must be correctly adjusted, total gap in distance between guide rails 2-3 mm (if sliding
guide shoes).
• Oil cups should be full (if sliding guide shoes).
• Roller guide shoes must be adjusted correctly.
• Locking pins must be removed from the guide shoe linings.
Travelling cable
• Travelling cable loop should be min. 150 mm from the pit bottom, when the car is on the
compressed buffer. Ensure also that the travelling cable is not too tight when the car is at
the topmost landing level. When the counterweight is driven to the buffer the car jumps
(this must be taken care of also). Minimum distance between cables is 100 mm inside the
loop.
• 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.
• Emergency light should operate.
Car top connection box
• All electrical devices and switches must work correctly.
Safety devices
• All safety switches must operate correctly.
Counterweight
• Free movement between rails should be between 2 to 3 mm (if sliding guide shoes).
• Roller guide shoes must be adjusted correctly.
• Oil cups must be full (if sliding guide shoes).
• Rope guards must be in place.
• Filler blocks must be in place and securely fixed.
Landing door mechanical
• 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 diverter 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. Refer to AM.
Landing door locks and contacts
• Contacts should be clean and have minimum wear (metal visible).
• 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.
• Inspection hatches and emergency exit doors must be locked and electrically interlocked
in the safety chain.
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.
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 others when pressed with thumb in the centre of
the belt.
• Coupler rollers should be in the middle of operator vanes, running clearance min. 8 mm,
nom. 13 mm.

• Couplers should engage properly, engagement with rollers 10 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.
Overspeed governor and rope
• Should run quietly.
• Must operate freely when tested by hand.
• Electrical contact must operate.
• Seal should be intact.
• Rope should not be dirty and there should be no strands, kinks or twists.
Safety gear
• Must be correctly aligned, the wedges must meet both guide rails evenly.
• All bolts and nuts must be in place and correctly 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 safety gear rope.
Pit
• There should be no oil, rubbish or water in the pit.
• Oil collectors should be in place.
• Buffers must be securely fixed and filled with oil.
Overspeed governor tension weight
• Must fully tension the overspeed governor rope.
• Safety switch trigger should be in the middle of the opening.
• Should move easily.

E -line M iniS pace™

D ate
Installation/S ervice H andover
G eneral data
E levator N um ber E levator A ddress

Installation R epresentative M aintenance R epresentative

H andover C hecks

A ccepted
Yes No W hy not?

R ide Q uality

Levelling

C ar & S ignalization

C ontrol panel

B rake

M achine

Traction sheave and ropes

G uide rails

Shaft

D oors

Landing door m echanical

Landing door locks and contacts
C ar door m echanical
C ar door electrical

O SG and Safety gear

Pit

Installation accepted to m aintenance

Y es No

If rejected, person responsible for corrective actions

A greed deadline for com pletion of the w ork

Installation R epresentative M aintenance R epresentative

47 APPROVALS AND VERSION HISTORY

Compiled by: Technical Writer / Xu Yang

Checked by: EAP Installation Development & Support Engineer / Jason Shen
Approved by: Global Installation Support / Anssi Venho
EAP Installation Support & Development Senior Manager / Crane Hon
Translation approved by: /

Issue Date Description of change Ref CR Approved by

- 2005-11-28 First issue Anssi Venho
A 2007-09-13 KONE 3000X and KONE Ecodom® Anssi Venho
3000/5000 added.
B 2008-03-03 Lifting beam in the machine room ceiling Anssi Venho
added as an option. Plumbing jig
assembly and installation removed and
replaced by plumbing templates. Car
guide rail alignment method changed.
Small details in CFE10 installation
updated. Appendix C added. Other
minor changes.
C 2009-05-26 Installation tasks for KONE 3000S Anssi Venho
MiniSpace™ elevators with rear
counterweight added. Major updates for
bed plate and car sling; minor updates
for OSG, safety gear, brake release
lever, guide rail brackets and so on.
D 2010-05-31 Add MX14 reference information. Add Anssi Venho
KDL16 and KDL32 drives. Update
information for tools. Update site
requirements. Add note for brass plate
installation.

APPENDIX A. Fuses and LEDs

A.1 Fuses and voltage indication LEDs

Fuse Size/type Fuse LED LED Normal

location location
F1 Safety chain 1 A/T LCEADO, Safety input LCECPU, ON
230 V (5x20 mm) 379 pos 375
F2 Control 6.3 A/T Power Control voltage Power ON
voltage (6.3x32 mm) module 230 V module
F3 Door 2A Power Door 230 V Power ON
operators multifuse module module
F4 Car and 4A Power 24 V Car& LCECPU, ON
Shaft 24 V multifuse module Shaft OK pos 375
F5 Controller 4A Power Controller 24 V LCECPU, ON
24 V multifuse module pos 375
F6 & F7 6 A/500 V Power
Transformer time delay module
400 V multifuse
F8 24 V Car 4A Power Car and Shaft LCECPU, ON
and Shaft multifuse module 24 V pos 375
F1 Group 24 V 5A GTWO Lift 24 V OK GTWO ON
multifuse board Group 24 V OK board
F1, F2 Optional 315 mA/F OPT board
inputs 24 V (5x20 mm)

1
2

7
3

1018506.wmf

1. F6 & F7 time delay 6 A/400 VAC, Transformer 400VAC

2. F2 T6.3 A/230 VAC, Control voltage
3. F3 T2 A/230 VAC, Door
4. F4 T4 A/24 VDC, Car/Shaft
5. F5 T4 A/24 VDC, CPU
6. F8 T4 A/24 VDC, Car/Shaft
7. LEDs at the power module

A.2 LEDs in the user interface

1018507.wmf

LED Function when LED is ON Normal Colour

status
EMERGENCY Emergency alarm push button pushed in OFF RED
ALARM car.
LIFT IN FAULT Fault prevents the car driving. OFF RED
CPU RUNNING Indicates that CPU and SW are working. Blinking YELLOW
INSPECTION Inspection drive from car roof is ON OFF YELLOW
(42:DS).
RESCUE DRIVE Rescue drive from control panel is ON OFF YELLOW
(270). Input XM11/2 on LCECPU pos. 375.
CAR Car communication network is working. ON GREEN
COMMUNICATION
OK
SHAFT COMM. OK Elevator shaft communication network is ON GREEN
working.
+24V + 24 V DC Control voltage is OK. ON GREEN
CONTROLLER OK
+5V CONTROLLER + 5 V DC Control voltage is OK. ON GREEN
OK
+24V CAR & + 24 V DC Car and elevator shaft voltage is ON GREEN
SHAFT OK OK.
CHANGE BOARD Fatal failure on the LCECPU board. OFF RED

LED Function when LED is ON Normal Colour

status
SPEED > 0,1m/s The LED is ON when the speed goes over ON/OFF YELLOW
0.1 m/s while accelerating. The LED goes
OFF when the speed goes under 0.3 m/s or
0.1 m/s while decelerating.
START PERMIT One of the main contactors (201:1, 201:2, ON/OFF YELLOW
201:3, 201:4) has not been released. Input
XD1/3 on board 379.
MAIN LCECPU has given main contactor ON/OFF YELLOW
CONTACTOR activation command.
SHAFT DOOR Elevator shaft doors are closed. Input XH2/3 ON/OFF YELLOW
CONTACT on board pos. 379 has voltage.
CAR DOOR Car doors are closed. Input XC1/7 on board ON/OFF YELLOW
CONTACT pos. 379 has voltage.
CLOSE DOOR Close the door command is given. ON/OFF YELLOW
COMMAND
DRIVE NEED Controller has recognised a need for drive. ON/OFF YELLOW
V3F OK V3F has no faults. It is able to drive. ON GREEN
SAFETY INPUT Safety chain input XC1/5 on board pos. 379 ON GREEN
has voltage.
OPEN DOOR Open door command is given. ON/OFF YELLOW
COMMAND
PHOTOCELL Photocell is active. Inputs XB29/2 and ON/OFF YELLOW
XB31/2 on LCECCBN2 board pos. 806.
OPEN BUTTON Door open button is active. Input XC10/1 on ON/OFF YELLOW
board LCECOB pos. 32.
CLOSE FORCE Door closing force limiter is active. Inputs OFF YELLOW
LIMITER XB28/8 and XB30/8 on LCECCBN2 board
pos. 806.
DRIVE UP Drive up command is given to V3F. ON/OFF YELLOW
77:U Car is at top floor deceleration area. ON/OFF YELLOW
61:U Car is at about +10 mm ... -140 mm from ON/OFF YELLOW
floor level.
30 Car is at door zone of front door. ON/OFF YELLOW
B30 Car is at rear door zone. ON/OFF YELLOW
61:N Car is at about -10 mm ... +140 mm from ON/OFF YELLOW
floor level.
77:N Car is at bottom floor deceleration area. ON/OFF YELLOW
77:S Car is at terminal floor area. ON/OFF YELLOW
DRIVE DOWN Drive down command is given V3F. ON/OFF YELLOW
INHIBIT DOOR Door opening is inhibited with the switch OFF YELLOW
OPENING beside this LED.
INHIBIT LANDING Landing calls are inhibited with the switch OFF YELLOW
CALLS beside this LED.

