AS-11.65.031 KDL32 Repair [PDF]

Zitiervorschau

KDL32 Maintenance Instruction

REPAIR INSTRUCTION FOR KDL32 DRIVE MODULE © 2009 AS-11.65.031 KDL32 All (-) 2009-03-04 rightsKONE reserved. Corporation

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This document is intended to be used by people who are familiar with elevator maintenance and installation and have received proper training on methods and safety as specified by KONE.

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KDL32 Maintenance Instruction

CONTENTS

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1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Modules in the elevator shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Main components of drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Table of tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

ENVIRONMENTAL ISSUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.1 General safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.2 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.3 Maintenance method safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.4 Basic rules preventing ESD hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5

REPLACEMENT OF COMPLETE KDL32 DRIVE MODULE . . . . . . . . . . . . . . . . . . . . . . . 5.1 Before switching OFF the power from the drive module . . . . . . . . . . . . . . . . . . . . . 5.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Replacing KDL32 drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 13 13 13 16

6

REPLACEMENT OF POWER COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Replacing control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 Replacing DC-link capacitor module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 Replacing power module (MCDM board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 17 17 20 21 23

7

REPLACEMENT OF BRAKE CONTROL-, CONTACTOR MODULES AND DRIVE FAN . 7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Replacing brake control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 Replacing contactor module components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Replacing drive fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 28 28 31 31 33

8

REPLACEMENT OF DYNAMIC BRAKING CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 Replacing dynamic braking contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 34 34 37

9

REPLACEMENT OF BRAKING RESISTOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 Replacing braking resistor module (machineroomless elevators) . . . . . . . . . . . . . . 9.4 Replacing braking resistor module (elevators with machine room) . . . . . . . . . . . . .

38 38 38 41 43

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KDL32 Maintenance Instruction

10

UPDATE OF DRIVE SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 Updating drive software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 44 44 47

11

APPROVALS AND VERSION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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KDL32 Maintenance Instruction

1

INTRODUCTION

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The repair and replacement tasks with KDL32 drive module require special training and technical expertise. The environment where the tasks are executed requires special attention to guarantee safety on the work. The KDL32 drive module weighs approximately 30 kg.

1.1

Related documents

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The following documents are required to complete the corrective actions: • • • • • • • • • • • • • • •

1.2

AM-01.03.001 Use of fall arrest systems on elevator construction and modernization sites AM-01.03.002 Take 5 - Electrical safety when working on elevators, escalators and autowalks AM-11.65.029 KONE Minispace™ commissioning with KDL32 drive and safety inspection AM-11.65.030 KONE Monospace® commissioning with KDL32 drive and safety inspection AM-11.65.029-USK KONE Minispace™ commissioning with KDL32 drive and safety inspection AM-11.65.030-USK KONE Monospace® commissioning with KDL32 drive and safety inspection AR-11.65.031 Spare parts manual for KDL32 drive (KM921317AR01) AS-01.01.004 Take Care, End user safety focal points in elevator maintenance AS-01.05.001 Instruction manual for counterweight lifting device AS-12.02.001 Instruction for handling electrostatic-discharge-sensitive-devices on site AS-12.07.011 Power component replacement instruction for V3F drive ASG-11.65.031 Preventive maintenance instruction for KDL32 drive module 948570D01 KDL32 drive parameter list 948570D02 KDL32 drive diagnostics list 959231D01 KDL32 software package

Abbreviations The following abbreviations are used in this instruction Abbreviation CWT LWD MAP ESD LCE RDF SEPt PCB

Counterweight Load Weighing Device Maintenance Access Panel Electrostatic Discharge Lift Controller Electrification Recall Drive Feature Shaft Electrification Panel top Printed Circuit Board

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KDL32 Maintenance Instruction

1.3

Modules in the elevator shaft

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Modules in the elevator shaft in the KONE MonoSpace® elevators 1. Drive module (385) 2. LCE and optional boards

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Shaft electrification panel in the KONE MonoSpace® Special and TranSys™ elevators 1. Drive module (385) 2. Main switch module 3. Main switch (220:1) 4. LCE and optional boards

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KDL32 Maintenance Instruction

1.4

Main components of drive module

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Table 1: KDL32 drive module Pos 1 2 3 4 5 6 7 8 9 10

Name Dynamic braking contactor LOP-ADA module Main circuit and driver board (MCDM-C) Control module DC-link capacitor module Backup power module Contactor module Network filter module Brake control module Fan

Illustration

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KDL32 Maintenance Instruction

Table 2: Braking resistor modules Pos 1, 2

Name Braking resistor module (not included in the drive assembly)

Illustration

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1

2

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Table of tightening torques Fixing screws in mechanical assembly Size (metric) Torque (Nm) M3 1,2 M4 2,9 M5 5,0 M8 14,0

2

ENVIRONMENTAL ISSUES Hazardous waste material must be taken care of according to the local requirements and KONE Environment Strategy.

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KDL32 Maintenance Instruction

3

SAFETY

3.1

General safety precautions

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Safety precautions Follow your national lift codes and other safety related regulations. Follow your local hot work procedures. The local safety codes and rules must be obeyed at all times. Follow the safe working methods.