A.3 How to use the user interface

1 2 3 4 5 6 7

1018508.wmf

1. Menu button
2. Menu display
3. Floor and submenu display
4. New floor or value display
5. Arrow buttons
6. Landing call buttons
7. Car call button

Button Action
MENU Push MENU button to select the menu. Refer to the delivery
documents.
NOTE! d is for drive faults.
SELECT / ACCEPT Push SELECT / ACCEPT button to select the submenu.
Refer to the delivery documents.
Arrow buttons When MENU display is blank, you can choose the required
CAR CALL floor number using arrow buttons and then pushing CAR
CALL.
UP CALL You can give landing calls up and down by pushing UP CALL
DOWN CALL or DOWN CALL.

Button Action
INHIBIT DOOR OPENING Use these switches to inhibit door opening and landing calls
INHIBIT LANDING CALLS during test drives. These switches prevent the interruption of
the test or trapping of passengers.
OSG TEST Use this switch to make the overspeed governor test and to
release the overspeed governor after testing. Refer to the
SAFETY INSPECTION.
BUFFER TEST Use this switch to make the buffer test.
Refer to the SAFETY INSPECTION.

APPENDIX B. Electrification panels, introduction

B.1 Drive panel (V3F16L)

1. Brake cable connector, XBR3

2. LCE cable connector, XS3
3. Motor cable connector, U-V-W
4. Supply cable connector, T1-T2-T3
5. LWD motor current cable connector, XW1
6. Tachometer connector, XLG1
7. Tachometer cable connector, XG1
8. LCECPU cable connector, XL1
9. Motor thermistor connector, XT1
10. Braking resistor cable connector,
XBRE2
11. Cover plate
12. Holding wire for cover plate
13. Slots for cable bushings

B.2 User interface

B.2.1 The buttons and display in the user interface

1. User interface
2. Overspeed governor test button
XL1 XL8 XL9
3. Menu display
1
4. Sub menu display S14

5. Value display 2 OSG TEST

6. Value setting button
7. Menu button
3
8. Select/Accept button
4
LOP-CB 763603H01

9. Up call button
10. Down call button 5
11. Car call button 6 D22 D23 D24 D25 D26

UP CALL
12. Inhibit door opening switch MENU
S8
SELECT
S6
CAR CALL
13. Inhibit landing calls switch S10 S7 S4
7 S5
14. RS232 mode, always keep the ACCEPT
8 S9
switch in left position DOWN CALL
15. RDF up button
16. RDF down button 9
17. OFFSET 10
18. GAIN
11

12 S13

13 S12

14 RS232 MODE S11

SPEED
15 RDF
UP
>0.6 m/s
LOPCB
TEST
S2
-0 m/s
RDF
DW
16 S1 >0.6 m/s SPEED
MEASUREMENTS
TP4 TP3
OFFSET LWD
GAIN
R127 TP6 TP5 R146
MOTOR
17 CURRENT
TP2

18
TP1
XL2

XL3 XL4 XL5 XL6

1007529.wmf

B.2.2 Use of the buttons in the user interface

Pos. Button Action

7 MENU Push MENU button to select the menu.
Refer to the LCE parameter table, APPENDIX 2.
8 SELECT / Push SELECT / ACCEPT button to select the sub
ACCEPT menu.
Refer to the LCE parameter table, APPENDIX 2.
6 Arrow buttons When MENU display is blank, you can choose the
11 CAR CALL required floor number using arrow buttons and push
CAR CALL.
9 UP CALL You can give landing calls up and down by pushing
10 DOWN CALL UP CALL or DOWN CALL.
15 RDF UP Recall drive up.
16 RDF DW Recall drive down.

Pos. Switch Action

12 INHIBIT DOOR Use these switches to inhibit door opening and
OPENING landing calls during test drives to avoid interruption
13 INHIBIT of the test or trapping of passengers.
LANDING CALL
2 OSG TEST Use this switch to make the overspeed governor
test and to release the overspeed governor after
testing. Refer to the chapter 42.23 Car safety gear
test (Annex D2.j) on page 371.
14 RS232 Keep this switch always in the left position.

Pos. Potentiometers Action

18 GAIN These potentiometers are used to set the load
17 OFFSET weighing device.

Measuring point Polarity Description

LWD TP5 Gain Not used.
TP6 Offset
Speed TP3 + Tachometer voltage Use these measuring points for
measurements TP4 - speed measurements.
Motor current TP1 + Motor current Use these measuring points for
TP2 - measuring the motor current.

B.2.3 LEDs in the user interface board

LED Function when LED is ON Normal Colour

status
+24V + 24 V DC control voltage is OK. ON GREEN
+5V + 5 V DC control voltage is OK. ON GREEN
+12V + 12 V DC control voltage is OK. ON GREEN
-12V - 12 V DC control voltage is OK. ON GREEN

LED Function when LED is ON Normal Colour

status
LCECPUnc Indicates that CPU and SW are working. Blinking YELLOW
RUNNING
LIFT IN FAULT Fault prevents the car driving. OFF RED
EMERGENCY Emergency alarm push button pushed in OFF RED
ALARM car.
INSPECTION Inspection drive from car roof is ON OFF YELLOW
(42:DS).
RESCUE DRIVE Rescue drive from controller is ON (270). OFF YELLOW
Input XM11/2 on LCECPU pos. 375.
CAR COMM OK Car communication network is working. ON GREEN
HOISTWAY Elevator shaft communication network is ON GREEN
COMM. OK working.
+24V CAR&SHAFT + 24 V DC car and elevator shaft voltage is ON GREEN
OK OK.
SPEED > 0.1m/s The LED is ON when the speed goes over ON/OFF YELLOW
0.1 m/s while accelerating and goes OFF
when the speed goes under 0.3 m/s while
decelerating.
START PERMIT One of the main contactors (201:1, 201:2) or ON/OFF YELLOW
the dynamic brake contactor (204) has not
been released. Input XD1/3 on board 379.
MAIN LCECPU has given main contactor ON/OFF YELLOW
CONTACTOR activation command.
SHAFT DOOR Elevator shaft doors are closed. Input XH2/3 ON/OFF YELLOW
CONTACT on board pos. 379 has voltage.
CAR DOOR Car doors are closed. Input XC1/7 on board ON/OFF YELLOW
CONTACT pos. 379 has voltage.
CLOSE DOOR Close the door command is given. ON/OFF YELLOW
COMMAND
DRIVE NEED Need for driving recognised. ON/OFF YELLOW
V3F OK Drive unit is able to drive. ON GREEN
SAFETY INPUT Safety chain input XC1/5 on board pos. 379 ON GREEN
is powered.
DRIVE UP Drive up command is given to the drive unit. ON/OFF YELLOW
77:U Car is at top floor deceleration area. ON/OFF YELLOW
61:U Car is at about +10 mm... -140 mm from ON/OFF YELLOW
floor level.
30 Car is at door zone of front door. ON/OFF YELLOW
B30 Car is at rear door zone. ON/OFF YELLOW
61:N Car is at about -10 mm... +140 mm from ON/OFF YELLOW
floor level.

LED Function when LED is ON Normal Colour

status
77:N Car is at bottom floor deceleration area. ON/OFF YELLOW
77:S Car is at terminal floor area. ON/OFF YELLOW
DRIVE DOWN Drive down command is given to the drive ON/OFF YELLOW
unit.
OPEN DOOR Open door command is given. ON/OFF YELLOW
COMMAND
PHOTOCELL Photocell LED is ON when there is OFF YELLOW
something between doors. Inputs XB29/2
and XB31/2 on board LCECCB pos. 806.
OPEN BUTTON Door open button LED is ON when button is OFF YELLOW
pressed. Input XC10/1 on board LCECOB
pos. 32.
CLOSE FORCE Door closing force limiter is active. Inputs OFF YELLOW
LIMITER XB28/8 and XB30/8 on board LCECCB pos.
806.
DOOR ZONE Car is at door zone. Signal is present even if ON/OFF GREEN
INDICATOR the power supply is switched off.
INHIBIT DOOR Door opening is inhibited with the switch OFF YELLOW
OPENING beside this LED.
INHIBIT LANDING Landing calls are inhibited with the switch OFF YELLOW
CALLS beside this LED.
SPEED >0.6m/s Car speed more than 0.6 m/s, up direction. ON/OFF RED
(D68)
SPEED >0.3m/s Car speed more than 0.3 m/s, up direction. ON/OFF GREEN
(D67)
SPEED >0.02m/s Car speed more than 0.02 m/s, up direction. ON/OFF GREEN
(D66)
SPEED >0.02m/s Car speed more than 0.02 m/s, down ON/OFF GREEN
(D65) direction.
SPEED >0.3m/s Car speed more than 0.3 m/s, down ON/OFF GREEN
(D64) direction.
SPEED >0.6m/s Car speed more than 0.6 m/s, down ON/OFF RED
(D63) direction.

B.3 Fuses and LEDs on LOP-230 board

Fuse Size/type LED Normal

F1 Safety chain 230 V 1 A/T (5x20 mm) - -
F2 Safety chain, brake and fan 6.3 A/T (5x20 mm) F2 OK ON
supplies
F3 Door supply 2 A/T (5x20 mm) F3 OK ON

B.4 Fuses on LCEREC board

Fuse Size/type
F4 Car and shaft 24 V 4 A multi fuse
F5 Control voltage 24 V 4 A multi fuse
F6 & F7 Short circuit protection of transformer 6 A/500 V (10x38 mm)
F8 24 V Car and shaft (optional if > 10 floors) 8 A multi fuse

APPENDIX C. TROUBLE-SHOOTING INSTRUCTION/VERTICAL VIBRATIONS

FOR MX10 ELEVATORS WITH V3F18 OR V3F25 DRIVE

If elevator has high vertical vibrations that can be clearly felt inside the car:
1. Make EVA-625 measurements according to AM-01.05.008 from EDMS.
2. Download data to PC.
3. Check vertical vibration data: peak-to-peak value [gal], intensity [dB] and frequency [Hz].
4. If vertical vibrations in [gal] OR [dB] are above limits shown in Table 1 AND dominant
frequency on FFT matches those according to Table 1 (speed dependent), then change
tachometer friction wheel from d37.3 mm to d55 mm by using material package
KM922375G01 (includes d55 mm traction wheel, adaptor plate and fixing screws).
Package can be ordered through GSS.
5. Change LCE parameter 6_8 to value 55.

100 Run S ound: 68.9 L Aleq: 54.8 Max S ound: 71.6

Sound ( dBA)

80
60.0
60

40
40 Max P k/P k: 29.6 A 95: 16.0 0-P k: 17.6
20
7.4
LP X

0 -7.4

-20
-40
40 Max P k/P k: 67.2 A 95: 18.8 0-P k: 36.0
20
7.4
LP Y

0 -7.4

-20
-40
100 Max P k/P k: 63.6 A 95: 43.6 0-P k: 90.9

7.4
0
Z

-7.4

21 43
-100
0 5 10 15 20 25
Seconds
Low Pass = 12 Hz

Table 1.
Spectrum - Z Channel
IF vertical vibration level is:
File: VF2 N5 RGG.VE2 19:4 6:08 11/05 /07
Frequency (Hz)
0 5 10 15 20 25 30 35 40 45 50 55
Motor RPM > 45 gal peak-to-peak OR
Max = 100.355 @40.438Hz
100 > 90 dB
decibels

60 AND vibration frequency is:

~ 40 Hz (1.6 m/s)
~ 44 Hz (1.75 m/s)
FFT of full-speed region, z-channel, in decibels.

=> Change to d55 tachometer.

Project: Project lift number:

Done
Check Action Note
Machine room:
The correct installation time overspeed governor is fixed on the floor and the direction of rotation
1. is correct.

2. Check that the protection deck has been installed in staged installation.
3. The fixing of Tirak diverting is safe.
4. The fixing of material hoist is safe.
Shaft:

5. Check that the openings to the shaft are closed.

On the lift working platform:

Check that the safety gear wedges are not touching the rail when the safety pedal is pushed
6. down.

7. Check that the safety pedal lifts the wedges up so that the lift doesn’t descend.
8. Check that the overspeed governor rope is fixed properly to the safety gear lever..

9. Check that the Tirak hoist and hook are fixed to the sling in the right way.

10. Check that the safe balustrades have been installed.

11. Check that the protection has been installed.

12. Check that the electric supply is safe.

Pit:

13. Check that the tension weight is installed correctly.

Comments

14.

Title: Fitter
Signature/
15.
Date
Name

All rights reserved. (-) 2002-04-30
MP Installation quality document
P1 Check-up (Plumbing down from template) form
Project: Project lift number:
Check Done
Action Note
1. Check that the plumbing template has been secured to the temporary deck or machine room floor.
Check the reference distances between the small plumbline holes in the template (Nominal distances
from GA drawings) and record them in the table. Mark also the identifications of the neighbouring
elevators in the same group, using the boxes in the picture.
Template Actual in pit TP5 TP1 TP6
TP1
2. TP2 TP3 TP4

TP3 TP2

TP4
Check that all of the templates
TP5
are aligned
TP6
Check that the nominal distances from the plumblines to the

A5
shaft walls have been recorded to the plumbing table. Verify (D)

the measurements by checking the distances on adequate A3

3. amount of levels. (For the plumbing table refer to the elevator A4 (A8)
level AM manual)

A6
(B)

A2
Ensure that the dimensions at all levels between the shaft walls and the door plumblines are within
4. allowed tolerances (see GA drawings) to suit for the sill entrances and car and counterweight guide rail
brackets. (If not contact the builder to agree how to proceed)
• At the main floor verify the position of the elevator by measuring the distances from the builder
advised gridline reference point (Preferably RP1) to the lift door centerlines (RP1 / RP2). Fill the
distances to the table below.
• Fill the “Y” distances to the table and check that they are within given tolerances (Y = nominal
distance from the gridline to the shaft front wall (advised by the builder, Ymax ≤ 800 mm) + nominal
A3/A4 distances from the GA drawings).
• Fill the “R” distances (From the door centerline and gridline intersection to the plumblines) to the
5. table and verify the position of plumblines by checking that the “R” distance pairs are the same.
y Main floor Nominal Actual

X1
X2
Y1
Gridline
Y1

R1
Y2

R2
advised by Y2
X1 x
X2 RP2 builder
RP0 RP1 R1 R2
Ensure that the plumblines are secured in the pit and that the final positions of the lines have been
6. marked on the adjacent walls with two dimensions and that the precise places where they were
measured from are marked.
Measure and record the distances between the secured plumblines in the pit and verify that they are
7.
within the given tolerances from the reference distances recorded in step 1.
Check that no offset is present in the plumblines, by releasing one line from the support bracket and
8.
verifying again its position.
9. Comments:
Title: Fitter

10. Signature/Date
Name
Installation tolerances: ± 1 mm within the dimensions of one elevator, ± 2 mm between the dimensions of two lifts

All rights reserved. (-) 2002-04-30
MP Installation quality document
P2 Check-up (Plumbing in the rehang of staged installation) form
Project: Project lift number:
Done
Check Action Note
Check that the plumbing template has been secured to the temporary deck or machine room
1. floor and that the plumblines are properly attached to the template.