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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 DEENERGISED BEFORE WORKING ON THEM. A locking off system for main electric supply isolator or other system (for example fuse removal, locking and tagging system, etc. when applicable) must be agreed with person responsible for the building electrification. Personal safety equipment must be available and used as required. IF RISK OF INJURY FROM A FALL Adequate fall prevention system must be in place. If the safety harness is used incorrectly you may still sustain severe injury or death during a fall or uncontrolled movement of the elevator. If you have attached the harness to a guide rail bracket or other fixed point in the lift well, you must ensure that there can be no unwanted movement of the car or counterweight. Handle and dispose of waste materials in accordance with the regulations applicable to your country/state. Ensure that your work does not cause a hazard to others. Keep the entrance and emergency exits clear. Prevent unintentional access to working area with additional fences.

Note In case of conflict between the Code and the present instructions, rely on your national code. Refer to your local procedures for the type of entrance protection required. Use barriers and warning signs to inform and protect the building users. Warning signs highlight possible hazards.

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

Refer to the list of Personal safety items on the next chapter.

For using fall prevention systems refer to AM01.03.001.

In particular keep access ways and fire exits clear. Refer to AS-01.01.004 Take Care End user safety in elevator maintenance.

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KDL32 Maintenance Instruction

3.2

Personal safety

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Gloves, safety shoes, helmets, goggles, dust masks, ear defenders and harnesses are provided for your personal protection. USE THEM AS REQUIRED. Safety item Fall preventation equipment. Refer to AM01.03.001. Dust mask, suitable for working with mineral wool insulation in landing doors First aid kit Safety goggles Safety gloves Rubber gloves for cleaning rails Hearing protection Hard hats Work clothes / overalls Safety shoes with ankle protection

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3.3

Figure

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Maintenance method safety Note the following safety items when working with KDL32 drive module: •

• • • •

• • • • • • •

•

Refer to AM-01.03.002 Take 5 - Electrical safety when working on elevators, escalators and autowalks. The Take 5 safety initiative is designed for installation, servicing, maintenance and modernization work done on the elevators. Personal safety equipment must be used as required. Safety must be ensured with additional fences or guarding, depending on the site conditions. Do not work on the different levels in the elevator shaft at the same time. Ensure that the working site do not cause a danger to the outsiders in the staircase! It is strongly recommended to use additional fences or guarding to prevent dangerous situations. For example the outsiders enter the working zone or some parts or tools cause risks of tripping on the landing. Ensure, that proper lighting is arranged at the work area The cover of the drive module must be kept closed always when not working with the module, even if the main power has been switched OFF. Do not continue the work after opening the covers of the drive module before checking that all circuits are safely de-energized. Power must be turned OFF 5 min. before removing the protection shields. Prevent the reconnection of the possible emergency power supplies etc. Check that there is no voltage (AC) in the supply to RFI filter (389). Check operation of the multi meter before and after the test. Check that there is no voltage (DC) in the intermediate circuit between plus (DC+) and minus (DC-) terminals. Also in the motor and braking resistor terminals. Check the operation of the multimeter before and after the test. Each replacement case must be separately assessed for the risks due to environmental conditions. Replacement cases must not limit environmental conditions.

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KDL32 Maintenance Instruction

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WARNING

Inverter drives usually remain energized 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 VDC range. The test equipment must be checked before and after the test to ensure that it functions correctly.

3.4

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Basic rules preventing ESD hazards

1 Disconnect all power supplies. 2 Earth yourself before touching components. 3 Do not unpack the spare parts before installation. 4 Do not touch the components on the board unnecessarily. 5 Hold the PCB from its edges. 6 The old component must be handled in the same way as the new one. 7 Do not wear combinations of clothing that can create static charges.

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KDL32 Maintenance Instruction

4

TOOLS Part number

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Tool Normal hand tool set Test weights Multimeter

Illustration/Note

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For LWD setup, according to rated load Fluke 179 (or equivalent) with insulated test probes (min. L = 100 mm) specified to 1000 VDC voltage

Height approximately 700 mm

1007089.wmf

Chain hoist

Capacity 100 kg

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Safety barriers

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KDL32 Maintenance Instruction

Part number

Tool ESD protection kit

Illustration/Note

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Cleaner KM969444 KM994397R01 KM953527R01 KM959231H01

Heat conducting paste Paste stencils Metal trowel Programming kit DCBM KDL32 software package

Torque range 2 - 20 Nm

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Alcohol based, locally supported For cleaning heatsink surface Austerlitz WPS II

Includes a PCB and wires (2 pcs.) Includes design document 959231D01 with instructions.

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KDL32 Maintenance Instruction

5

REPLACEMENT OF COMPLETE KDL32 DRIVE MODULE

5.1

Before switching OFF the power from the drive module

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The drive parameters are written to a separate list in the commissioning. Copy the parameters to the new control board. If the recorded resolver angle cannot be found, perform commissioning of the drive module according to elevator type: • •

5.2

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Elevators with machine room AM-11.65.029(-USK) Machineroomless elevators AM-11.65.030(-USK)

Tools

Following tools are recommended to be used when replacing the drive module: • • •

5.3

Chain hoist or equivalent, capacity min. 100 kg Multimeter (Fluke 179 or equivalent) with testing probes specified to 1000 VDC voltage ESD protection kit for PCB replacement

Safety measures The drive module is located in the elevator shaft or in the machine room. In machineroomless elevators the car roof is used as a working platform. Therefore the special safety procedures and working methods are mandatory. The following safety items must be carried out before the actual work:

5.3.1

Safety measures for elevators with machine room

Step 1 2

3 4

Action Ensure that the car is empty. Open the control panel. Switch OFF the main switch (220:2) and main switch light (262). Lock and tag them. Close the control panel. Disconnect and prevent reconnection of the possible emergency power supplies. Wait for 5 minutes.

Illustration/Note Take the elevator out of use.

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KDL32 Maintenance Instruction

Step 5

Action Test by using the multimeter that AC voltage is not supplied to the drive. Check the operation of the multimeter before and after the test.

Illustration/Note The exact location of the cable ends depends on the electrification.

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NOTE! Check the AC voltage (400 VAC) at the end of the power supply cables which inside the drive cabinet are connected to the RFI filter (389).

6 7

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Remove the covers of the drive module. Test by using the multimeter that there is no DC voltage in the drive module. Check the operation of the multimeter before and after the test.

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Loosen the fixing screws.

NOTE! Check DC voltage (600 - 750 VDC) in the intermediate circuit between the (DC+) and (DC-) terminals.

5.4

Safety measures for machineroomless elevators Step 1 2

Action Ensure the car and car roof are empty. Open the MAP. Move the car using RDF to a suitable working level with access to topmost landing and car roof.

3

Switch OFF the main switch (220:2) and main switch light (262). Lock and tag them. Close the MAP.

Illustration/Note Take the elevator out of use. If the elevator does not move using RDF, continue by switching OFF power (Step 3) and then move the car by opening the brake or lifting the counterweight (Step 4). When the MAP is located at the second topmost floor, the SEP and drive module can be disconnected from the power supplies using switches (220:1) and (290:1), located in the shaft near the SEP.

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KDL32 Maintenance Instruction

Step 4

5 6

7

Action If the elevator could not be moved to a suitable working level using RDF (in Step 2), do one of the following: • Empty car upwards: Open the machine brake. Move the car upwards in small steps. • Empty car downwards: Use CWT lifting device, refer to operation instruction AS-01.05.001. Disconnect and prevent reconnection of the possible emergency power supplies. Wait for 5 minutes.

Illustration/Note The power must be switched OFF (Step 3) before moving the car!

Test by using the multimeter that AC voltage is not supplied to the drive. Check the operation of the multimeter before and after the test.

The exact location of the cable ends depends on the electrification.

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NOTE! Check the AC voltage (400 VAC) at the end of the power supply cables which inside the drive cabinet are connected to the RFI filter (389).

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8 9

Remove the covers of the drive module. Test by using the multimeter that there is no DC voltage in the drive module. Check the operation of the multimeter before and after the test.

Loosen the fixing screws.

NOTE! Check DC voltage (600 - 750 VDC) in the intermediate circuit between the (DC+) and (DC-) terminals.

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KDL32 Maintenance Instruction

5.5

Replacing KDL32 drive module Step 1 2

3

4

5 6 7 8 9

10 11 12

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Action Install the chain hoist above the drive module. Disconnect the motor cable, the power supply cable, the braking resistor cable and the control cables from the drive module.

Illustration/Note

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NOTE! Mark the wires! Attach the chain hoist above the drive module.

NOTE! Attach the cover plates of the drive module before lifting out. Loosen the nuts of the fixing bolts. NOTE! The drive module weighs approximately 30 kg. Lower the drive module to the car roof or machine room floor. Attach the chain hoist to the new drive module. Lift the drive module up and lower it to the wall fixing bolts. Tighten all nuts of the fixing bolts. Open the covers of the drive module. Reconnect the cables.

NOTE! Ensure that the power cable connections are tight and the phase order is correct in the power supplyand the motor side. Close the covers of the drive module. Set the recorded drive parameters by the user interface. Perform LWD and shaft setup according to AM-11.65.029 (elevators with machine room) or AM-11.65.030 (machineroomless elevators).

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KDL32 Maintenance Instruction

6

REPLACEMENT OF POWER COMPONENTS

g n i t o

Generally the repair actions for the electrical components are recommended to be limited to the module replacement level. The contactor module and dynamic braking module components are exceptional cases where a single part can be replaced with a spare part. The authorized service personnel can operate the replacement of the power components if there is urgent need for the replacement on the site.

6.1

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Tools

Following tools are recommended to be used with the replacement work: • • • • • • •

6.2

Multimeter (Fluke 179 or equivalent) with testing probes specified to 1000 VDC voltage ESD protection kit Torque wrench (for DC-link capacitor and power module replacements) Cleaner (for power module replacement) Paste stencils: KM994397R01 (for power module replacement) Heat conducting paste (for power module replacement) Metal trowel (for power module replacement)

Safety measures The drive module is located in the elevator shaft or in the machine room. In machineroomless elevators the car roof is used as a working platform. Therefore the special safety procedures and working methods are mandatory. The following safety items must be carried out before the actual work:

6.2.1

Safety measures for elevators with machine room

Step 1 2

3 4

Action Ensure that the car is empty. Open the control panel. Switch OFF the main switch (220:2) and main switch light (262). Lock and tag them. Close the control panel. Disconnect and prevent reconnection of the possible emergency power supplies. Wait for 5 minutes.

Illustration/Note Take the elevator out of use.

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KDL32 Maintenance Instruction

Step 5

Action Test by using the multimeter that AC voltage is not supplied to the drive. Check the operation of the multimeter before and after the test.

Illustration/Note The exact location of the cable ends depends on the electrification.

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NOTE! Check the AC voltage (400 VAC) at the end of the power supply cables which inside the drive cabinet are connected to the RFI filter (389).

6 7

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Remove the covers of the drive module. Test by using the multimeter that there is no DC voltage in the drive module. Check the operation of the multimeter before and after the test.

1062680.wmf

Loosen the fixing screws.

NOTE! Check DC voltage (600 - 750 VDC) in the intermediate circuit between the (DC+) and (DC-) terminals.