Check that the nominal distances from the

plumblines to the shaft walls have been recorded

A5
(D)
to the plumbing table. Verify the measurements by
checking the distances on adequate amount of A3
A7
2. levels. (For the plumbing table refer to the
elevator level AM manual) A4 (A8)

A6
(B)

A2
Ensure that the dimensions at all levels between the shaft walls and the door plumblines are
3. within allowed tolerances (see GA drawings) to suit for the sill entrances and car and
counterweight guide rail brackets. (If not contact the builder to agree how to proceed)

Check that the last pair of car guide rail brackets, which have been adjusted with the previous
4. position of the plumbing template, are clearly marked on the wall or supporting beams.

Check with the DBG gauge that the car guide rail
plumblines are in the correct position at the last
marked pair of guide rail brackets.
5.
DBG gauge

Measure and record the distances between the plumblines at the level of the last marked pair of
guide rails and verify that they are within the given tolerances from the reference distances
recorded in step 1 of P1 check-up. Mark also the identifications of the neighbouring elevators in
the same group, using the boxes in the picture.

Template Actual (Last marked TP5

guide rail bracket pair) TP1 TP6

6. TP1
TP3 TP4
TP2
TP2
TP3
TP4
Check that all of the templates
TP5 are aligned
TP6
Ensure that the plumblines are secured in the pit in their original positions (Original positions are
7. marked on the pit walls.) (Possibly just the car guide rail plumblines extend to the pit.)

Comments:
8.

Title: Fitter

Signature/
9. Date
Name

Check the guide rail

positions in relation to each 300 mm
other and to the plumblines
with the DBG gauge
(Tolerance ± 0,5 mm).
1.
Pointing fault at 300 mm DBG gauge
from the blade towards the
opposite rail max 1 mm.

Check with a 1000 mm

long rigid ruler and filler
gauge or pocket light every
guide rail joint for
straightness.
Check also the straightness
2. from the side of the guide
rails.

Check with a 1000 mm

long rigid ruler and filler
gauge or pocket light every
guide rail joint for
straightness.
Check also the straightness
3. from the side of the guide
rails.

4. Check that the fitter has marked his initials on the adjusted brackets and guide rail joints.
Final:
Check the positions of the guide rails by driving with the Tirak from end to end and by having the DBG
5. gauge on balustrades. Check at every bracket the relation to the plumblines (Tolerance ± 1 mm). See
picture in Step 1.

6. Randomly check 10 % of the guide rail joints as advised in Step 2.

7. Check that the fitter has marked his initials on the adjusted brackets and guide rail joints.
Comments:
8.

Title: Fitter
Signature/
9.
Date
Name

1. Check the position of the travelling cables to be according to the general arrangement drawings.

Check the position of compensation cable(s), if applicable, to be according to the general

2.
arrangement drawings.
Check that the safety gear blocks are adjusted to the X
center and they stand vertically, wedged in the right place X
on the rail.
3.

4. The roller guide shoes with slippers without rollers shall be installed under safety gear assemblies.
Check that there is a 5mm gap around the rail in the
groove of the RG body when slipper is against the rail, if
not, add shims between fixing plate and safety gear
5. assembly. 5 5

In the middle of the shaft:

6. The lift is driven to the middle of the travel.

Check that:
• In 1:1 suspension the ropes are correctly installed in the hitch plate; order and giving minimum
7. eccentricity.
• In 2:1 suspension the ropes are on the right grooves giving minimum eccentricity.
• The tension in suspension and compensation ropes, if applicable, is equal
• Check that the gap around the ESB if applicable, is
according to the AM instructions. If not, adjust.
• Check that there is a 5mm gap around the rail in the groove
of the RG body when slipper is against the rail, if not, add
shims between the roller guide shoe fixing plate and the
8. upper beams.
• Ensure that the encoder side of the upper beam assembly 5 5
is adjusted to the center of the guide rail.
• The non-encoder side can be left in it’s natural position, 5
unless the sling is more than 15 mm twisted, in that case it
has to straightened with shims at lower beam assembly
9. Remove the slippers from upper roller guide shoes.
Check that the rails touch the edges of the grooves in the RG body simultaneously in back to front
10.
direction.
11. Install the slippers back to upper roller guide shoes.
If the rails didn't touch the rails simultaneously in back to front direction, re-position roller guide shoes
12.
on car top according to AM.
13. Comments:
Title: Fitter

Signature/
14.
Date
Name

Project: Project lift number(s):

Done
Check Action Note
Check that the door plumblines are secured in the brackets fixed on the landing of the topmost
1. possible level and check that the final positions of the plumblines and the points where they were
measured from are marked on the landing.

Record the distances from the plumblines to the centrelines of the vertical columns. Ensure that the
dimensions are within the allowed tolerances. (Tolerance ±10 mm)

Y
Sill Bracket Vertical Column

X3 X4 X5

Y2 Y5

2. Y1 Y4 90º
90º Y3 Gridline advised Y6
RP0 RP1 by builder RP2
X1 X2 X

Nominal Actual Nominal Actual

X1 Y1
X2 Y2
X3 Y3
X4 Y4
X5 Y5
Y6

3. Verify that the plumblines hang freely and nothing is interfering with them.

Verify the positions of the plumblines at the main floor, that the distances to the door centerlines
4. are correct and that the door centerlines are in a 90° angle in relation to the gridlines. Ensure
that the plumblines are secured after the check-up is completed.
The B1 check-up can be used for example to guide subcontractors in the installation of vertical
5. columns for dividing beams and for sill brackets or other shaft material. Or the check-up is used to
inspect the installation quality of the subcontractors, that are used to match the construction process.
Comments:

Title: Fitter
Signature/
7.
Date
Name

Project: Project lift number:

Done
Check Action Note
Model:

1. Check that the closing weight is able to close the doors

2. Check that the door lock is adjusted properly.

Check that the horizontal level of the sill matches with the Finished Floor Level (FFL) marked by
3.
the builder (Tolerance ± 1mm).
Check that the door sill and
railing are positioned correctly in
relation to the door plumblines.

Door Door
4.
sill toptrack

5. Check that the fitter has marked his initials on the door components.
Final (Check from adequate amount of installed landing doors):

6. Check that the closing weight is able to close the doors

7. Check that the door lock is adjusted properly.

Check that the horizontal level of the sill matches with the Finished Floor Level (FFL) marked by
8.
the builder (Tolerance ± 1mm).

9. Check that the door toptrack and sill are positioned correctly in relation to the door plumblines.

10. Check that the fitter has marked his initials on the door components.
Comments

11.

Title: Fitter
Signature/
12.
Date
Name

Site responsible: Commissioner:

Check Done
Action Note
Elevator:
1. Elevator is not roped or the ropes are not on the motor sheave.
Machine room:
2. Machine room is cleared of unnecessary objects: tools, unnecessary equipment and waste material.
3. Machine room is lockable.
4. Machine room lighting is operational and electricity for the tools is arranged.
5. Cable routes are installed.
6. Main switch is installed.
Main elevator supply cable and earthings are connected and ready for powering during
7.
commissioning.
Machinery:
8. Machinery is aligned and fixed in the final position.
9. Air filters are correctly positioned to protect the machinery against dust and foreign objects.
10. Motor supply cable is connected.
11. Motor fan is connected.
12. Resolver cable is connected.
13. Tachometer cable is connected.
14. Brake control cable is connected.
15. Thermistor cable is connected.
16. Hand winding switch (if applicable) is installed and connected.
Controller:
17. Control and drive panels are fixed.
18. Cables between control and drive panels are connected.
19. Motor supply cable is connected.
20. Resolver cable is connected.
21. Tachometer cable is connected.
22. Brake control cable is connected.
23. Thermistor cable is connected.
24. Emergency drive unit is connected.

25. Power supply and earthing are connected in the main switch unit and in the controller.

All rights reserved. 1 ( 2) (-) 2002-04-30
MP Installation quality document
E1 Check-up (Adjusting drive without ropes) form
NOTE: It is essential for your safety that the relevant documented installation steps have been completed
before each commissioning stage.
Follow these instructions, your local safety codes and work according to accepted safe working practices.
If it is necessary to deviate from the official method, consult your supervisor and local specialists before
26.
continuing work.
Where necessary a method statement and standard hazard and risk assessment should be carried out
for the deviations.

Comments:

27.