6.2.2

Safety measures for machineroomless elevators

Step 1 2

Action Ensure the car and car roof are empty. Open the MAP. Move the car using RDF to a suitable working level with access to topmost landing and car roof.

3

Switch OFF the main switch (220:2) and main switch light (262). Lock and tag them. Close the MAP.

Illustration/Note Take the elevator out of use. If the elevator does not move using RDF, continue by switching OFF power (Step 3) and then move the car by opening the brake or lifting the counterweight (Step 4). When the MAP is located at the second topmost floor, the SEP and drive module can be disconnected from the power supplies using switches (220:1) and (290:1), located in the shaft near the SEP.

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KDL32 Maintenance Instruction

Step 4

5 6

7

Action If the elevator could not be moved to a suitable working level using RDF (in Step 2), do one of the following: • Empty car upwards: Open the machine brake. Move the car upwards in small steps. • Empty car downwards: Use CWT lifting device, refer to operation instruction AS-01.05.001. Disconnect and prevent reconnection of the possible emergency power supplies. Wait for 5 minutes.

Illustration/Note The power must be switched OFF (Step 3) before moving the car!

Test by using the multimeter that AC voltage is not supplied to the drive. Check the operation of the multimeter before and after the test.

The exact location of the cable ends depends on the electrification.

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NOTE! Check the AC voltage (400 VAC) at the end of the power supply cables which inside the drive cabinet are connected to the RFI filter (389).

1062680.wmf

8 9

Remove the covers of the drive module. Test by using the multimeter that there is no DC voltage in the drive module. Check the operation of the multimeter before and after the test.

Loosen the fixing screws.

NOTE! Check DC voltage (600 - 750 VDC) in the intermediate circuit between the (DC+) and (DC-) terminals.

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KDL32 Maintenance Instruction

6.3

Replacing control module Step 1 2

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Action Mark and disconnect the wiring of the control module. Loosen the fixing screws (4 pcs.).

Illustration/Note

NOTE! Be carefully to not drop the fixing screws.

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3 4 5 6 7

Lift the old module out of the drive module. Install new module into the drive module. Reconnect the wiring. Install the covers of the drive module. Perform commissioning to the elevator.

Refer to AM-11.65.029 (elevators with machine room) or AM-11.65.030 (machineroomless elevators).

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KDL32 Maintenance Instruction

6.4

Replacing DC-link capacitor module Step 1

g n i t o

Action Mark and disconnect the wiring of the control module. Note the cable routing in order to reassemble the components correctly. Remove the cable clamp plate. Loosen the fixing screws (5 pcs.) of the protection plate. Remove the control module together with protection plate.

Illustration/Note

l i P

2

Loosen the Allen screws (2 pcs.). NOTE! Be careful not to drop the screws.

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KDL32 Maintenance Instruction

Step 3

Action Remove the M3 fixing screws (6 pcs.).

Illustration/Note

g n i t o

NOTE! Be careful not to drop the screws.

4

5

Lift the old DC-link capacitor module out of the drive module. Install new DC-link capacitor module into the drive module.

NOTE! Do not damage MCDM board when installing the DC-link capacitor module. Attach the M3 fixing screws (6 pcs.). Tighten the Allen screws (2 pcs.) to 1.8 Nm tightness, use torque wrench.

l i P

6

Install the control module and protection plate. Tighten the fixing screws (5 pcs.)

7

Reconnect the wiring to the control module using cable ties. Install the covers of the drive module.

8

Ground the resolver and encoder cables to the protection plate.

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KDL32 Maintenance Instruction

6.5

Replacing power module (MCDM board)

6.5.1

Removing power module

g n i t o

The power module assembly includes MCDM board and copper bus bars (2 pcs.). Step 1 2 3

Action Remove DC-link capacitor module according to section 6.4. Mark and disconnect the wiring of the power module. Remove Allen screws (6 pcs.) of the semiconductors.

Illustration/Note

l i P

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KDL32 Maintenance Instruction

Step 4

Action Remove the six M3 fixing screws (A) and six spacers (B).

Illustration/Note

g n i t o A

NOTE! Keep the screws and spacers in safe.

l i P

A

B B 1062703.wmf

1055063.wmf

A 5

Lift the old power module out of the drive module. Keep the module facing up always!

6

Remove copper bus bars (2 pcs.) opening the Allen screws (4 pcs.) from the old MCDM board.

7

B

B

NOTE! Be careful not to drop parts to the shaft. Install the copper bus bars (2 pcs.) with M4 Allen screws (4 pcs.) to the new MCDM board. NOTE! Tightening torques for M4 Allen screws is 5 Nm. 1058917.wmf

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KDL32 Maintenance Instruction

6.5.2

Applying heat conducting paste to IGBT modules

g n i t o

Ambient temperature must be within 18 - 30 °C and relative humidity below 80 % when applying the heat conducting paste to the heatsink. Ensure the conditions remain in the specified range during the work. Paste must be applied and IGBT module fixed to the heat sink within 10 minutes from taking the paste out of the tube. Hardened or dry paste must not be used. Once the new paste tube is opened, it must be used within the next 5 days. Step 1 2

3 4

Action Clean the surface of the heatsink and IGBT modules with alcohol based cleaner. Clean the stencil from both sides using cleaning agent which does not leave any residue on the stencil. Check that the stencil is not scratched or mechanically damaged. Place the cleaned paste stencil on the IGBT module. Apply paste on the other side of the stencil. Required amount of the paste is about 0.5 1.5 cm3 (amount depends on the size of the stencil and IGBT module).

l i P

5

Spread the paste with metal trowel over the stencil and to the holes in the stencil.

6

Remove the stencil. Place the IGBT module carefully on the heat sink.

Illustration/Note Surfaces should be free of heat conducting paste, grease and impurities. Do not use dirty stencils. The stencil must fit well on top of the IGBT module.

NOTE! Be careful not to spread paste in wrong places, only to the spot on heat sink that is reserved for the IGBT module. Avoid moving the IGBT module after it touches the heat sink. If needed, support the IGBT module for example by attaching pins (2 pcs.) to the opposite corner holes.

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KDL32 Maintenance Instruction

6.5.3

Reinstalling power module

Step 1

2

g n i t o

Action Install the power module into the drive module and fix the Allen screws (6 pcs.) to the semiconductors. Tighten the screws to hand-tightness.

Illustration/Note

l i P

Install the six M3 fixing screws (A) and six spacers (B). Tighten the screws to handtightness.

A

A B B 1055063.wmf

1062703.wmf

A

B

B

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KDL32 Maintenance Instruction

Step 3

Action Tighten the six Allen screws, M3 fixing screws and spacers fully.

Illustration/Note

g n i t o 4

1

2

3

NOTE! Tighten the Allen screws of the little by little to the final torque: • • •

First torque: 1 Nm. Second torque: 2-3 Nm. Final torque: 4 Nm.

l i P

Tighten to each torque in the order displayed in the illustration!

5

6 1062064.wmf

4 5 6

Reconnect the wiring. Install the DC-link capacitor module and control module according to section 6.4. Install the covers of the drive module.

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KDL32 Maintenance Instruction

7

REPLACEMENT OF BRAKE CONTROL-, CONTACTOR MODULES AND DRIVE FAN

g n i t o

Replacement tasks of these modules are technically easy but they require that strict safety procedures are followed.

7.1

Tools

l i P

Following tools are recommended to be used with the replacement work: • •

7.2

Multimeter (Fluke 179 or equivalent) with testing probes specified to 1000 VDC voltage ESD protection kit

Safety measures

The drive module is located in the elevator shaft or in the machine room. In machineroomless elevators the car roof is used as a working platform. Therefore the special safety procedures and working methods are mandatory. The following safety items must be carried out before the actual work:

7.2.1

Safety measures for elevators with machine room

Step 1 2

3 4

Action Ensure that the car is empty. Open the control panel. Switch OFF the main switch (220:2) and main switch light (262). Lock and tag them. Close the control panel. Disconnect and prevent reconnection of the possible emergency power supplies. Wait for 5 minutes.

Illustration/Note Take the elevator out of use.

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KDL32 Maintenance Instruction

Step 5

Action Test by using the multimeter that AC voltage is not supplied to the drive. Check the operation of the multimeter before and after the test.

Illustration/Note The exact location of the cable ends depends on the electrification.

g n i t o

NOTE! Check the AC voltage (400 VAC) at the end of the power supply cables which inside the drive cabinet are connected to the RFI filter (389).

6 7

l i P

Remove the covers of the drive module. Test by using the multimeter that there is no DC voltage in the drive module. Check the operation of the multimeter before and after the test.

1062680.wmf

Loosen the fixing screws.

NOTE! Check DC voltage (600 - 750 VDC) in the intermediate circuit between the (DC+) and (DC-) terminals.

7.2.2

Safety measures for machineroomless elevators

Step 1 2

Action Ensure the car and car roof are empty. Open the MAP. Move the car using RDF to a suitable working level with access to topmost landing and car roof.

3

Switch OFF the main switch (220:2) and main switch light (262). Lock and tag them. Close the MAP.

Illustration/Note Take the elevator out of use. If the elevator does not move using RDF, continue by switching OFF power (Step 3) and then move the car by opening the brake or lifting the counterweight (Step 4). When the MAP is located at the second topmost floor, the SEP and drive module can be disconnected from the power supplies using switches (220:1) and (290:1), located in the shaft near the SEP.

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KDL32 Maintenance Instruction

Step 4

5 6

7

Action If the elevator could not be moved to a suitable working level using RDF (in Step 2), do one of the following: • Empty car upwards: Open the machine brake. Move the car upwards in small steps. • Empty car downwards: Use CWT lifting device, refer to operation instruction AS-01.05.001. Disconnect and prevent reconnection of the possible emergency power supplies. Wait for 5 minutes.

Illustration/Note The power must be switched OFF (Step 3) before moving the car!

Test by using the multimeter that AC voltage is not supplied to the drive. Check the operation of the multimeter before and after the test.

The exact location of the cable ends depends on the electrification.

g n i t o

l i P

NOTE! Check the AC voltage (400 VAC) at the end of the power supply cables which inside the drive cabinet are connected to the RFI filter (389).

1062680.wmf

8 9

Remove the covers of the drive module. Test by using the multimeter that there is no DC voltage in the drive module. Check the operation of the multimeter before and after the test.

Loosen the fixing screws.

NOTE! Check DC voltage (600 - 750 VDC) in the intermediate circuit between the (DC+) and (DC-) terminals.

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KDL32 Maintenance Instruction

7.3

Replacing brake control module Step 1 2

3 4 5 6

7.4

g n i t o

Action Disconnect the wiring of brake control module. Open the fixing screws.

Illustration/Note

NOTE! Be careful not to drop the fixing screws. Lift the old brake control module out of the drive module. Install new brake control module to its place and tighten the fixing screws. Reconnect wiring to the brake control module. Install the upper and lower cover plates.

l i P

Replacing contactor module components Step 1 2

3

Action Remove the brake control module according to section 7.3. Machineroomless elevators: Remove fixing screws (2 pcs.) and fixing screw for earthing cable of bottom noise reduction module. Remove the bottom noise reduction module.