Title: Fitter

28. Signature/Date
Name

25. Buffers are installed and oil levels are checked.

26. Overspeed governor tension weight is installed and roped.

27. Pit is dry and cleared of unnecessary objects: tools, unnecessary equipment and waste material.

NOTE: It is essential for your safety that the relevant documented installation steps have been completed
before each commissioning stage.
Follow these instructions, your local safety codes and work according to accepted safe working practices.
28. If it is necessary to deviate from the official method, consult your supervisor and local specialists before
continuing work.
Where necessary a method statement and standard hazard and risk assessment should be carried out
for the deviations.
Comments:

29.

Title: Fitter

30. Signature/Date
Name

Site responsible: Commissioner:

Check Done
Action Note
Elevator:
1. Car and counterweight guide rails are cleaned and installed.
2. Initial commissioning before roping is succesfully done.
3. Elevator is roped and compesation ropes are installed (if applicable).
Machine room:
4. Machine room is cleared of unnecessary objects: tools, unnecessary equipment and waste material.
5. Machine room temperature is less than 40 degrees Celsius in all circumstances.
Additional power supplies are connected (e.g. car and lift well lighting, signal power supply) and
6.
ready for powering during commissioning.
Controller:
7. Overspeed governor cable is connected.
8. Travelling cables are connected.
9. Car lighting and addittional signal power supply are connected.
Overspeed governor:
10. Tripping speed and direction of the overpeed governor are checked.
11. Overspeed governor is installed and roped (temporary overspeed governor is used, if applicable).
12. Cable is connected.
Car:
13. Raw car is installed in the final position according to AM-06.06.018..
Car and car roof are cleared of unnecessary objects: tools, unnecessary equipment and waste
14.
material.
15. Car safety gear is operational.
16. Top and bottom roller guide shoe bodies are installed (the rollers are installed later).
17. Load weighing device is installed.
18. Car Top Module and Inspection Drive Unit are installed.
19. Safety gear contact is installed and the cable is connected to the Car Top Module.
20. Final limit switch is operational and connected to the safety chain.
21. Trap door contact is operational.
22. Travelling cables are connected to the Car Top Module.
23. Position encoder is installed according to AM-05.05.031.
Counterweight:

Counterweight is installed and loaded with filler bits excluding the amount corresponds to the
24.
nominal load.

Site responsible: Commissioner:

Check Done
Action Note
Elevator:
1. Car and counterweight are balanced.
2. Commissioning for the installation drive (with ropes) is succesfully done.
Safety chain is operational and there are no overconnections (especially at the landing door lock
3.
contacts).
Machine room:
4. Machine room is cleared of unnecessary objects: tools, unnecessary equipment and waste material.
5. All the safety devices in the machine room are operational.
Controller:
6. Shaft bundle is connected
7. All overconnections are removed.
Overspeed governor:
8. The final overspeed governor is installed for the car.
9. Counterweight overspeed governor (if applicable) is installed, roped and connected.
Car:
Car and car roof are cleared of unnecessary objects: tools, unnecessary equipment and waste
10.
material.
11. Car door is installed according to AM-03.12.067.
12. Car door cables are connected and car door is commissioned and adjusted.
13. Car lighting and construction time COP (if applicable) are installed and connected.
Rollers are installed to the roller guide shoe bodies and adjusted according to the AM, if they have
14.
not been sealed at the factory. The slippers are removed.
15. Car is balanced statically.
16. Load weighing device is connected and mechanically adjusted.
17. All the car safety devices are operational.
18. Hipo reader is installed and connected according to AM-05.05.030.
19. Position encoder is installed according to AM-05.05.031.
20. ESB is installed (if applicable) according to AM-07.04.030.
Counterweight:
Counterweight frame is aligned by releasing one corner and finding the natural position of the
21.
frame. The guide shoe positions are adjusted accordingly with 50 % of the nominal load.
Lift well:
Landing doors are installed, aligned and adjusted according to AM-03.12.066. Landing door
22.
contacts are operational in the safety chain.

23. Maintenance platform is installed (if applicable)

25. Hipo code plates are installed, aligned and finalised according to AM-05.05.030.

Signalisation (e.g. floor computer) is installed according to AM-03.09.012.

26.
Landing call buttons and displays do not have to be installed at this stage.

27. All safety devices in the lift well are operational.

28. Alignment of the ETS and NTS switches and ramps is checked by driving at LOW speed.

29. Pit is dry and cleared of unnecessary objects: tools, unnecessary equipment and waste material.

NOTE: It is essential for your safety that the relevant documented installation steps have been completed
before each commissioning stage.
Follow these instructions, your local safety codes and work according to accepted safe working practices.
30. If it is necessary to deviate from the official method, consult your supervisor and local specialists before
continuing work.
Where necessary a method statement and standard hazard and risk assessment should be carried out
for the deviations.
Comments:

31.

Title: Fitter

32. Signature/Date
Name

Site responsible: Commissioner:

Check Done
Action Note
Elevator:
1. Car and counterweight are balanced with final decorations.
2. Commissioning for the nominal speed is succesfully done.
3. The lift complies with the lift standards (e.g. EN81-1)
Machine room:
4. Machine room is cleared of unnecessary objects: tools, unnecessary equipment and waste material.
Machine room ventilation is operative. Air conditioning is installed if it is needed to keep the
5.
temperature below 40 degree Celsius.
6. Optional devices are operational.
Car:
Car is finalised (e.g. wind-deflectors, compensation ropes, if applicable, are installed) according to
7.
AM-06.06.018.
8. Car interior is completed according to AM-06.06.012.
9. Car is balanced statically.
10. Load weighing device is adjusted.
11. Roller guide shoes are adjusted according to the AM, if they have not been sealed at the factory.
Car and car roof are cleared of unnecessary objects: tools, unnecessary equipment and waste
12.
material.
Counterweight:

13. Counterweight and car are in balance with 50% of rated load.

Lift well:

14. Guide rails are cleaned.

15. Pit is dry and cleared of unnecessary objects: tools, unnecessary equipment and waste material.

NOTE: It is essential for your safety that the relevant documented installation steps have been completed
before each commissioning stage.
Follow these instructions, your local safety codes and work according to accepted safe working practices.
16. If it is necessary to deviate from the official method, consult your supervisor and local specialists before
continuing work.
Where necessary a method statement and standard hazard and risk assessment should be carried out
for the deviations.
Comments:
17.

Title: Fitter

18. Signature/Date
Name

Elevator number:

Site address:

Site responsible:

Checked by:

Date:

Check Done
Action Note
Communications:
1. Communication device in place and working as called for in EN-81.1: 14.2.3.4.
The emergency alarm device allows two-way communication with a rescue service. (EN-81.1:
2.
14.2.3.3)
Doors / trap door:
3. The machine room/trap doors are fitted with a suitable lock. (EN-81.1: 6.3.3.3.)
Minimum dimensions of (EN-81.1: 5.2.2):
• Inspection doors 1.4m x 0.35m,
4.
• Emergency doors 1.8m x 0.35m
• Inspection traps 0.5m x 0.5m
5. Any door or trap does not open into the lift well.
Doors and traps are openable by key, but self locking and interlocked with the safety chircuit (EN-
6.
81.1: 5.2.2).
7. Emergency doors if the consecutive landing sill to sill distance is greater than 11m.
The access door to the pit if the pit depth is 2.5m or more.
8. If the building does not permit the pit door, there should be permanent means to descent to the pit
floor (EN-81.1: 5.7.3.2).
Running clearance in both car and landing doors between door panels, and between panels and
9.
uprights, lintels or sills are 6mm or less (EN-81.1: 7.1).
No recess or projection on the face of the sliding car or landing door panels exceeds 3mm. (EN-
10.
81.1: 7.5.1)
The horizontal distance between the sills of the car and landing doors is 35mm or less (EN-81.1:
11.
11.2.2).
12. The automatic self closing function works correctly (EN-81.1: 7.7.3.2).
Each landing door is capable of being unlocked with emergency key from outside (EN-81.1:
13.
7.7.3.1).
The car door can be manually opened within the unlocking zone with a force of less than 300N with
14.
the power off (EN-81.1: 8.11.2).
Each contact of landing doors prevents car movement outside the unlocking zone, if the contact is
15.
broken (EN-81.1: 7.74).
Car door contact prevents car movement outside the unlocking zone, if the contact is broken (EN-
16.
81.1: 8.9).
17. The mechanical locks of each landing have been proved for positive locking (EN-81.1: 7.7.5).
© 2002 KONE Corporation QD-181.330
All rights reserved. (-) 2002-04-30
MP Installation quality document
Check list for compliance with standard EN 81-1
18. All electrical safety devices on the landing door panels operate correctly (EN-81.1: 7.7.6.2).
19. The car door lock (if fitted) operates correctly (EN-81.1: 8.9.3).