Illustration/Note

Mark and disconnect the wiring of the damaged part.

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KDL32 Maintenance Instruction

Step 4

Action Replace damaged part(s) of the contactor module.

Illustration/Note

g n i t o

Spare parts for the contactor module: 1 Main contactor 2 Control voltage transformer 3 Circuit breaker 4 Relay 5 Main contactor control board

l i P

NOTE! When replacing the control voltage transformer, the contactor module must be lifted up a few centimeters so that the fixing screws of the transformer can be opened:

5

Open the fixing screws (4 pcs.) of the contactor module. Lift the contactor module few centimetres upwards and open the fixing screws of the transformer. Do not disconnect plugs or wires of other components. Install the contactor module.

6 7

Reconnect the wiring. Machineroomless elevators: Install the bottom noise reduction module. Tighten the fixing screws (2 pcs.) and fixing screw for earthing cable of bottom noise reduction module.

8

Install the brake control module according to section 7.3. Close the covers of the drive module.

9

Only when replacing control voltage transformer!

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KDL32 Maintenance Instruction

7.5

Replacing drive fan Step 1

2 3

g n i t o

Action Open the cover of the drive fan.

Note / Illustration Disconnect cable of the backup power module, if applicable. The back up module is fixed to the cover of the drive fan.

l i P

Remove locking plate of the fan. Replace the old fan with a new one. NOTE! Check that blowing direction is upwards and outwards from inside the drive cabinet.

Do not damage the fan cable.

4 5

Install locking plate of the fan. Attach cover of the fan.

6 7

Attach covers of the drive module. Switch ON the main power.

Reconnect cable of the backup power module, if applicable. The drive fan blows in full power for 10 seconds after switching ON the power.

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KDL32 Maintenance Instruction

8

REPLACEMENT OF DYNAMIC BRAKING CONTACTOR

8.1

Tools

g n i t o

Following tools are recommended to be used with the replacement work: • •

8.2

Multimeter (Fluke 179 or equivalent) with testing probes specified to 1000 VDC voltage ESD protection kit

l i P

Safety measures

The drive module is located in the elevator shaft or in the machine room. In machineroomless elevators the car roof is used as a working platform. Therefore the special safety procedures and working methods are mandatory. The following safety items must be carried out before the actual work:

8.2.1

Safety measures for elevators with machine room

Step 1 2

3 4

Action Ensure that the car is empty. Open the control panel. Switch OFF the main switch (220:2) and main switch light (262). Lock and tag them. Close the control panel. Disconnect and prevent reconnection of the possible emergency power supplies. Wait for 5 minutes.

Illustration/Note Take the elevator out of use.

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KDL32 Maintenance Instruction

Step 5

Action Test by using the multimeter that AC voltage is not supplied to the drive. Check the operation of the multimeter before and after the test.

Illustration/Note The exact location of the cable ends depends on the electrification.

g n i t o

NOTE! Check the AC voltage (400 VAC) at the end of the power supply cables which inside the drive cabinet are connected to the RFI filter (389).

6 7

l i P

Remove the covers of the drive module. Test by using the multimeter that there is no DC voltage in the drive module. Check the operation of the multimeter before and after the test.

1062680.wmf

Loosen the fixing screws.

NOTE! Check DC voltage (600 - 750 VDC) in the intermediate circuit between the (DC+) and (DC-) terminals.

8.2.2

Safety measures for machineroomless elevators

Step 1 2

Action Ensure the car and car roof are empty. Open the MAP. Move the car using RDF to a suitable working level with access to topmost landing and car roof.

3

Switch OFF the main switch (220:2) and main switch light (262). Lock and tag them. Close the MAP.

Illustration/Note Take the elevator out of use. If the elevator does not move using RDF, continue by switching OFF power (Step 3) and then move the car by opening the brake or lifting the counterweight (Step 4). When the MAP is located at the second topmost floor, the SEP and drive module can be disconnected from the power supplies using switches (220:1) and (290:1), located in the shaft near the SEP.

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KDL32 Maintenance Instruction

Step 4

5 6

7

Action If the elevator could not be moved to a suitable working level using RDF (in Step 2), do one of the following: • Empty car upwards: Open the machine brake. Move the car upwards in small steps. • Empty car downwards: Use CWT lifting device, refer to operation instruction AS-01.05.001. Disconnect and prevent reconnection of the possible emergency power supplies. Wait for 5 minutes.

Illustration/Note The power must be switched OFF (Step 3) before moving the car!

Test by using the multimeter that AC voltage is not supplied to the drive. Check the operation of the multimeter before and after the test.

The exact location of the cable ends depends on the electrification.

g n i t o

l i P

NOTE! Check the AC voltage (400 VAC) at the end of the power supply cables which inside the drive cabinet are connected to the RFI filter (389).

1062680.wmf

8 9

Remove the covers of the drive module. Test by using the multimeter that there is no DC voltage in the drive module. Check the operation of the multimeter before and after the test.

Loosen the fixing screws.

NOTE! Check DC voltage (600 - 750 VDC) in the intermediate circuit between the (DC+) and (DC-) terminals.

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KDL32 Maintenance Instruction

8.3

Replacing dynamic braking contactor Step 1

g n i t o

Action Remove the fixing screw and fixing screw for earthing cable of top noise reduction module. Remove the top noise reduction module from dynamic braking contactor.

Illustration/Note

l i P

2 3

4

5

6

Disconnect the wires from the dynamic braking contactor (A). Replace the old contactor with new one. Move the auxiliary contact block to new contactor. Reconnect the wiring.

Install the top noise reduction module, Tighten the fixing screw and fixing screw for earthing cable. Install the covers of the drive module.

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KDL32 Maintenance Instruction

9

REPLACEMENT OF BRAKING RESISTOR MODULE

9.1

Tools

g n i t o

Following tools are recommended to be used with the replacement work: • •

9.2

Multimeter (Fluke 179 or equivalent) with testing probes specified to 1000 VDC voltage ESD protection kit

l i P

Safety measures

The drive module is located in the elevator shaft or in the machine room. In machineroomless elevators the car roof is used as a working platform. Therefore the special safety procedures and working methods are mandatory. The following safety items must be carried out before the actual work:

9.2.1

Safety measures for elevators with machine room

Step 1 2

3 4

Action Ensure that the car is empty. Open the control panel. Switch OFF the main switch (220:2) and main switch light (262). Lock and tag them. Close the control panel. Disconnect and prevent reconnection of the possible emergency power supplies. Wait for 5 minutes.

Illustration/Note Take the elevator out of use.

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KDL32 Maintenance Instruction

Step 5

Action Test by using the multimeter that AC voltage is not supplied to the drive. Check the operation of the multimeter before and after the test.

Illustration/Note The exact location of the cable ends depends on the electrification.

g n i t o

NOTE! Check the AC voltage (400 VAC) at the end of the power supply cables which inside the drive cabinet are connected to the RFI filter (389).

6 7

l i P

Remove the covers of the drive module. Test by using the multimeter that there is no DC voltage in the drive module. Check the operation of the multimeter before and after the test.

1062680.wmf

Loosen the fixing screws.

NOTE! Check DC voltage (600 - 750 VDC) in the intermediate circuit between the (DC+) and (DC-) terminals.

9.2.2

Safety measures for machineroomless elevators

Step 1 2

Action Ensure the car and car roof are empty. Open the MAP. Move the car using RDF to a suitable working level with access to topmost landing and car roof.

3

Switch OFF the main switch (220:2) and main switch light (262). Lock and tag them. Close the MAP.

Illustration/Note Take the elevator out of use. If the elevator does not move using RDF, continue by switching OFF power (Step 3) and then move the car by opening the brake or lifting the counterweight (Step 4). When the MAP is located at the second topmost floor, the SEP and drive module can be disconnected from the power supplies using switches (220:1) and (290:1), located in the shaft near the SEP.

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KDL32 Maintenance Instruction

Step 4

5 6

7

Action If the elevator could not be moved to a suitable working level using RDF (in Step 2), do one of the following: • Empty car upwards: Open the machine brake. Move the car upwards in small steps. • Empty car downwards: Use CWT lifting device, refer to operation instruction AS-01.05.001. Disconnect and prevent reconnection of the possible emergency power supplies. Wait for 5 minutes.

Illustration/Note The power must be switched OFF (Step 3) before moving the car!

Test by using the multimeter that AC voltage is not supplied to the drive. Check the operation of the multimeter before and after the test.

The exact location of the cable ends depends on the electrification.

g n i t o

l i P

NOTE! Check the AC voltage (400 VAC) at the end of the power supply cables which inside the drive cabinet are connected to the RFI filter (389).

1062680.wmf

8 9

Remove the covers of the drive module. Test by using the multimeter that there is no DC voltage in the drive module. Check the operation of the multimeter before and after the test.

Loosen the fixing screws.

NOTE! Check DC voltage (600 - 750 VDC) in the intermediate circuit between the (DC+) and (DC-) terminals.

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KDL32 Maintenance Instruction

9.3

Replacing braking resistor module (machineroomless elevators)

9.3.1

Connecting new braking resistor module

g n i t o

In order to replace the braking resistor module in the shaft, the new braking resistor module must be connected to the drive before moving the elevator. Step 1

Action Lift the new braking resistor module on to the car roof.

2

Disconnect and remove the cable of the old braking resistor module from the terminals on the top of the drive module.

l i P

Illustration/Note

WARNING!Before disconnecting the cable ensure that terminals are safely de-energized. 3

Route the cable of the new braking resistor module carefully so that it cannot come into contact with moving parts of the elevator (for example ropes).

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KDL32 Maintenance Instruction

9.3.2

Step 4 5

Action Connect the cable to the terminals. Tighten the cable clamp.

6

Close the covers of the drive module.

Replacing braking resistor module

Step 1

2

3 3

4

Illustration/Note Shielding of the resistor cable is terminated and earthed to the cable clamp. The full width of the shielding should made contact to the earthed cable clamp.

g n i t o

l i P

Action Check that the cover of the drive module is closed and the elevator is on inspection drive. Switch ON the disconnector switch (220:2) beside the SEPt. Switch ON the main switch (220:1). Drive the car on inspection drive to a level where the braking resistor module can be replaced from the car roof.

Illustration/Note

NOTE! Keep the cables clear when moving the car. Push down the stop button on the car roof. Remove the upper fixing screws of the old braking resistor module. Loosen the lower fixing screws. Lift the old braking resistor module and cable to the car roof. NOTE! Be careful when guiding the braking resistor module from side of the ropes.

5

Install new braking resistor module to the shaft wall.

Fix the new cable properly. Be careful when guiding the box from the side of the ropes.

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KDL32 Maintenance Instruction

9.4

Replacing braking resistor module (elevators with machine room) Step 1

g n i t o

Action Disconnect and remove the cable of the old braking resistor module from the terminals on the top of the drive module.