Lift well:
20. Lift well lighting is adequate.
When the car is empty and the counterweight is brought to contact with the buffer at the speed for
21.
which the buffer is designed confirm that no deterioration occurs to the lift (EN-81.1: 10.4.3).

C D
B
A

22.

23. When counterweight is on the fully compressed buffer (H = 0.035 x v2, Where v = rated speed):
• The rail lengths will accommodate a further travel (A) of the car for at least (0.1 + H)m (EN-
24.
81.1: 5.7.1.1a)
• The dimension (B) from the standing area on the car roof to the first striking point above is at
25.
least (1.0 + H)m (EN-81.1: 5.7.1.1.b)
• The free vertical (C) between the lowest part of the ceiling of the lift well and the highest item on
26.
the car roof is at least (0.3 + H)m (EN-81.1: 5.7.1.1.c.1)
• The free vertical distance (D) between the lowest part of the ceiling of the lift well and the
27. highest part of the guide shoes/rollers, attachments / header or parts of vertical sliding doors is
at least (0.1 + H )m (EN-81.1: 5.7.1.1.c.2)
• There is sufficient space for a rectangular block of 0.5m x 0.6m x 1.0m resting on one its
28.
surface on the car roof.
Slowdown monitoring is tested (EN-81.1: 5.7.1.3 and EN-81.1: 12.8). Refer to the safety inspection
29.
instruction in AM-01.01.036 chapter 9.9 Optional tests for ETS and NTS testing.
Reduced stroke buffering is equipped with the terminal speed reduction (EN-81.1: 10.4.3.2). Test
30. according to the safety inspection instruction in AM-01.01.036 chapter 9.7.3 Buffer test with rated
load and reduced speed.
31. If compensation is required, it has been correctly fitted.
32. Anti-rebound device (EN-81.1: 5.7.1.4) is correctly adjusted.
33. The electrical safety device on the anti-rebound device operates correctly (EN-81.1: 9.6.2)
When the car with rated load is brought into contact with the buffer at the speed for which the buffer
34.
is designed confirm that no deterioration occurs to the lift (EN-81.1: 10.4.3).

35.

B A
C

36. When the car is on the fully compressed buffer (H = 0.035 x v2, where v = rated speed):

37. • The further guided travel of counterweight is at least (0.1 + h)m (EN-81.1: 5.7.1.2)

• There is sufficient space for a rectangular block of 0.5m x 0.6m x 0.8m resting on one its
38.
surface below the car (EN-81.1: 5.7.3.3.a).
• Free vertical space between the bottom of the pit and the lowest part of the car is at least 0.5m
39.
(EN-81.1: 5.7.3.3.b)
• Free vertical distance of not less than 0.1m within a horizontal distance of 0.15m between (EN-
81.1: 5.7.3.3.b):
• The apron or parts of the vertical sliding door and adjacent walls
40.
• The lowest part of the car and the guide rails.
• The free vertical distance between other highest parts of the pit and lowest parts of the car then
those mentioned above is at least 0.3m (EN-81.1: 5.7.3.3.c)

41. Counterweight screen is fitted (EN-81.1: 5.6.1).

In case of adjacent lifts there is a screen in the pit extending to height of 2.5m above the lowest
42.
landing floor to prevent access from one pit to the other (EN-81.1: 5.6.2.1)
Traction / Braking / Safety gear:
Does the car stop under emergency condition:
• Empty car at rated speed travelling upwards in the upper part of the lift well (EN-81.1: Annex
D.2.h.1.a and D.2.j.1). Refer to chapter 9.5.5 traction test in the safety inspection instruction.
43. • Car with 125% load travelling downwards in the lower part of the lift well (EN-81.1: Annex
D2.h.1.b).
Refer to the safety inspection instruction in AM-01.01.036 chapter 9.6.2 Test of traction in the
safety inspection instruction.
Counterweight safety gear stops the elevator at approriate speed with empty car travelling in up
direction (EN-81.1: Annex D.2.k.).
44.
Refer to the the safety inspection instruction in AM-01.01.036 chapter 9.5.4 Counterweight safety
gear test in the safety inspection instruction.

Balance:
Current and speed measurements (EN-81.1: Annex D.2.h.3 and D.2.e). Refer to the safety
inspection instruction in AM-01.01.036 chapter 9.5.1 Measure the current and speed in the safety
45.
inspection instruction. The measured balanced load speeds should be within 5% of the rated
speed.
Current measurement UP Speed DOWN Speed
Start Run m/s Start Run m/s
Empty car
Empty car
Empty car

46. Car with half load

Car with half load
Car with half load
Car with rated load
Car with rated load
Car with rated load

Safety circuit:

47. Final limit switches are correctly positioned and they operate correctly.

Stop buttons on the car roof (EN-81.1: 8.15, 15.3, 14.2.2), in the pit (EN-81.1: 5.7.3.4) and in
48. machine room or pulley room (EN-81.1: 6.4.5) are correctly positioned and stop or prevent the
movement of the car.
Safety chain is tested to ensure that an earth fault at the most remote safety contact will cause
49. disconnection without delay (EN-81.1: 14.1.1.1d). Refer to the safety inspection instruction in AM-
01.01.036 chapter 9.8.2 Safety chain short circuit test.

50. All safety chain contacts stop or prevent the movement of the car when operated.

Drive time supervision:

Motor run time limiter operates satisfactorily (EN-81.1: 12.10). Refer to the safety inspection
51.
instruction in AM-01.01.036 chapter 9.9.4 Drive time supervision test.

52. Electrical wiring is in accordance with EN-81.1: 13.5.

Insulation resistance to earth is measured (EN-81.1: 13.1.3 and EN-81.1: Annex D.2.f.1). Refer to
53.
the safety inspection instruction in AM-01.01.036 chapter 9.4.2 Wiring test.
All metal work of the elevator is earthed and the earth is properly connected to the building earth
54.
(EN-81.1: annex D.2.f.2).
Car:
The emergency alarm system allows two-way communication with a rescue service. (EN-81.1:
55.
14.2.3.3)
Following is displayed in the car:
• Maximum load
56. • Number of persons (EN-81.1: 15.2.1)
• Vendors name
• Lift identification (EN-81.1: 15.2.2)

Emergency lighting in the car is sufficient, automatically rechargeable and automatically switched on
58.
with mains failure (EN-81.1: 8.17.4).

59. Car top station is in accordance with EN-81.1: 8.15.

60. Car top station is constructed and operates in accordance with EN-81.1: 14.2.1.3.

Car overload device operates with rated load + 10% (75kg minimum) and prevents normal starting
61.
(EN-81.1: 14.2.5).

62. The car top alarm device operates (EN-81.1: 5.10).

Comments:

63.

APPENDIX E. Roping (rise > 120 m)

WARNING
The following chapters describe the basic roping principles for MiniSpace™, release 1.6
elevators. Due to the varied nature of high rise elevator installation sites it is essential to
pre-plan the roping operation, communication rules and individual personnel
responsibilities in each individual case with your on site management.

WARNING
Recheck the tightness of the platform fixing bolts and re-tighten as necessary before
roping. This is essential due to the roping loads that will be imposed on the platform.

In 2:1 cases where it is not possible to use the Tirak after roping, service drive commissioning
must be complete. Ensure overspeed governor and safety gear contacts are in circuit and all
safety devices are tested.
Do not loose the rope data plate. It will be attached to the controller/machinery for
maintenance purposes.

E.1 Prerequisites (additional fitter(s) to be confirmed by site

manager) +
Before beginning the roping, the following conditions need to be met:
• empty counterweight frame installed on counterweight guide rails
• car sling installed on guide rails
• working platform installed on top of car sling
• attach rope fixing plates to balustrade on working platform (top)
Counterweight, overspeed governor and rope must be installed before roping.