Illustration/Note

WARNING!Before disconnecting the cable ensure that terminals are safely de-energized.

2

l i P

6

Loosen the fixing screws of the old braking resistor module. Lower the old braking resistor module and cable to the machine room floor. Install new braking resistor module to its place. Connect the cable to the terminals on the drive module. Tighten the cable clamp.

7

Close the covers of the drive module.

3 4 5

Fix the new cable properly. Shielding of the resistor cable is terminated and earthed to the cable clamp. The full width of the shielding should made contact to the earthed cable clamp.

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KDL32 Maintenance Instruction

10

UPDATE OF DRIVE SOFTWARE

10.1

Tools

g n i t o

Following tools are recommended to be used with the replacement work: • • • •

10.2

Multimeter (Fluke 179 or equivalent) with testing probes specified to 1000 VDC voltage ESD protection kit Programming kit, DCBM, KM953527R01 KDL32 software package, KM959231H01

l i P

Safety measures

The drive module is located in the elevator shaft or in the machine room. In machineroomless elevators the car roof is used as a working platform. Therefore the special safety procedures and working methods are mandatory. The following safety items must be carried out before the actual work:

10.2.1

Safety measures for elevators with machine room

Step 1 2

3 4

Action Ensure that the car is empty. Open the control panel. Switch OFF the main switch (220:2) and main switch light (262). Lock and tag them. Close the control panel. Disconnect and prevent reconnection of the possible emergency power supplies. Wait for 5 minutes.

Illustration/Note Take the elevator out of use.

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KDL32 Maintenance Instruction

Step 5

Action Test by using the multimeter that AC voltage is not supplied to the drive. Check the operation of the multimeter before and after the test.

Illustration/Note The exact location of the cable ends depends on the electrification.

g n i t o

NOTE! Check the AC voltage (400 VAC) at the end of the power supply cables which inside the drive cabinet are connected to the RFI filter (389).

6 7

l i P

Remove the covers of the drive module. Test by using the multimeter that there is no DC voltage in the drive module. Check the operation of the multimeter before and after the test.

1062680.wmf

Loosen the fixing screws.

NOTE! Check DC voltage (600 - 750 VDC) in the intermediate circuit between the (DC+) and (DC-) terminals.

10.2.2

Safety measures for machineroomless elevators

Step 1 2

Action Ensure the car and car roof are empty. Open the MAP. Move the car using RDF to a suitable working level with access to topmost landing and car roof.

3

Switch OFF the main switch (220:2) and main switch light (262). Lock and tag them. Close the MAP.

Illustration/Note Take the elevator out of use. If the elevator does not move using RDF, continue by switching OFF power (Step 3) and then move the car by opening the brake or lifting the counterweight (Step 4). When the MAP is located at the second topmost floor, the SEP and drive module can be disconnected from the power supplies using switches (220:1) and (290:1), located in the shaft near the SEP.

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KDL32 Maintenance Instruction

Step 4

5 6

7

Action If the elevator could not be moved to a suitable working level using RDF (in Step 2), do one of the following: • Empty car upwards: Open the machine brake. Move the car upwards in small steps. • Empty car downwards: Use CWT lifting device, refer to operation instruction AS-01.05.001. Disconnect and prevent reconnection of the possible emergency power supplies. Wait for 5 minutes.

Illustration/Note The power must be switched OFF (Step 3) before moving the car!

Test by using the multimeter that AC voltage is not supplied to the drive. Check the operation of the multimeter before and after the test.

The exact location of the cable ends depends on the electrification.

g n i t o

l i P

NOTE! Check the AC voltage (400 VAC) at the end of the power supply cables which inside the drive cabinet are connected to the RFI filter (389).

1062680.wmf

8 9

Remove the covers of the drive module. Test by using the multimeter that there is no DC voltage in the drive module. Check the operation of the multimeter before and after the test.

Loosen the fixing screws.

NOTE! Check DC voltage (600 - 750 VDC) in the intermediate circuit between the (DC+) and (DC-) terminals.

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KDL32 Maintenance Instruction

10.3

Updating drive software Step 1

g n i t o

Action Connect the software updating tool to the connectors XPR5 (DCBM MCB) and XPR2 (DCBM CPU).

Illustration/Note

l i P

1064345.wmf

2

Switch ON the main switch.

Go back to the landing, if machineroomless elevator. Refer to 959231D01 for exact procedures.

3

Update the drive software.

4

Switch OFF the main swtich.

5 6 7

Remove the software updating tool. Install covers of the drive module. Switch ON the main switch.

8

Return the elevator to service.

Ensure the power is OFF. Refer to section 10.2.

Go back to the landing, if machineroomless elevator. Refer to 959231D01 for exact procedures.

FOR PILOTING AS-11.65.031

© 2009 KONE Corporation All rights reserved. Disclosure prohibited

47 (48)

(-) 2009-03-04

KDL32 Maintenance Instruction

11

APPROVALS AND VERSION HISTORY

g n i t o

Compiled by:

Information Product Author

Janne Kaskimies

Checked by:

SEB Maintenance Specialist Product Change Manager

Jukka Lindberg Pasi Raassina

Approved by:

SEB Maintenance Development Manager

Seppo Valliovuo

Translation approved by:

l i P

Issue Date 2009-03-04

Description of Change

First issue

Ref CR

Approved by Seppo Valliovuo

FOR PILOTING AS-11.65.031

© 2009 KONE Corporation All rights reserved. Disclosure prohibited

48 (48)

(-) 2009-03-04