WARNING
The strength of the rope grip is dependant on which way up it is installed. Ensure that the
teeth of the rope grip half (A) are installed according to direction of pull.

A 2.
1033191.wmf

1. Pulling ropes up
2. Pulling ropes down

1012707.wmf

E.2 Counterweight buffer installation

Step Action Note

1 Lift and secure empty counterweight
frame above buffer level using material
hoist and parking chain.
2 Install and align counterweight buffer.

1021994.wmf

E.3 Lifting up the compensation sheave

Step Action Note

1 Using the hydraulic bottle jack lift up the Do not remove transporting supports.
compensation sheave.
2 Secure the compensation sheave to the
top position by adding timber blocks
under transporting supports.

1030235.wmf

E.4 Roping 1:1

+
E.4.1 Position of ropes in grooves

If there is less ropes than pulley grooves, it is recommended place the ropes according to
picture below.
NOTE! Always check the actual rope positions in the general arrangement and installation
instructions of the elevator.

Principal for positioning the ropes in grooves

Even number of Even number of

grooves ropes
Odd number of Even number of
ropes. ropes, but less
than grooves.

Odd number of Odd number of

grooves grooves
Even number of Odd number of
ropes. ropes,
but less than
grooves.
1026756.wmf

E.4.2 Preparations

Step Action Note

1 Transport the compensating rope reels
to the bottom landing.
2 Transport the hoisting rope reels to the
middle landing.

1012711.wmf

3 Drive the working platform to the bottom

of the lift well.

Step Action Note

4 Install a rope fixing plate to the landing WARNING!The rope fixing plate may
side of the working platform. Install a only be used in conjunction with the
second rope fixing plate to the steel handrail supplied with the
counterweight side.
working platform.

2.
1033

1013859.wmf

5 Install the rope clamp on the machinery

bedplate.

1011811.wmf

E.4.3 Marking the overspeed governor rope for roping

WARNING
No one is allowed to be in the elevator shaft below the car at this point.
Ensure there are no loose tools or equipment on the car roof.

Step Action Note

1 Drive the platform exactly to the topmost Ensure that the platform is securely
landing level. attached to hoist and the safety gear is
engaged.

Step Action Note

2 Make a marking to the car overspeed The buffer must be uncompressed.
governor rope at counterweight buffer Ensure no loose tools or equipment can
height. fall from the platform.
Mark the free side of the overspeed
governor rope.
Use spirit level and tape.
3 Make a second marking to the Distance between the markings is:
overspeed governor rope above the first Overtravel + rope stretch + 100 mm.
one.
Check overtravel from layout drawing.
Measure the counterweight height. B = 2 x H / 1000 (mm)
Write it down. H = Travelling height
B = Rope stretch
H

2
H

1021997.wmf 1012720.wmf

E.4.4 Roping 1:1, rear counterweight

Step Action Note

1 From the bottom of the elevator shaft, WARNING!No one is allowed in the
drive the platform upwards until the elevator shaft below the car at this
overspeed governor second marking point!
appears.
Make sure there are no loose tools or
equipment on the car roof.
2 Make a third marking above the second
one. The distance to the third marking is
3
the height of the counterweight.
3 Position the platform to a suitable
working position according to the third
marking.
4 Drive the counterweight frame upwards
using material hoist.
2

1012755.wmf

Step Action Note

5 Raise the top of the counterweight to Position the empty counterweight so
the level of the third marking on the car that you can reach its top from the
overspeed governor rope. Secure the working platform (top) and its bottom
counterweight on guide rail clamps and from the working platform (bottom).
parking chains.
3

1012757.wmf

Step Action Note

6 Fix the hoisting ropes to the landing Arrange the rope ends in coils on the
side rope fixing plate, leaving working platform. Secure the rope coils
approximately 10 metres of rope end with cable ties.
free.
7 Drive the platform to the top of the Feed the ropes off the reels as the car
elevator shaft. sling moves upwards. DO NOT lean into
8 Route the free rope ends over the the elevator shaft! Do not remove the
traction sheave and back down into the landing opening protection.
elevator shaft. Pull ropes as tight as WARNING!Do not release the ropes
possible. Fix the rope ends to the until they are securely fixed to the
counterweight side rope fixing plate.
counterweight. The ropes should be in
Release the ropes from the landing side
rope fixing plate. balance, but do not take any chances.

Step Action Note

7 8

1012760.wmf

Step Action Note

9 Drive the platform back to the
counterweight. Fix the rope ends to the
counterweight rope fixing and release
them from the rope fixing plate. Tie the
car side rope ends back to a guide rail
bracket. Do not mix the order of ropes.
10 Drive the platform to the bottom of the Feed the compensating ropes off the
elevator shaft. Fix compensating ropes reels as the car is driven upwards.
to car sling. Refer to AM-05.07.009.
11 Drive the platform back to the Check that rope tension is even.
counterweight so that 3rd marking is in
level with counterweight top. Fix the
hoisting ropes to the car sling rope
fixing.

Step Action Note

1012767.wmf

Step Action Note

12 Lower the platform enough that the Only raise the counterweight enough
counterweight is supported by the that the guide rail clamps and chains
hoisting ropes. Remove the chains and can be removed.
guide rail clamps from the Before connecting compensating
counterweight. Drive the platform to the ropes to the counterweight, check
top of the elevator shaft. Park the car on that overtravel is approximately
safety gear and parking chains. correct.

Step Action Note

13 At the bottom of the elevator shaft, Refer to AM-05.07.009.
attach the compensating ropes to the
counterweight. Load the counterweight Build a working platform in the pit if
with the maximum of 20 % of filler necessary to reach the counterweight.
weights. Fit the counterweight securing
clipses immediately. Ensure that the
working platform stays heavier than the
counterweight at this stage.

1033582.wmf

12
13

1012769.wmf

Step Action Note

14 Using the hydraulic bottle jack lift up the
compensation sheave. Cut the bands
and remove all supports under the
compensation sheave.

1030235.wmf

15 Lower the compensation sheave onto

the ropes.
16 Check the overtravel.
17 Check and adjust the rope tensions. Refer to chapter 27.5 Checking and
adjusting rope tensions.

E.4.5 Roping 1:1, side counterweight

Step Action Note

1 Position the empty counterweight at the
midway position.

Raise the top of the counterweight to

the level of the third marking on the car
overspeed governor rope. Secure the
counterweight on guide rail clamps and
parking chains.

1012779.wmf

2 Attach ropes to rope fixing plate on Arrange rope ends in coils on the
platform, leaving approximately 20 working platform. Secure the rope coils
metres spare rope. with cable ties.
3 Drive the platform to the top of the Feed the ropes off the reels as the sling
elevator shaft. Place the wooden rope moves upwards. DO NOT lean into the
guiding frame on working platform. elevator shaft! Do not remove the
landing opening protection.

Step Action Note

4 Route the free rope ends over the Route the ropes one at a time. DO NOT
traction sheave and back down into the release the ropes from the rope fixing
elevator shaft. Fix the ropes in the plate until they are securely fixed to the
locking device in the machine room. locking device on the machine bed plate
Install the rope anchorages at the end and the wooden rope guiding frame.
of the ropes. Fix the rope anchorages
to the wooden guiding frame. Assemble
the guiding frame over the
counterweight guides. Release the
ropes from the rope fixing plate in the 1012787.wmf

working platform.

2 4

1025619.wmf

Step Action Note

5 Drive the platform down approximately Ensure that ropes are clamped
5-10 metres. Fix the ropes to the rope securely.
fixing plate in the working platform.
Release the locking device.

1012846.wmf

6 Manually release the MX brake and Be careful that the ropes do not start
locking device. Drive the platform to the coiling on the car roof. If this happens,
top of the elevator shaft. Allow the take the rope up in smaller steps.
wooden rope guiding frame to descend
towards the counterweight.
7 Close the brake. Refit the locking
device on the machine bed plate.

1012787.wmf

8 Release the ropes from the rope fixing

plate.
9 Lower the platform down to the level of
the wooden rope guiding frame.

5 6 9

1025621.wmf

Step Action Note

10 Reclamp the ropes to the rope fixing
plate.

1012846.wmf

11 Loosen locking device for the ropes and open MX brake and drive up until you are
level with the top floor.
12 Reclamp the locking device for the
ropes.

1012787.wmf

13 Unclamp the platform rope fixing plate and drive back down to the wooden rope
guiding frame.
14 Repeat until wooden rope guiding frame reaches the counterweight.
15 Drive the platform down to Tie the car side rope ends to a guide rail
counterweight level. Partially dismantle bracket.
the wooden rope guiding frame and
transfer rope anchorages to the Do not mix the rope order.
counterweight, one at a time.
16 Drive down to the bottom of the Refer to AM-05.07.009.
elevator shaft. Fix compensating ropes
to the car sling.
17 Drive back to the counterweight. When
the top of the counterweight aligns the 3.
third marking (3.) on the car overspeed
governor rope, the car is at a correct
height for fixing the ropes. Fix the
hoisting ropes to the car rope fixings.
Do not mix the rope order and make 1014071.wmf

sure that rope tension is even.

Step Action Note

15 16 17

1025623.wmf

18 Drive the platform slightly down to raise

the counterweight off the guide rail
clamps. Release the counterweight
from the guide rail clamps and chains.
19 Drive the platform up. Attach Refer to AM-05.07.009
compensating ropes to the
counterweight. Build a working platform in the pit to
reach the counterweight, if necessary.
Load the counterweight with the
maximum of 20% of filler weights. Fit
the counterweight securing clipses
immediately. Ensure that the working
platform stays heavier than the
counterweight at this stage.

Before connecting compensating

ropes to the counterweight, check
that overtravel is approximately
correct.

1033582.wmf 1012858.wmf

Step Action Note

20 Using the hydraulic bottle jack lift up the
compensation sheave. Cut the bands
and remove all supports under the
compensation sheave.

1030235.wmf

21 Lower the compensation sheave onto

the ropes.
22 Check the overtravel.
23 Check and adjust the rope tensions. Refer to chapter 27.5 Checking and
adjusting rope tensions.
24 Remove the locking device for the
ropes from the machine.

E.5 Roping 2:1

+
E.5.1 Position of ropes in grooves

Principal for positioning the ropes in grooves

Even number of Even number of

grooves ropes
Odd number of Even number of
ropes. ropes, but less
than grooves.

Odd number of Odd number of

grooves grooves
Even number of Odd number of
ropes. ropes,
but less than
grooves.

1026756.wmf

Rope order
12345

A - Counterweight diverter pulley

A
54321 B - Car top diverter pulley
C - Machine sheave

54321
B
54321

a1131r1.wmf

E.5.2 Preparations

Step Action Note

1 Transport the compensating rope reels
to the bottom landing. 3
2 Transport the hoisting rope reels to the
landing located two thirds of the way
down from the top of the lift well.
3 Raise the empty counterweight to the
top of the lift well using the material
hoist. Secure the counterweight with
guide rail clamps and parking chains.

~2/3

1012868.wmf

4 Install a roping tool to the working

platform (top).
5 Install the locking device for ropes on
~1/3

the machinery bedplate.

1012871.wmf

E.5.3 Roping 2:1, rear or side counterweight

Step Action Note

1 Drive the car to the landing two thirds of Arrange the free rope ends in coils on
the way down from the top of the lift the working platform floor. Secure the
well. Attach hoisting ropes to the roping rope coils with cable ties.
tool for working platform. Leave
approximately 20 meters of rope end
free.
2 Drive the car to the top of the lift well.
Route the rope ends through the locking
device, traction sheave and
counterweight diverter pulley. Fix the
ropes to the counterweight side rope
fixings.
3 Lock the ropes using the locking device
in the machine room. Make sure the
locking device holds the ropes securely.
Release the ropes from the roping tool
on the working platform. 1012787.wmf

Step Action Note

1 2

1012873.wmf

4 Lift the counterweight slightly using a

material hoist to take the load off the
guide rail clamps. Release the
counterweight from the guide rail
clamps and parking chains.
5 Drive the platform down approximately
50 metres. Fix the hoisting ropes to the
roping tool on the working platform.
6 Release the locking device in the WARNING!Use two way radios. One
machine room and manually open the designated person must control the
brake. Drive the platform up and lower hoist movement.
the counterweight using the material
hoist simultaneously.
7 When the platform reaches the top of
the lift well reclamp the locking device.
Release the roping tool for working
platform.
1012787.wmf

Step Action Note

8 Repeat steps 5 to 7 until the
counterweight is on the same level with
the rope reels.

5 6 8
~50m

1012897.wmf

9 Reclamp the locking device for ropes. Refer to AM-05.07.009.

Release the ropes from the roping tool WARNING!Failure to pick the
for working platform.
compensating ropes at this stage will
result in an imbalanced load, possibly
pulling the car to the lift well roof!

1012787.wmf

Drive the car to the bottom of the lift

well. Attach the compensating ropes to
the car sling.
10 Drive to the landing where the hoisting rope reels are located. Attach the hoisting
ropes to the roping tool on the platform handrail. Take the rope ends off the reels,
coil them and store them on platform floor.

Step Action Note

11 Release the locking device for ropes in Drive the counterweight with material
the machine room and open the brake hoist to the correct roping position
manually. Drive to the top of the lift well (overtravel and rope stretch included).
simultaneously lowering the
counterweight with the material hoist.
Reclamp the ropes in the machine
room.

1012905.wmf

2/3 11

9 10
1/3

1012909.wmf

12 Route the hoisting ropes through the car

pulley and fix them to the car side rope
fixings. One at the time release the
ropes from the roping tool on the
working platform. Release the locking 1012913.wmf

device for ropes in the machine room.

13 Shorten the hoisting ropes at top floor
level until the car is at the correct
position.
14 Pass the ends of the compensating Refer to AM-05.07.009.
ropes through the compensation
sheave. Attach the compensating ropes
to the counterweight rope anchorages.

Step Action Note

15 Load the counterweight with the
maximum of 20% of filler weights. Fit the
counterweight securing clipses
immediately. Ensure that the working
platform stays heavier than the
counterweight at this stage.

1033582.wmf

12 14

1012916.wmf

16 Using the hydraulic bottle jack lift up the

compensation sheave. Cut the bands
and remove all supports under the
compensation sheave.

1030235.wmf

Step Action Note

17 Lower the compensation sheave onto
the ropes.
18 Check the overtravel.
19 Check and adjust the rope tensions. Refer to chapter 27.5 Checking and
adjusting rope tensions.

E.6 Checking and adjusting compensation rope tensions

Compensation rope hitches

Counterweight at side Counterweight at rear

1026633.wmf

1012732.wmf

Step Action Note

1 Verify that spring lengths are equal.
2 Verify that ropes are not twisted and
rope bottles have no tension.

=
3 Adjust spring lengths equal.

= =

= = =
1033136.wmf

E.7 Rope guards

The rope guards installation details are copied from AM-04.05.050 issue A (MX40).
Detailed instructions for machine type MX32 are shown in AM-04.05.049 or AM-04.05.052.

E.7.1 Rope jump cover (MX40)

B1 B1

B2
B2 B2 C

O
160
O
162.5
O
165
167.5
O
O
C
170
O
172.5
O
175
3...5 mm

1025847.wmf

1. A = Standard rope guard

2. B = Earthquake rope guard
3. C = Earthquake rope guard

Step Action Note

1 Fix the rope guards (threaded holes on
the machine body).
2 Adjust the guards to a space of 3 mm between guard and ropes.

E.7.2 Diverter pulley rope guard (MX40)

Step Action Note

2
3 mm
1022002.wmf

1. Lock screws
2. Fixing collar
1 Install the rope guard to the fixing Loosen the fixing collar lock screws and
collars on the diverter pulley axle. adjust the collar position if needed.
2 Adjust the guards to a gap of 3 mm between guard and ropes.

E.8 Lock down device of the compensation sheave

Step Action Note

1 Adjust the lock down device.

Refer to AM-05.07.009.

20
1012960.wmf

2 Adjust the rod (1) and the lock down

contact (2). 1
3
Refer to AM-05.07.009. 2

16
1012965.wmf

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